Rockwell Automation 20A-70EC, 20A-700VC User Manual

70 Enhanced Control and 700 Vector Control

www.abpowerflex.com

Reference Manual

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 www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and

understanding of the product.

ATT E NT I ON : Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you:

• identify a hazard

• avoid the hazard

• recognize the consequences

Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.

DriveExplorer, DriveExecutive and SCANport are trademarks of Rockwell Automation, Inc.

PowerFlex and PLC are registered trademarks of Rockwell Automation, Inc.

ControlNet is a trademark of ControlNet International, Ltd.

DeviceNet is a trademark of the Open DeviceNet Vendor Association.

Preface Overview

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Reference Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Table of Contents

Reference Information

Detailed Drive Operation

Accel/Decel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Auto/Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Auto Restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Bus Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Copy Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Datalinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

DC Bus Voltage / Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Direction Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

DPI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

DriveGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Drive Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Flux Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Flux Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

High Resolution Speed Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Input Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Load Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Masks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

MOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Motor Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Motor Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Position Indexer/Speed Profiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Power Loss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Process PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

PTC Motor Thermistor Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

PWM Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Regen Power Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Reset Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

S Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Safe-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Scale Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Shear Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

ii Table of Contents

Speed Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Speed/Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Start Permissives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

User Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

User Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Voltage Class. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Voltage Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Appendix Supplemental Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Engineering Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

PowerFlex 70EC Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

PowerFlex 700VC Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Index

Preface

Overview

The purpose of this manual is to provide detailed drive information including operation, parameter descriptions and programming.

Manual Conventions This manual covers the PowerFlex 70EC and the PowerFlex 700VC Drives. Some

of the information presented applies to specific drives. The following symbols will be used throughout to identify specific drive information.

Symbol Information pertains to …

PowerFlex 70 Enhanced Control (EC) drive

70EC

700H

700V

✔

PowerFlex 700 Vector Control (VC) drive

70EC

700H

700V

✔

Reference Materials In addition to the User Manual for your drive, the following manuals are

recommended for general drive information:

Title Publication Available Online at . . .

Wiring and Grounding Guidelines for PWM AC Drives

Preventive Maintenance of Industrial Control and Drive System Equipment

Safety Guidelines for the Application, Installation and Maintenance of Solid State Control

For Allen-Bradley Drives Technical Support:

Title Online at . . .

Allen-Bradley Drives Technical Support

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.”

• The following words are used throughout the manual to describe an action:

Word Me aning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not recommended

DRIVES-IN001…

DRIVES-TD001…

SGI-1.1

www.ab.com/support/abdrives

www.rockwellautomation. com/literature

2 General Precautions

General Precautions

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application

errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.

ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement

the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the

drive. Measure the DC bus voltage at the +DC & –DC terminals of the Power Terminal Block (refer to the User Manual for location). The voltage must be zero.

ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products must not be directly connected together via

1202 cables. Unpredictable behavior can result if two or more devices are connected in this manner.

ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most

common causes are:

• Wiring AC line to drive output or control terminals.

• Improper bypass or output circuits not approved by Allen-Bradley.

• Output circuits which do not connect directly to the motor.

• Contact Allen-Bradley for assistance with application or wiring.

ATTENTION: Loss of control in suspended load applications can cause personal injury and/or equipment damage. Loads must always be

controlled by the drive or a mechanical brake. Parameters 600-611 are designed for lifting/torque proving applications. It is the responsibility of the engineer and/or end user to configure drive parameters, test any lifting functionality and meet safety requirements in accordance with all applicable codes and standards.

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/Decel Time [Accel Time 1, 2]

70EC

✔✔

[Decel Time 1, 2]

700VC

700H

The Accel Time parameters set the rate at which the drive ramps its output frequency after a Start or Stop command or during a change in command frequency (speed change). The rate established is the result of the programmed Accel or Decel Time and the Maximum Frequency.

Reference Information

Maximum Speed

------------------------------------

Accel Time

Accel Rate (Hz/sec.)=

Maximum Speed

------------------------------------

Decel Time

De cel Rate (Hz/sec.)=

Two accel and decel times exist to allow the user to change rates “on the fly” via PLC command or digital input. Times are adjustable in 0.1 second increments from

0.0 seconds to 3600.0 seconds.

In its factory default condition, the secondary accel/decel times are not active if the related digital input functions or network commands have not been invoked.

Alarms Alarms are indications of situations that are occurring within the drive or

70EC

✔✔

application that should be annunciated to the user. These situations may affect the

700VC

700H

drive operation or application performance. Conditions such as Power Loss or Analog input signal loss can be detected and displayed for drive or operator action.

There are two types of alarms:

• Typ e 1 Al a r m s are conditions that by themselves, do not cause the drive to

“trip” or shut down, but they may be an indication that, if the condition persists, it may lead to a drive fault.

• Typ e 2 Al a r m s are conditions that are caused by improper programming and

they prevent the drive from Starting until programming is corrected. An example of a Type 2 alarm is when a “Start” function is assigned to a digital input without a “Stop” function also assigned to a digital input.

Alarm Status Indication

[Drive Alarm 1] [Drive Alarm 2]

Drive Alarm 1 is 16 bit parameter with each bit representing a specific Type 1 Alarm. Drive Alarm 2 is 16 bit parameter with each bit representing a specific Type 2 Alarm. For each Drive Alarm bit, 0 = alarm not active and 1 = alarm active.

4 Analog Inputs

Configuration

Type 2 Alarms are always enabled (not configurable). Type 1 Alarms will always be displayed in [Drive Alarm 1], but can be configured to either mask or allow specific alarms from a) turning on the “Alarm” bit within the [Drive Status 1] parameter and b) turning on a digital output when [Digital Outx Sel] is set to “Alar m.”

For each Alarm Config bit, 0 = alarm disabled and 1 = alarm enabled.

Drive Alarm

Alarm Config ↓↓↓

Analog Inputs Possible Uses of Analog Inputs

70EC

700VC

700H

✔✔

The analog inputs provide data that can be used for the following purposes:

• Provide a value to [Speed Ref A] or [Speed Ref B].

• Provide a trim signal to [Speed Ref A] or [Speed Ref B].

• Provide a reference when the terminal block has assumed manual control of the

reference

• Provide a reference and/or feedback for the PI loop. See "Process PID Loop" on

page 77

• Provide an external and adjustable value for the current limit and DC braking

level

• Start and Stop control using the Sleep/Wake mode.

• Provide a value to [Torque Ref A] or [Torque Ref B].

111

100

↓

Active

Inactive

Alarm

Analog Scaling

[Analog In x Lo] [Analog In x Hi]

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 analog value (e.g. in volts or mA) with a low and high target (e.g. Hz).

For many features such as Current Limit and DC Brake Level, the target scaling values are fixed (not adjustable) to the minimum and maximum of the selected function. However, the PowerFlex 700 contains “Scale Blocks” for additional flexibility (refer to page 91

Analog Inputs 5

Example 1

− [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] = 10V

− [Analog In 1 Lo] = 0V

This is the default setting, where 0 volts represents 0 Hz and 10 volts represents 60 Hz providing 1024 steps (10 bit analog input resolution) between 0 and 60 Hz.

Input Volts

601218

24 30 36 42 48 54 60

Output Hertz

Example 2

Consider the following setup:

− [Anlg In Config], bit 0 = “0” (voltage)

− [Speed Ref A Sel] = “Analog In 1”

− [Analog In1 Hi] = 10V

− [Analog In1 Lo] = 0V

− [Speed Ref A Hi] = 60 Hz

− [Speed Ref A Lo] = 0 Hz

− [Maximum Speed] = 45 Hz

− [Minimum Speed] = 15 Hz

This configuration is used when non-default settings are desired for minimum and maximum speeds, but full range (0-10V) scaling from 0-60 Hz is still desired.

[Analog In1 Hi]

10V

Motor Operating Range

Frequency Deadband

Command Frequency

[Analog In1 Lo]

[Speed Ref A Lo] [Speed Ref A Hi]

15 Hz 45 Hz 60 Hz0 Hz

Slope defined by (Analog Volts)/(Command Frequency)

[Maximum Speed][Minimum Speed]

Frequency Deadband

7.5-10 Volts0-2.5 Volts

In this example, a deadband from 0-2.5 volts and from 7.5-10 volts is created. Alternatively, the analog input deadband could be eliminated while maintaining the 15 and 45 Hz limits with the following changes:

− [Speed Ref A Lo] = 15 Hz

− [Speed Ref A Hi] = 45 kHz

6 Analog Inputs

Example 3

− [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 frequency, but is still configured for full 10 volt input. The result is that the resolution of the input has been doubled, providing 1024 steps between 0 and 30 Hz.

Input Volts

601218

24 30 36 42 48 54 60

Output Hertz

Example 4

− [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.

Input mA

601218

24 30 36 42 48 54 60

Output Hertz

Example 5

− [Anlg In Config], bit 0 = “0” (Voltage)

− [Speed Ref A Sel] = “Analog In 1”

− [Speed Ref A Hi] = 0 Hz

− [Speed Ref A Lo] = 60 Hz

− [Analog In 1 Hi] = 10V

− [Analog In 1 Lo] = 0V

This configuration is used to invert the operation of the input signal. Here, maximum input (10 Volts) represents 0 Hz and minimum input (0 Volts) represents 60 Hz.

Input Volts

601218

24 30 36 42 48 54 60

Output Hertz

Analog Inputs 7

Example 6

− [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. Here, minimum input (0 Volts) represents 0 Hz and maximum input (5 Volts) represents 60 Hz. This allows full scale operation from a 0-5 volt source.

Input Volts

601218

24 30 36 42 48 54 60

Output Hertz

Example 7

− [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 (PowerFlex 700VC Only)

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%.

Input Volts

2004060

80 100 120 140 160 180 200

Torque Ref %

8 Analog Inputs

Square Root

The square root function can be applied to each analog input through the use of [Analog In Sq Root]. The function should be enabled if the input signal varies with the square of the quantity (e.g. drive speed) being controlled.

If the mode of the input is bipolar voltage (–10v to 10v), then the square root function will return 0 for all negative voltages.

The function uses the square root of the analog value as compared to its full scale

5V 0.5 or 50% and 0.5 0.707==

(e.g. ) and multiplies it times the full scale of what it will control (e.g. 60 Hz).

The complete function can be describes as:

Analog Value - [Analog In x Lo]

⎛⎞

------------------------------------------------------------------------

⎝⎠

[Analog In x Hi] - [Analog In x Lo]

Setting high and low values to 0V, 10V, 0 Hz and 60 Hz, the expression reduces to:

Analog Value

⎛⎞

-----------------------------

⎝⎠

10V

60 Hz×

( Speed Ref A Hi[] – [Speed Ref A Lo]) [Speed Ref A Lo]+×

Output (Volts)

2046

Input (Volts)

810

Signal 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.

• Hold input

• Set input Lo

• Set input Hi

• Goto Preset 1

• Hold Output Frequency

Analog Inputs 9

[Analog In x Loss] Normal Operation

Operation with Analog Selected as Process PID Fdbk Exclusive Mode

Operation with Analog Selected as Process PID Fdbk Trim Mode

0, “Disabled” (default) Disabled Disabled Disabled

1, “Fault” Faults Faults Faults

2, “Hold Input” Holds speed at last valid analog

input level.

3, “Set Input Lo” Follows the maximum of [Minimum

Speed] or [Speed Ref x Lo].

4, “Set Input Hi” Follows the minimum of [Maximum

Speed] or [Speed Ref x Hi].

Disables PID and follows selected speed reference.

Disables PID and follows selected speed reference

Disables PID and follows selected speed reference.

Disables PID and follows selected speed reference

5, “Goto Preset1” Follows [Preset Speed 1]. Follows [Preset Speed 1] Follows [Preset Speed 1]

6, “Hold OutFreq” Follows the last commanded output

frequency.

Disables PID and follows the last commanded output frequency.

Disables PID and follows selected speed reference.

If the input is in current mode, 4 mA is the normal minimum usable input value. Any value below 2.0 mA will be interpreted by the drive as a signal loss, and a value of 3.0 mA will be required on the input in order for the signal loss condition to end.

4 mA

3.0 mA

2.0 mA

Signal Loss

Condition

End Signal Loss

Condition

If the input is in unipolar voltage mode, 2V is the normal minimum usable input value. Any value below 1.0 volts will be interpreted by the drive as a signal loss, and a value of 1.5 volts will be required on the input in order for the signal loss condition to end.

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.

1.9V

1.6V

Signal Loss

Condition

End Signal Loss

Condition

Value Display

Parameters are available in the Monitoring Group to view the actual value of an analog input regardless of its use in the application.

The value displayed includes the input value plus any factory hardware calibration value, but does not include scaling information programmed by the user (e.g. [Analog In 1 Hi/Lo]). The units displayed are determined by configuration of the input.

10 Analog Outputs

Analog Outputs Each drive has one or more analog outputs that can be used to annunciate a wide

70EC

✔✔

variety of drive operating conditions and values. The user selects the analog output

700VC

700H

source by setting [Analog Out Sel].

Configuration

The analog outputs have 10 bits of resolution yielding 1024 steps. The analog output circuit has a maximum 1.3% gain error and a maximum 100 mV offset error. For a step from minimum to maximum value, the output will be within 0.2% of its final value after 12ms.

Absolute (default)

Certain quantities used to drive the analog output are signed, e.g. 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 bit enumerated parameter [Anlg Out Absolut].

Scaling

The scaling for the analog output is defined by entering analog output voltages into two parameters, [Analog Out1 Lo] and [Analog Out1 Hi]. These two output voltages correspond to the bottom and top of the possible range covered by the quantity being output. Scaling of the analog outputs is accomplished with low and high analog parameter settings that are associated with fixed ranges (see User Manual) for each target function. Additionally, the PowerFlex 700VC contains an adjustable scale factor to override the fixed target range.

Examples

This section gives a few examples of valid analog output configurations and describes the behavior of the output in each case.

Example 1: Unsigned Output Quantity

− [Analog Out1 Sel] = “Output Current”

− [Analog Out1 Lo] = 1 volt

− [Analog Out1 Hi] = 9 volts

10V

[Analog Out1 Hi]

Analog

Output Voltage

[Analog Out1 Lo]

0% 200%

Output Current

Analog Outputs 11

Example 2: Unsigned Output Quantity, Negative Slope

− [Analog Out1 Sel] = “Output Current”

− [Analog Out1 Lo] = 9 volts

− [Analog Out1 Hi] = 1 volts

10V

[Analog Out1 Lo]

Analog

Output Voltage

[Analog Out1 Hi]

0% 200%

Output Current

This example shows that [Analog Out1 Lo] can be 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.

Example 3: Signed Output Quantity, Absolute Value Enabled

− [Analog Out1 Sel] = “Output Torque Current”

− [Analog Out1 Lo] = 1 volt

− [Analog Out1 Hi] = 9 volts

− [Anlg Out Absolut]

[Analog Out1 Hi]

Analog

Output Voltage

[Analog Out1 Lo]

200%

10V

0% 200%–

Output Torque Current

Example 4: Signed Output Quantity, Absolute Value Disabled

− [Analog Out1 Sel] = “Output Torque Current”

− [Analog Out1 Lo] = 1 volt

− [Analog Out1 Hi] set to 9 volts

− [Anlg Out Absolut]

[Analog Out1 Hi]

Analog

Output Voltage

[Analog Out1 Lo]

200%

10V

0% 200%–

Output Torque Current

Example 5: Overriding the Default Analog Output Target Scaling

Analog Output 1 set for 0-10V DC at 0-100% Commanded Torque. Setup:

− [Analog Out1 Sel], parameter 342 = 14 “Commanded Torque”

− [Analog Out1 Hi], parameter 343 = 10.000 Volts

− [Analog Out1 Lo], parameter 344 = 0.000 Volts

− [Anlg Out1 Scale], parameter 354 = 100.0 (PowerFlex 700VC Only)

If [Analog Out1 Lo] = –10.000 Volts the output will be –10.0 to +10.0V DC for –100% to +100% Commanded Torque.

If [Anlg Out1 Scale] = 0.0, the default scaling listed in [Analog Out1 Sel] will be used. This would be 0-10V DC for 0-800% torque.

12 Analog Outputs

Filtering

Software filtering is performed on quantities that can be monitored as described in the following table. The purpose of this filtering is to provide a signal and display that is less sensitive to noise and ripple.

Software Filters

Quantity Filter

Output Frequency No Filtering

Commanded Frequency Filtered

Output Current Filtered

Output Torque Current Filtered

Output Flux Current Filtered

Output Power Filtered

Output Voltage Filtered

DC Bus Voltage Filtered

PI Reference No Filtering

PI Feedback No Filtering

PI Error No Filtering

PI Output No Filtering

Scale Block Analog Output

700VC ONLY

In addition to the common selections, an analog output can be driven by any available data. The data can then be scaled before it reaches the output. A “Link” function establishes a connection from the data to the input of a “Scale Block.”

The analog output selection “Scale Block x” makes the connection from the output of the scale block to the physical output.

Link

Testpoint 1 Data

235

477

476

478

In Hi

In Lo

Scale 1

Out Hi

Out

Out Lo

479

481

480

Example

Analog Output 2 set for 0-10V DC for Heat Sink Temp 0-100 Degrees C. using Scale Block 1. Setup:

− Link [Scale1 In Value], parameter 476 to [Testpoint 1 Data], param. 235

− [Testpoint 1 Sel], parameter 234 = 2 “Heat Sink Temp”

− [Analog Out2 Sel], parameter 345 = 20 “Scale Block 1”

− [Analog Out2 Hi], parameter 346 = 10.000 Volts

− [Analog Out2 Lo], parameter 347 = 0.000 Volts

− [Scale1 In Hi], parameter 477 = 100

− [Scale1 In Lo], parameter 478 = 0

Network Controlled Analog Output

Enables the analog outputs to be controlled by network Datalinks to the drive.

Example

Analog Output 1 controlled by DataLink C1. Output 0-10V DC with DataLink values of 0-10000. Setup:

− [Data In C1], parameter = 304 “Analog Output 1 Setpoint”

− [Analog Out1 Sel], parameter 342 = 24 “Parameter Control”

− [Analog Out1 Hi], parameter 343 = 10.000 Volts

− [Analog Out1 Lo], parameter 344= 0.000 Volts

The device that writes to DataLink C1 now controls the voltage output of Analog Out1. For example: 2500 = 2.5V DC, 5000 = 5.0V DC, 7500 = 7.5V DC.

Auto/Manual 13

Auto/Manual The purpose of the Auto/Manual function is to permit temporary override of speed

70EC

✔✔

control, or both speed control and start (run)/stop control. Each connected HIM or

700VC

700H

the control terminal block is capable of performing this function. However, only one device may own “Manual” control and must release the drive back to “Auto” control before another device can be granted “Manual” control. The network or digital input control function named “local,” has priority over the Auto/Manual function.

The HIM can request or release Manual control by pressing the “Alt” key followed by the “Auto/Man” key. When the HIM is granted manual control, the drive uses the speed reference in the HIM. If desired, the auto speed reference can be automatically preloaded into the HIM when entering HIM manual control, so that the transition is smooth.

To use manual control from the terminal block, a digital input must be programmed to the “Auto/Man” selection. In this case, the speed control comes from the setting in [TB Man Ref Sel], and is limited to terminal block sources.

By default, only the speed reference (not Start or Jog control) changes when toggling between Auto and Manual. However, it is possible for both Speed Reference and Start/Jog control to change when toggling between Auto and Manual.

Refer to the appropriate parameter description for your drive and the tables that follow for detailed operation.

PowerFlex 70: Parameter 192, [AutoMan Cnfg] PowerFlex 700: Parameter 192, [Save HIM Ref]

Table A Parameter Bit Definitions

Bit Definition

0 Save HIM Ref 0 = Disabled, 1 = Enabled

Saves the HIM reference at power-down and reloads it at power-up.

1 Manual Mode 0 = Disabled, 1 = Enabled

(1)

ManRefPrld 0 = Disabled, 1 = Enabled

3 HIM Disable 0 = HIM starts, 1 = HIM doesn't start

(1)

PowerFlex 70 Only. PowerFlex 700 functionality is handled in parameter 193.

Table B Bit Combinations and Results

Parameter 192

Bit 3 = Bit 1 =

(1)

012 wireN Y Y N

1 0 2 wire Same as 0 0 Same as 0 0 Same as 0 0 Same as 0 0

112 wireN Y Y N

(1)

Default setting.

Adds exclusive HIM start/jog control while in manual mode.

Preloads the auto reference into the HIM upon transition from Auto to Manual.

HIM Start/Jog operation while in 3 wire Auto mode.

Auto Control HIM Manual Control

Ter minals Programmed

(1)

for

2 wire N Y N Y

3 wire Y Y Y Y

3 wire Y Y Y N

3 wire Same as 0 0 Same as 0 0 Same as 0 0 Same as 0 0

3 wire N Y Y N

HIM Starts Drive (Y/N)?

Termi nal Block Starts Drive (Y/N)?

HIM Starts Drive (Y/N)?

Termi nal Block Starts Drive (Y/N)?

14 Auto/Manual

General Rules

The following rules apply to the granting and releasing of Manual control:

1. Manual control is requested through a one-time request (Auto/Man toggle, not

continuously asserted). Once granted, the terminal holds Manual control until the Auto/Man button is pressed again, which releases Manual control (e.g. back to Auto mode).

2. Manual control can be granted to a device only if another device does not

presently own Manual control.

3. Local control has priority over Manual control and can terminate the manual

state of a device.

4. Any connected HIM will indicate when it has been granted Manual control, but

will not indicate the manual status of other devices.

5. If the drive is configured such that the HIM can not select the reference (via

Reference Mask setting), the drive will not allow the HIM to acquire Manual control. If the Reference Mask for a device’s port becomes masked while that device is in Manual control, then Manual control will be released.

6. If a terminal has Manual control and clears its DPI logic mask (allowing

disconnect of the terminal), then Manual control will be released. If the drive is configured such that the HIM can be unplugged (via logic mask setting), then the drive will not allow the terminal to acquire Manual control. The disconnect also applies to a HIM that executes a Logout. If the Logic Mask for a device’s port becomes masked while that device is in Manual control, then Manual control will be released.

7. If a com loss fault occurs on a device that has Manual control, then Manual

control will be released.

8. Manual control cannot be granted to a device which is already assigned as a

reference in Auto mode.

9. When a restore factory defaults is performed Manual control is aborted.

Auto Restar t 15

Auto Restart The Auto Restart feature provides the ability for the drive to automatically perform

70EC

✔✔

a fault reset followed by a start attempt without user or application intervention.

700VC

700H

This allows remote or “unattended” operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable.

Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming.

Configuration

Setting [Auto Rstrt Tries] to a value greater than zero will enable the Auto Restart feature. Setting the number of tries equal to zero will disable the feature.

The [Auto Rstrt Delay] parameter sets the time, in seconds, between each reset/run attempt.

The auto reset/run feature supports the following status information:

Parameter 210 [Drive Status 2], bit 8 - “Auto Rst Ctdn” Provides indication that an Auto Restart attempt is presently timing out and the drive will start at the end of the timing event.

Parameter 210 [Drive Status 2], bit 9 - “Auto Rst Act” Indicates that the drive has been programmed for the Auto Restart function.

The typical steps performed in an Auto Reset/Run cycle are as follows:

1. The drive is running and an auto resettable fault occurs, tripping the drive.

2. After the number of seconds in [Auto Rstrt Delay], the drive will automatically

perform an internal Fault Reset, resetting the faulted condition.

3. The drive will then issue an internal Start command to start the drive.

4. If another auto resettable fault occurs the cycle will repeat itself up to the

number of attempts set in [Auto Rstrt Tries].

5. If the drive faults repeatedly for more than the number of attempts set in [Auto

Rstrt Tries] with less than five minutes between each fault, the auto reset/run is considered unsuccessful and the drive remains in the faulted state.

6. Aborting an Auto Reset/Run Cycle (see Aborting an Auto-Reset/Run Cycle

for

details).

7. If the drive remains running for five minutes or more since the last reset/run

without a fault, or is otherwise stopped or reset, the auto reset/run is considered successful. The entire process is reset to the beginning and will repeat on the next fault.

Beginning an Auto-Reset/Run Cycle

The following conditions must be met when a fault occurs for the drive to begin an auto reset/run cycle.

• The fault must be defined as an auto resettable fault

• [Auto Rstrt Tries] setting must be greater than zero.

• The drive must have been running, not jogging, not autotuning, and not

stopping, when the fault occurred. (Note that a DC Brake state is part of a stop sequence and therefore is considered stopping.)

16 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.

• A fault which is not auto resettable.

• Removing power from the drive.

• Exhausting an Auto Reset/Run Cycle

After all [Auto Rstrt Tries] have been made and the drive has not successfully restarted and remained running for five minutes or more, the auto reset/run cycle will be considered exhausted and therefore unsuccessful. In this case the auto reset/ run cycle will Tries) will be issued if bit 5 of [Fault Config 1] = “1.”

terminate and an additional fault, “Auto Rstrt Tries” (Auto Restart

Autotune Description of parameters determined by the autotune tests.

70EC

700VC

700H

✔✔

Flux Current Test

[Flux Current Ref] is set by the flux current test, and is the reactive portion of the motor current (portion of the current that is out of phase with the motor voltage) and is used to magnetize the motor. The flux current test is used to identify the value of motor flux current required to produce rated motor torque at rated current. When the flux test is performed, the motor will rotate. The drive accelerates the motor to approximately two-thirds of base speed and then coasts for several seconds.

IR Voltage Drop Test

[IR Voltage Drop] is set by the IR voltage drop test, and is used to provide additional voltage to offset the voltage drop developed across the stator resistance. An accurate calculation of the [IR Voltage Drop] will ensure higher starting torque and better performance at low speed operation. The motor does not rotate during this test.

Leakage Inductance Test

[Ixo Voltage Drop] is set by the leakage inductance test and measures the inductance characteristics of the motor. A measurement is required to determine references for the regulators that control torque. The motor does not rotate during this test.

Inertia Test

[Total Inertia] is set by the inertia test and 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 approximately 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”. The [Total Inertia] and [Speed Desired BW] automatically determine the [Ki Speed Loop] and [Kp Speed Loop] gains for the speed regulator.

Autotune 17

Autotune Procedure for Sensorless Vector and Economizer

The purpose of Autotune is to identify the motor flux current and stator resistance for use in Sensorless Vector Control and Economizer modes.

The user must enter motor nameplate data into the following parameters for the Autotune procedure to obtain accurate results:

• [Motor NP FLA]

• [Motor NP Volts]

• [Motor NP Hertz]

• [Motor NP Power]

Next, the Dynamic or Static Autotune should be performed:

• Dynamic - the motor shaft will rotate during this test. The dynamic autotune

procedure determines both the stator resistance and motor flux current. The test to identify the motor flux current requires the load to be uncoupled from the motor to find an accurate value. If this is not possible then the static test can be performed.

• Static - the motor shaft does not rotate during this test. The static test determines

only [IR Voltage Drop]. This test does not require the load to be uncoupled from the motor.

The static and dynamic tests can be performed during the Start-up routine on the LCD HIM. The tests can also be run manually by setting the value of the [Autotune] parameter to 1 “Static Tune” or 2 “Rotate Tune”.

Alternate Methods for [IR Voltage Drop] & [Flux Current Ref]

If it is not possible or desirable to run the Autotune tests use one of the following two methods:

• When [Autotune] is set to 3 “Calculate”, any changes made by the user to motor

nameplate FLA, HP, Voltage, or Frequency activates a new calculation. This calculation is based on a typical motor with those nameplate values.

• If the stator resistance and flux current of the motor are known, voltage drop

across the stator resistance can be calculated. Then set [Autotune] to 0 “Ready” and directly enter these values into the [Flux Current] and [IR Voltage Drop] parameters.

Autotune Procedure for Flux Vector

For FVC vector control an accurate model of the motor must be used. For this reason, the motor data must be entered and the autotune tests should be performed with the connected motor.

Motor nameplate data must be entered into the following parameters for the Autotune procedure to obtain accurate results:

• [Motor NP Volts]

• [Motor NP FLA]

• [Motor NP Hertz]

• [Motor NP RPM]

• [Motor NP Power]

• [Motor Poles]

Next the Dynamic or Static Autotune should be performed.

18 Bus Regulation

Refer to the "Autotune Procedure for Sensorless Vector and Economizer" on

page 17

After the Static or Dynamic Autotune, the Inertia test should be performed. The motor shaft will rotate during the inertia test. During the inertia test the motor should be coupled to the load to find an accurate value. The inertia test can be performed during the Start-up routine on the LCD HIM. The inertia test can also be run manually by setting [Inertia Autotune] to 1 “Inertia Tune”, and then starting the drive.

for a description of these tests.

Troubleshooting the Autotune Procedure

If any errors are encountered during the Autotune process, or the procedure is aborted by the user:

• drive parameters are not changed

• the appropriate fault code will be displayed in the fault queue

• [Autotune] parameter is reset to 0.

The following conditions will generate a fault during an Autotune procedure:

• Incorrect stator resistance measurement

• Incorrect motor flux current measurement

• Load too large

• Autotune aborted by user

• Incorrect leakage inductance measurement

Bus Regulation Some applications create an intermittent regeneration condition. The following

70EC

✔✔

example illustrates such a condition. The application is hide tanning, in which a

700VC

700H

drum is partially filled with tanning liquid and hides. 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 an overvoltage fault.

When an AC motor regenerates energy from the load, the drive DC bus voltage increases unless there is another means (dynamic braking chopper/resistor, etc.) of dissipating the energy, or the drive takes some corrective action prior to the overvoltage fault value.

Motoring Regenerating

With bus regulation disabled, the bus voltage can exceed the operating limit and the drive will fault to protect itself from excess voltage.

Bus Regulation 19

Single Seq 500 S/s

Ch1

100mV

Ch3

500mV

0V Fault @V

Ch2 100mV M 1.00s Ch3 1.47 V

bus

Max

Drive Output Shut Off

With bus regulation enabled, the drive can respond to the increasing voltage by advancing the output frequency until the regeneration is counteracted. This keeps the bus voltage at a regulated level below the trip point.

DB Bus

Motor Speed

Output Frequency

The bus voltage regulator takes precedence over acceleration/deceleration. See

Figure 1

Bus voltage regulation is selected by the user in the Bus Reg Mode parameter.

Operation

Bus voltage regulation begins when the bus voltage exceeds the bus voltage regulation set point Vreg and the switches shown in Figure 1 shown in .

Switch Positions for Bus Regulator Active

SW 1 SW 2 SW 3 SW 4 SW 5

Bus Regulation Limit Bus Reg Open Closed Don’t Care

move to the positions

20 Bus Regulation

Current Limit Level

Figure 1 Bus Voltage Regulator, Current Limit and Frequency Ramp.

Current Limit

U Phase Motor Current

W Phase Motor Current

PI Gain Block

Derivative Gain

Block

SW 3

I Limit,

No Bus Reg

Magnitude

Calculator

Integral Channel

SW 1

Limit

No Limit

I Limit,

No Bus Reg

Acc/Dec Rate

Jerk

Ramp

Jerk

Clamp

No Limit

SW 2

Bus Reg

Frequency

(Integrator)

Frequency Set Point

Maximum Frequency, Minimum Speed, Maximum Speed, Overspeed Limit

Frequency Reference (to Ramp Control, Speed Ref, etc.)

Speed Control (Slip Comp, Process PI, etc)

Integral Channel

Bus Voltage Regulation Point, V

reg

PI Gain Block

Ramp

SW 4

Bus Reg On

Proportional Channel

Frequency

Reference

SW 5

Frequency

Limits

Speed

Control

Mode

Proportional Channel

Output Frequency

Bus Voltage Regulator

Derivative

Gain Block

Bus Voltage (Vbus)

Bus Regulation 21

The derivative term senses a rapid rise in the bus voltage and activates the bus regulator prior to actually reaching the bus voltage regulation set point Vreg. The derivative term is important since it minimizes overshoot in the bus voltage when bus regulation begins thereby attempting to avoid an over-voltage fault. The integral channel acts as the acceleration or deceleration rate and is fed to the frequency ramp integrator. The proportional term is added directly to the output of the frequency ramp integrator to form the output frequency. The output frequency is then limited to a maximum output frequency.

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. Fast positive changes in input voltage (more than a 10% increase

within 6 minutes) can cause uncommanded positive speed changes. However an “OverSpeed Limit” fault will occur if the speed reaches [Max Speed] + [Overspeed Limit]. If this condition is unacceptable, action should be taken to 1) limit supply voltages within the specification of the drive and, 2) limit fast positive input voltage changes to less than 10%. Without taking such actions, if this operation is unacceptable, the “adjust freq” portion of the bus regulator function must be disabled (see parameters 161 and 162).

2. Actual deceleration times can be longer than commanded deceleration

times. However, a “Decel Inhibit” fault is generated if the drive stops decelerating altogether. If this condition is unacceptable, the “adjust freq” portion of the bus regulator must be disabled (see parameters 161 and 162). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases.

Important: These faults are not instantaneous. Test results have

shown that they can take between 2-12 seconds to occur.

The drive can be programmed for one of five different modes to control the DC bus voltage:

• Disabled

• Adjust Frequency

• Dynamic Braking

• Both with Dynamic Braking first

• Both with Adjust Frequency first

[Bus Reg Mode A], parameter 161 is the mode normally used by the drive unless the “Bus Reg Md B” digital input function is used to switch between modes instantaneously, in which case [Bus Reg Mode B], parameter 162 becomes the active bus regulation mode.

22 Bus Regulation

The bus voltage regulation setpoint is determined from bus memory (a means to average DC bus over a period of time). The following tables and figure describe the operation.

Voltage Class DC Bus Memory DB On Setpoint DB Off Setpoint

240 < 342V DC 375V DC On – 4V DC

> 342V DC Memory + 33V DC

480 < 685V DC 750V DC On – 8V DC

> 685V DC Memory + 65V DC

600 < 856V DC 937V DC On – 10V DC

> 856V DC Memory + 81V DC

600/690V PowerFlex 700 Frames 5 & 6 Only

880

815

< 983V DC 1076V DC On – 11V DC

> 983V DC Memory + 93V DC

750

685

DC Volts

650

509

453

320 360 460 484 528 576

DB Turn On

DB Turn Off

Bus Reg Curve #1

Bus Reg Curve #2

Bus Memory

AC Volts

If [Bus Reg Mode x] is set to “Dynamic Brak”

The Dynamic Brake Regulator is enabled. In “Dynamic Brak” mode the Bus Voltage Regulator is turned off. The “DB Turn On” and turn off curves apply. For example, with a DC Bus Memory at 684V DC, the Dynamic Brake Regulator will turn on at 750V DC and turn back off at 742V DC.

If [Bus Reg Mode x] is set to “Both-Frq 1st”

Both regulators are enabled, and the operating point of the Bus Voltage Regulator is lower than that of the Dynamic Brake Regulator. The Bus Voltage Regulator setpoint follows the “Bus Reg Curve 2” below a DC Bus Memory of 650V DC and follows the “DB Turn Off” curve above a DC Bus Memory of 650V DC (Table C

). The Dynamic Brake Regulator follows the “DB Turn On” and turn off curves. For example, with a DC Bus Memory at 684V DC, the Bus Voltage Regulator setpoint is 742V DC and the Dynamic Brake Regulator will turn on at 750V DC and back off at 742V DC.

If [Bus Reg Mode x] is set to “Adjust Freq”

The Bus Voltage Regulator is enabled. The Bus Voltage Regulator setpoint follows “Bus Reg Curve 1” below a DC Bus Memory of 650V DC and follows the “DB Turn On” above a DC Bus Memory of 650V DC (Table C

). For example, with a DC

Bus Memory at 684V DC, the adjust frequency setpoint is 750V DC.

Copy Cat 23

If [Bus Reg Mode x] 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. The Dynamic Brake Regulator follows the “DB Turn On” and turn off curves. For example, with a DC Bus Memory between 650 and 685V DC, the Bus Voltage Regulator setpoint is 758V DC and the Dynamic Brake Regulator will turn on at 742V DC and back off at 734V DC.

Tab l e C

Voltage Class DC Bus Memory Bus Reg Curve #1 Bus Reg Curve #2

240 < 325V DC Memory + 50V DC Curve 1 – 4V DC

325V DC ≤ DC Bus Memory ≤ 342V DC 375V DC

> 342V DC Memory + 33V DC

480 < 650V DC Memory + 100V DC Curve 1 – 8V DC

650V DC ≤ DC Bus Memory ≤ 685V DC 750V DC

> 685V DC Memory + 65V DC

600 < 813V DC Memory + 125V DC Curve 1 – 10V DC

813V DC ≤ DC Bus Memory ≤ 856V DC 937V DC

> 856V DC Memory + 81V DC

600/690V PowerFlex 700 Frames 5 & 6 Only

< 933V DC Memory + 143V DC Curve 1 – 11V DC 933V DC ≤ DC Bus Memory ≤ 983V DC 1076V DC

> 983V DC Memory + 93V DC

Copy Cat PowerFlex drives have a feature called Copy Cat, which provides a way to upload a

70EC

✔✔

complete set of parameters to the LCD HIM. This information can then be used as

700VC

700H

backup or can be transferred to another drive.

The transfer process manages all conflicts. If a parameter from HIM memory does not exist in the target drive, or the value stored is out of range for the drive, or the parameter cannot be downloaded because the drive is running, the download will stop and a text message will be issued. The remainder of the download can then be aborted or continued by acknowledging the discrepancy. These parameters can then be adjusted manually.

The LCD HIM will store a number of parameter sets (memory dependent) and each individual set can be named.

24 Current Limit

Current Limit There are 5 ways that the drive can protect itself from overcurrent or overload

70EC

✔✔

situations:

700VC

700H

• Hardware Overcurrent - This is a feature that instantly faults the drive if the

output current exceeds this value. The value is fixed by hardware and is typically 250% of drive rated amps. The fault code for this feature is F12 “HW Overcurrent.” This feature cannot be defeated or mitigated.

• Software Overcurrent - This protection mode occurs when peak currents do not

reach the Hardware Overcurrent value and are sustained long enough and high enough to damage certain drive components. If this situation occurs, the drives protection scheme will cause an F36 “SW Overcurrent” fault. The point at which this fault occurs is fixed and stored in drive memory.

• Software Current Limit - This is a feature that attempts to reduce current by

folding back output voltage and frequency if the output current exceeds a programmable value. The [Current Lmt Val] parameter is programmable between approximately 25% and 150% of drive rating. The reaction to exceeding this value is programmable with [Shear Pin Fault]. Enabling this parameter creates an F63 “Shear Pin Fault.” Disabling this parameter causes the drive to use fold back to attempt load reduction.

• Heatsink Temperature Protection - The drive constantly monitors the heatsink

temperature. If the temperature exceeds the drive maximum, a “Heatsink OvrTemp” fault will occur. The value is fixed by hardware at a nominal value of 100 degrees C. This fault is generally not used for overcurrent protection due to the thermal time constant of the heatsink. It is an overload protection.

• Drive Overload Protection - Refer to "Drive Overload" on page 39.

Datalinks A Datalink is one of the mechanisms used by PowerFlex drives to transfer data to

70EC

✔✔

and from a programmable controller. Datalinks allow a parameter value to be

700VC

700H

changed without using an Explicit Message or Block Transfer. Datalinks consist of a pair of parameters that can be used independently for 16 bit transfers or in conjunction for 32 bit transfers. Because each Datalink consists of a pair of parameters, each Datalink occupies two 16 or 32-bit words in both the input and output image tables, depending on configuration. A parameter number is entered into the Datalink parameter. The value that is in the corresponding output data table word in the controller is then transferred to the parameter whose number has been placed in the Datalink parameter. The following example demonstrates this concept. The object of the example is to change Accel and Decel times “on the fly” under PLC control.

The user makes the following PowerFlex drive parameter settings: [Data In A1], parameter 300 = 140 (parameter number of [Accel Time 1] [Data In A2], parameter 301 = 142 (parameter number of [Decel Time 1]

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], parameter 140 = 10.0 seconds (output image table Word 3 value) [Decel Time], parameter 142 = 13.3 seconds (output image table Word 4 value).

Any time these values need to be changed, the new values are entered into the data table, and the parameters are updated on the next PLC I/O scan.

Datalinks 25

Programmable

Controller

I/O Image Table

Output Image

Block Transfer Logic Command Analog Reference WORD 3 WORD 4 WORD 5 WORD 6 WORD 7

Input Image

Block Transfer Logic Status Analog Feedback WORD 3 WORD 4 WORD 5 WORD 6 WORD 7

Remote I/O

Communication

Module

Datalink A

Adjustable Frequency

AC Drive

Parameter/Number

Data In A1 Data In A2

Data Out A1 Data Out A2

300 301

310 311

Rules for Using Datalinks

• A Datalink consists of 4 words, 2 for Datalink x IN and 2 for Datalink x Out.

They cannot be separated or turned on individually.

• Only one communications adapter can use each set of Datalink parameters in a

PowerFlex drive. If more than one communications adapter is connected to a single drive, multiple adapters must not try to use the same Datalink.

• Parameter settings in the drive determine the data passed through the Datalink

mechanism

• When Datalinks are used to change a value in the drive, the value is not written

to the Non-Volatile Storage (EEprom memory). The value is stored in volatile memory (RAM) and lost when the drive loses power.

32-Bit Parameters using 16-Bit Datalinks

To read (and/or write) a 32-bit parameter using 16-bit Datalinks, typically both Datalinks (A,B,C,D) are set to the 32-bit parameter. For example, to read Parameter 09 - [Elapsed MWh], both Datalink A1 and A2 are set to “9.” Datalink A1 will contain the least significant word (LSW) and Datalink A2 the most significant word (MSW). In this example, the parameter 9 value of 5.8MWh is read as a “58” in Datalink A1

Datalink Most/Least Significant Word Parameter Data (decimal)

A1 LSW 9 58

A2 MSW 9 0

Regardless of the Datalink combination, x1 will always contain the LSW and x2 will always contain the MSW.

In the following examples Parameter 242 - [Power Up Marker] contains a value of

88.4541 hours.

Datalink Most/Least Significant Word Parameter Data (decimal)

A1 LSW 242 32573

A2 -Not Used- 0 0

26 DC Bus Voltage / Memory

Datalink Most/Least Significant Word Parameter Data (decimal)

A1 -Not Used- 0 0

A2 MSW 242 13

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 Most/Least Significant Word Parameter Data (decimal)

A2 MSW 242 13

B1 LSW 242 32573

32-bit data is stored in binary as follows:

MSW 2

LSW 215 through 2

through 2

Example

Parameter 242 - [Power Up Marker] = 88.4541 hours MSW = 13 LSW = 32573 851968 + 32573 = 884541

decimal

= 1101

= 216 + 218 + 219 = 851968

binary

DC Bus Voltage / Memory

70EC

✔✔

[DC Bus Voltage] is a measurement of the instantaneous value. [DC Bus Memory] is a heavily filtered value or “average” bus voltage. Just after the pre-charge relay is

700VC

700H

closed during initial power-up, bus memory is set equal to bus voltage. Thereafter it is updated by ramping at a very slow rate toward the instantaneous bus voltage [DC Bus Voltage]. The filtered value ramps at approximately 2.4V DC per minute (for a 480V AC drive).

Bus memory is used as a comparison value to sense a power loss condition. If the drive enters a power loss state, the bus memory will also be used for recovery (e.g. pre-charge control or inertia ride through upon return of the power source) upon return of the power source. Update of the bus memory is blocked during deceleration to prevent a false high value caused by a regenerative condition.

Digital Inputs Digital Input Configuration

70EC

700VC

700H

✔✔

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.

Input Function Detailed Descriptions

Stop-Clear Faults

•

An open input will cause the drive to stop and become “not ready”. A closed input will allow the drive to run when given a Start or Run command.

If “Start” is configured, then “Stop - Clear Faults” must also be configured. Otherwise, a digital input configuration alarm will occur. “Stop - Clear Faults” is an optional setting in all other cases.

An open to closed transition is interpreted as a Clear Faults request. The drive will clear any existing faults.

If the “Clear Faults” input function is configured at the same time as “Stop Clear Faults”, then it will not be possible to reset faults with the “Stop - Clear Faults” input.

Digital Inputs 27

• Run Forward, Run Reverse

These settings cause the drive to run and with a specific direction, as long as the configured input is held closed. Also, these “2-wire” settings prevent any other connected device from starting the drive. To use a “2-wire” digital input setting that is compatible with start commands from a communication adapter, see "Run w/Comm" on page 28

An open to closed transition on one input or both inputs while the drive is stopped will cause the drive to run unless the “Stop - Clear Faults” input function is configured and open.

The table below describes the basic action taken by the drive in response to particular states of these input functions.

Run Forward Run Reverse Action

Open Open Drive stops, terminal block relinquishes direction ownership.

Open Closed Drive runs in reverse direction, terminal block takes direction

Closed Open Drive runs in forward direction, terminal block takes direction

Closed Closed Drive continues to run in current direction, but terminal block

It is not necessary to program both “Run Forward” and “Run Reverse.” These two functions will operate with or without each other.

ownership.

maintains direction ownership.

Important: Direction control is an “Exclusive Ownership” function (see

Owners). This means that only one control device (terminal block, DPI device, HIM, etc.) at a time is allowed to control direction at a time. The terminal block must become direction “owner” before it can be used to control direction. If another device is currently the direction owner (as indicated by [Direction Owner]), it will not be

possible to start the drive or change direction by using the terminal block digital inputs programmed for both Run and Direction control (e.g. Run/Fwd).

• Run

This setting is similar to “Run Forward” and “Run Reverse” settings. The only difference being that direction is determined by another input or another device’s command (HIM or comm adapter).

• Run Level, RunFwd Level, and RunRev Level

The “non-level” version of these “2-wire” control functions require a rising edge (open to close transition) in order for the drive to run. As long as a separate “Stop” command is not issued, these “level” versions do not require a rising edge, the level alone (no rising edge required) determines whether or not the drive will run.

Example 1

A drive is faulted and the “Run Level” input is held closed the entire time. Next, the network issues a “Clear Faults” command or another digital input programmed for “Clear Faults” is closed. The drive will immediately restart as long as the “Run Level” input is closed, even if this input did not get opened and then re-closed.

28 Digital Inputs

Example 2

A drive is faulted and the “Run Level” input is held closed the entire time. Next, the network issues a “Stop/Clear Faults” command, or another digital input programmed for “Stop/Clear Faults” is activated, or the “Stop button is pressed on the HIM. The drive will not restart until the “Run Level” input is opened and then re-closed, because the fault clearing method used was combined with a stop command.

Example 3

The drive is stopped by the network issuing a “Stop/Clear Faults” command, or another digital input programmed for “Stop/Clear Faults” being activated, or the “Stop” button being pressed on the HIM. The drive will not restart until the “Run Level” input is opened and then re-closed, because the fault clearing method used was one that is combined with a stop command.

Example 4

The drive is stopped by opening a digital input that is programmed for “Enable.” The Run Level input is held closed the entire time. Next, the Enable input is re-closed. The drive will immediately restart as long as the Run Level input is closed, even if this input did not get opened and then re-closed.

• Run w/Comm

All other “Run” digital input settings prohibit communication devices from starting the drive. “Run w/Comm” allows communication adapters to start the drive even if the digital input “Run w/Comm” is in the open state. In addition, the communication device must have given up its ownership in order for transitions on the “Run w/Comm” digital input to take any action.

• 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. If “Start” is configured, then “Stop-Clear Faults” must also be configured.

• Forward/Reverse

This function is one of the ways to provide direction control when the “Start” or “Run” functions (not combined with direction) are used.

An open input sets direction to forward. A closed input sets direction to reverse. If state of input changes and drive is running or jogging, drive will change direction.

• Jog Forward, Jog Reverse

Jog is a non-latched command such as Run, but overrides the normal speed reference and uses [Jog Speed 1].

An open to closed transition on one input or both inputs while the drive is stopped will cause the drive to jog unless the “Stop - Clear Faults” input function is configured and open. The table below describes the actions taken by the drive in response to various states of these input functions.

Jog Forward Jog Reverse Action

Open Open Drive will stop if already jogging, but can be star ted by other

means. Terminal block relinquishes direction ownership.

Open Closed Drive jogs in reverse direction. Terminal block takes direction

ownership.

Closed Open Drive jogs in forward direction. Terminal block takes direction

Closed Closed Drive continues to jog in current direction, but terminal block

ownership.

maintains direction ownership.

Digital Inputs 29

The drive will not jog while the drive is 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.

Important: Direction control is an “Exclusive Ownership” function (see

possible to jog the drive or change direction by using the terminal block digital inputs programmed for both Run and Direction control (e.g. Run/Fwd).

If another device is not currently the direction owner (as indicated by [Direction Owner]) and the terminal block bit is set in the [Direction Mask] 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.

• Jog 1, Jog 2

These settings are similar to “Jog Forward” and “Jog Reverse” with the only difference being that direction is determined by another input or another device’s command (HIM or comm adapter). In addition, these settings will use either [Jog Speed 1] or [Jog Speed 2], respectively. In unipolar mode, the absolute value will be used along with a separate direction command. In bipolar mode, the polarity of [Jog Speed 1] or [Jog Speed 2] will determine the direction of jog.

• Speed Select 1, 2, and 3

Up to three digital inputs can be used to select the speed reference. The open/ closed state of all speed select input functions combine to select which source is the speed reference. Refer to "Speed Reference" on page 98

• Auto/Manual

Refer to "Auto/Manual" on page 13 works in conjunction with the overall Auto/Manual function. When this input is closed, it overrides other speed references, but only if another device (HIM) did not have ownership of the Manual state. If the digital input is successful in gaining manual control, the speed reference comes from [TB Man Ref Sel], which can be set to any of the analog inputs.

. The Auto/Manual setting for a digital input

• Accel 2, Decel 2

These digital input functions toggle between primary and secondary ramp rates. For example, with a digital input programmed for Accel 2, an open digital input follows [Accel Time 1]. A closed digital input follows [Accel Time 2].

• Acc2 & Dec2

This setting is similar to the Accel 2 and Decel 2 settings, except that one digital input will toggle both Accel and Decel at the same time.

30 Digital Inputs

• MOP Increment, MOP Decrement

These functions are used to increment and decrement the Motor Operated Potentiometer (MOP) value inside the drive. The MOP is a reference value that can be incremented and decremented by external devices. The MOP value will be retained through a power cycle.

In order for the drive to use the MOP value as the current speed reference, either [Speed Ref A Sel] or [Speed Ref B Sel] must be set to “MOP.” Refer to "MOP" on page 50

• Stop Mode B

This digital input function selects between two different drive stop modes. See also "Stop Modes" on page 109

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. See also Bus Regulation

If the input is open, then [Bus Reg Mode A] selects which bus regulation mode to use. If the input is closed, then [Bus Reg Mode B] selects which bus regulation mode to use. If this input function is not configured, then [Bus Reg Mode A] always selects which bus regulation mode to use.

• PI Enable

If this input function is closed and [PI Control], bit 0 = “enabled”, the operation of the Process PI loop will be enabled.

If this input function is open, the operation of the Process PI loop will be disabled. See "Process PID Loop" on page 77

• PI Hold

If this input function is closed, the integrator for the Process PI loop will be held at the current value.

If this input function is open, the integrator for the Process PI loop will be allowed to increase. See "Process PID Loop" on page 77

• PI Invert

If this input function is closed, the PI Error is inverted. If this input function is open, the PI Error is not inverted.

• PI Reset

If this input function is closed, the integrator for the Process PI loop will be reset to 0.

If this input function is open, the integrator for the Process PI loop will integrate normally. See "Process PID Loop" on page 77

• Auxiliary Fault

This input function is normally closed and allows external equipment to fault the drive. When this input opens, the drive will fault with the “Auxiliary Input” (F2) fault code. If this input function is not configured, then the fault will not occur.

Digital Inputs 31

• Local Control

This input function allows exclusive control of all drive logic functions from the terminal block. If it 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.

The drive must be stopped and other devices must not own exclusive control in order for the terminal block to gain complete local control.

• Clear Faults

The “Clear Faults” digital input function allows an external device to reset drive faults through the terminal block. An open to closed transition on this input will cause an active fault (if any) to be reset.

If this input is configured at the same time as “Stop - Clear Faults”, then only the “Clear Faults” input can cause faults to be reset.

• Enable

Closing this input allows the drive to run when a Start command is issued.

If the drive is already running when this input is opened, the drive will coast and indicate “not enabled” on the HIM (if present). This is not considered a fault condition, and no fault will be generated.

If this function is not configured, the drive is considered enabled. If multiple “Enable” inputs are configured, then the drive will not run if any of the inputs are open.

Any of the digital inputs can be configured as “Enable.” However, Digital Input 6 can be configured as a “Dedicated Hardware Enable” by removing a jumper. In this case the parameter setting for [Digital In6 Sel] has no effect. This hardware configuration bypasses software processing of the enable function and provides hardware protection against a drive run condition. Refer to the User Manual for jumper locations.

• Exclusive Link

This function is used for exclusively controlling a digital output by activating a digital input. It is used when no other functionality s desired for the input. See

Digital Outputs

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. If the input is configured as “Not used” input function, the link to the input is considered non-functional.

• Power Loss Level

When the DC bus level in the drive falls below a certain level, a “power loss” condition is created in the drive logic. This function allows the user to select between two different “power loss” detection levels.

If the input is closed, the drive will take its power loss level from [Power Loss Level]. If the input is open, the drive will use a power loss level designated by internal drive memory, typically 82% of nominal.

If the input function is not configured, then the drive always uses the internal power loss level.

700VC ONLY

32 Digital Inputs

• Precharge Enable

This function is used to manage disconnection from a common DC bus.

If the input is closed, this indicates that the drive is connected to common DC bus and normal precharge handling can occur, and that the drive can run (start permissive). If the physical input is open, this indicates that the drive is disconnected from the common DC bus, and thus the drive should enter the precharge state and initiate a coast stop immediately in order to prepare for reconnection to the bus.

If this input function is not configured, then the drive assumes that it is always connected to the DC bus, and no special precharge handling will be done.

• Digital Input Data Logic

Digital Input Data Logic performs logical operations on the condition of digital inputs with that of data contained in a parameter. The output of the logical operation performs the function (start, stop, preset speed, etc.) that is “assigned” to the digital input. An example of an appropriate application for this function is the temporary override of a conveyor sensor that is wired directly to a digital input. In such a case, a controller could write the data to the drive over a network to start a drive, and then reset the data after the conveyor load clears the sensor, thus allowing the sensor to stop the next load.

When this feature is enabled through bit 9 (“DigIn DatLog”) of [Compensation], parameter 56, the operation is performed. If the feature is disabled, the functions assigned to the digital inputs will operate directly, regardless of the data in the “Digital Input Data Logic” parameter.

The following diagram shows the logical operation. The condition of each digital input is “ANDed” with the “ANDdata” from [DigIn DataLogic], parameter 411, then “ORed” with the “ORdata” from [DigIn DataLogic]. The result is fed to the assigned digital input function.

In1 ANDdata

Dig In 1 Condition

In1 ORdata

AND

Output to Assigned

DigIn function

The logical result (output) for each string of operations for a digital input can be viewed in the upper half of parameter 216 [Dig In Status].

When the feature is enabled, and the Input 6 Dedicated Enable Jumper is pulled, the Data Logic function will still be performed on input 6, but will not interfere with the dedicated hardware path to the gate drive circuit.

• Fast Stop

When this input is opened, the drive performs a “Fast Stop.” See "Stop Modes" on page 109

for a description of this stopping method.

• Speed/Torque Select 1, 2, and 3

These settings provide the ability to switch between different speed/torque modes from digital input combinations. See "Speed/Torque Mode" on page 105 for a complete description of these modes and the digital input combinations that activate each mode.

Digital Outputs 33

• User Set Select 1 and 2

These settings are used in the “dynamic mode” of user sets, which provides switching between entire parameter sets from digital input combinations. See "User Sets" on page 114

for a complete description of these modes and the digital input

combinations that activate each mode.

Digital Input Conflict Alarms

If the user configures the digital inputs so that one or more selections conflict with each other, one of the digital input configuration alarms will be asserted. As long as the Digital Input Conflict exists, the drive will not start. These alarms will be automatically cleared by the drive as soon as the parameters are changed to remove the conflicts.

Examples of configurations that cause an alarm are:

• Configuring 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

• Configuring the same toggle input function (for instance “Forward/Reverse”) to

more than one physical digital input simultaneously.

These alarms, called Type 2 Alarms, are different from other alarms in that it will not be possible to start the drive while the alarm is active. It should not be possible for any of these alarms to occur while the drive is running, because all digital input configuration parameters can only be changed while the drive is stopped. Whenever one or more of these alarms is present, the drive ready status will become “not ready” and the HIM will reflect a conflict message. In addition, the drive status light will be flashing yellow. Refer to the User Manual for a complete list of Type 2 Alarms.

Digital Outputs Each digital output can be programmed to change state based on one of many

70EC

✔✔

different conditions. These conditions fall into different categories as follows:

700VC

700H

• Drive Status Conditions (e.g. fault, reverse, etc.).

• Exceeded Levels (e.g. current, frequency, etc.)

• Controlled by a Digital Input.

• Controlled by the Network.

Drive Status Conditions

Condition Description

Fault A drive Fault has occurred and stopped the drive

Alarm A Drive Type 1 or Type 2 Alarm condition exists

Ready The drive is powered, Enabled and no Start Inhibits exist. It is “ready” to run

Run The drive is outputting Voltage and frequency to the motor (indicates 3–wire

control, either direction)

Forward Run The drive is outputting Voltage and frequency to the motor (indicates 2–wire

Reverse Run The drive is outputting Voltage and frequency to the motor (indicates 2–wire

Auto Restart The drive is currently attempting the routine to clear a fault and restart the drive

Powerup Run The drive is currently executing the Auto Restart or “Run at Power Up” function

DC Braking The drive is currently executing either a “DC Brake” or a “Ramp to Hold” Stop

Current Limit The drive is currently limiting output current

control in Forward)

control in Reverse)

command and the DC braking voltage is still being applied to the motor.

34 Digital Outputs

Condition Description

Economize The drive is currently reducing the output voltage to the motor to attempt to

reduce energy costs during a lightly loaded situation.

Motor Overld The drive output current has exceeded the programmed [Motor NP FLA] and the

electronic motor overload function is accumulating towards an eventual trip.

Power Loss The drive has monitored DC bus voltage and sensed a loss of input AC power

that caused the DC bus voltage to fall below the fixed monitoring value (82% of [DC bus Memory]

PI Enabled The drive’s process PID controller has been enabled (see “Process PID”).

PI Hold The process PID integrator is being held (see “Process PID”).

Drive Overld The drive is in a overload condition and will take action to avoid a fault, or

possibly fault if the load is not reduced (see “Drive Overload”).

Digital Out Mask Function

This feature provides a method for one of the digital outputs to change state based on monitoring of individual parameter bits. An AND or OR function can be chosen to determine the output result, based on the state of more than one bit in the selected source parameter.

Configuration

Parameters 380, 384, 388 [Digital Outx Sel] applies the mask function to the selected value in Parameter 393 [Dig Out Param]. A value of 31 chooses “Mask 1 AND” and a value of 32 chooses “Mask 1 OR”. Note: there is only one parameter (P393) that can feed this function with data and only 1 parameter (P394) than can mask the data. However, each digital output can apply either the AND function or the OR function to the result before it takes action on a digital output. The choices for parameter 393 are shown in the User Manual.

While monitoring the value of a particular choice for Parameter 393 [Dig Out Param], only the bits with a corresponding value of “1” in Parameter 394 [Dig Out Mask], will be monitored and passed through to the AND or OR digital output functions. All of the bits with zeros in the mask are ignored.

Example

This example demonstrates how to turn on a digital output if dynamic braking is occurring (the dynamic brake transistor is switching) and bus frequency regulation is also occurring. This would be an indication that the connected brake resistor is shunting energy, but there is too much regeneration for that moment in time and the drive is not following its commanded decel rate.

− P393 [Dig Out Param] = “Drive Sts 2"

− P380 [Digital Out 1 Sel] = “Mask 1 AND”

− P394 [Dig Out Mask] = 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0

Setting bits 7 and 11 of [Dig Out Mask] equal to 1 allows bit 7 (“DB Active”) and bit 11 (“Bus Freq Reg”) of [Drive Status 2]) to pass through to the AND function. This way, when both of these conditions occur together, the digital output will turn on.

2. Exceeded Levels

These functions require a level to be programmed into [Dig Out1 Level] and/or [Dig Out2 Level] depending on the output(s) being used. If the value for the specified function (frequency, current, etc.) exceeds the programmed limit, the output will activate. If the value falls back below the limit, the output will deactivate.

Notice that the [Dig Outx Level] parameters do not have units. The drive assumes the units from the selected function. For example, if the selection is current, the drive assumes that the value for [Dig Outx Level] is % rated Amps. If the selection is Temperature, the drive assumes that the value for [Dig Outx

Digital Outputs 35

Level] is degrees C. No units will be displayed on HIMs, offline tools, devices communicating over a network, PLC’s, etc.

The minimum and maximum value for [Dig Outx Level] is independent of the selection for [Dig Outx Sel].

The following values can be annunciated

Value Description

At Freq The drive output frequency equals or exceeds the programmed Limit

At Current The drive total output current exceeds the programmed Limit

At Speed The drive Output Frequency has equalled the commanded frequency

At Torque The drive output torque current component exceeds the programmed Limit

At Temp The drive operating temperature exceeds the programmed Limit

At Bus Volts The drive bus voltage exceeds the programmed Limit

At PI Error The drive Process PI Loop error exceeds the programmed Limit

Controlled by Digital Input

A digital output can be “linked” directly to a digital input. When the input is closed, the output will be energized, and when the input is open, the output will be de-energized. This “linking” will occur if two conditions exist:

– The Input is configured for any choice other than “Unused”

– The Output is configured for the appropriate “Input x Link”

Note that the output will be controlled by the state of the input, even if the input has been assigned a normal function (e.g. Start, Jog)

See "Exclusive Link" on page 31

. This selection provides a way to connect the input to the output without the output being used for another function. Note: the output still must be set for “Input x Link.”

Digital Output Timers

Each digital output has two programmable timers.

The “On Time” specifies the delay between the appearance of the programmed condition and the corresponding digital output change of state.

The “Off Time” specifies the delay between the appearance of the programmed condition and the corresponding digital output change of state.

If a transition on an output condition occurs and starts a timer, and the output condition goes back to its original state before the timer runs out, then the timer will be aborted and the corresponding digital output will not change state.

Relay Activates

CR1 On Delay = 2 Seconds

Current Limit Occurs

0510

Relay Does Not Activate

CR1 On Delay = 2 Seconds

0 5 10

Cyclic Current Limit (every other second)

36 Direction Control

4. Controlled by the Network

This configuration is used when it is desired to control the digital outputs over network communications instead of a drive related function. In this case, [Digital Out x Sel] is set to “Param Cntl,” in which case the bit value of [DigOut Setpt], parameter 379 energizes the respective digital output. Bit 0 corresponds to output 1. Bit 1 corresponds to output 2, and so on. To complete the configuration for control over a network, a datalink must be established with [Digital Out Setpt], parameter 379.

Example

Digital Output 2 controlled by Data In B1.

Setup

− [Data In B1], parameter 302 = 379 ([Dig Out Setpt] as the Data In target)

− [Digital Out2 Sel], parameter 384 = 30 “Param Cntl”

When Bit 1 of Data In B1 =1 Digital Out 2 will be energized.

Direction Control Direction control of the drive is an exclusive ownership function. Only one device

70EC

✔✔

can command direction at a time. Direction is defined as the forward (+) or reverse

700VC

700H

(–) control of the drive output frequency, not motor rotation

. Motor wiring and phasing determines its CW or CCW rotation. Direction of the drive is controlled in one of four ways:

1. 2-Wire digital input selection such as Run Forward or Run Reverse.

2. 3-Wire digital input selection such as Forward/Reverse, Forward or Reverse.

3. Control Word bit manipulation from a DPI device such as a communications

interface. Bits 4 & 5 control direction. Refer to the Logic Command Word information in Appendix A of the PowerFlex 70 or 700 User Manual.

4. The sign (+/-) of a reference signal, such as a bipolar analog input or the 16th bit

of a network reference.

Direction commands by various devices can be controlled using the [Direction Mask]. See page 49

Refer to "Digital Inputs" on page 26

for details on masks.

and "Analog Inputs" on page 4 for more detail

on the configuration and operating rules for direction control.

DPI 37

DPI Drive Peripheral Interface (DPI) is a CAN based, Master-Slave protocol, created to

70EC

✔✔

provide a standard way of connecting motor control products and optional

700VC

700H

peripheral devices together. It allows multiple (up to 6) devices to communicate with a motor control product without requiring configuration of the peripheral. DPI provides two basic message types called Client/Server (C/S) and Producer/ Consumer (P/C). Client/Server messages are used to transfer parameter and configuration information in the background (relative to other message types). Producer/Consumer messages are used for control and status information. Multiple devices can be attached to and communicate with drives at the same time. This communication interface is the primary way to interact with, and control the drive.

Important: The PowerFlex 700 Vector Control option only supports the DPI

communication protocol. It will not communicate with SCANport peripheral devices (previous generation HIM and communication adapters).

Client/Server Operation

Client/Server messages operate in the background (relative to other message types) and are used for non-control purposes. The Client/Server messages are based on a 10ms “ping” event that allows peripherals to perform a single transaction (e.g. 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 Client/Server operation. The following types of messaging are covered:

• Logging in peripheral devices

• Read/Write of parameter values

• Access to all parameter information (limits, scaling, default, etc.)

• User set access

• Fault/Alarm queue access

• Event notification (fault, alarm, etc.)

• Access to all drive classes/objects (e.g. Device, Peripheral, Parameter, etc.)

Producer/Consumer Operation

Producer/Consumer messages operate at a higher priority than Client/Server messages and are used to control/report the operation of the drive (e.g. start, stop, etc.). A P/C status message is transmitted every 5ms (by the drive) and a command message is received from every change of state in any attached DPI peripheral. Change of state is a button being pressed or error detected by a DPI peripheral. SCANport devices are slightly different in that those peripherals transmit command messages upon reception of a drive status message rather than on detection of a change of state. Producer/Consumer messages are of fixed size, so support of message fragmentation is not required. The following types of messaging are covered:

• Drive status (running, faulted, etc.)

• Drive commands (start, stop, logic parsing, etc.)

• Entering Flash programming mode

• “Soft” login and logout of peripheral devices (enabling/disabling of peripheral

control)

38 DPI

Peer-to-Peer operation

Peer-to-Peer messaging allows two devices to communicate directly rather than through the master or host (e.g. drive). They are the same priority as C/S messages and will occur in the background. If an LCD HIM is attached, it will be able to directly access peripheral parameters (e.g. communication adapter parameters) using Peer-to-Peer messages.

Peripheral devices will be scanned at a 10ms rate. Drive status messages will be produced at a 5ms rate, while peripheral command messages will be accepted (by the drive) as they occur (e.g. change of state). Based on these timings, the following worst case conditions can occur (independent of the baud rate and protocol):

• Change of peripheral state (e.g. Start, Stop, etc.) to change in the drive – 10ms

• Change in reference value to change in drive operation – 10ms

• Change in Datalink data value to change in the drive – 10ms

• Change of parameter value into drive – 20ms times the number of attached

peripherals

The maximum time to detect the loss of communication from a peripheral device is 500ms.

Table D Timing specifications contained in DPI and SCANport

DPI 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 is dependent on number of peripherals attached. Minimum time goal is 5ms (may have to be dependent on Port Baud Rate). DPI allows minimum 5ms status at 125k and 1ms status at 500k.

SCANport Host status messages only go out to peripherals once they log in. Peripherals time out if

>500ms. If Peripheral receives incorrect status message type, Peripheral generates an error. Actual time is dependent on number of peripherals attached. SCANport allows minimum rate of 5ms.

DPI Host determines MUT based on number of attached peripherals. Range of values from 2

to 125ms. Minimum goal time is 5ms. DPI allows 2ms min at 500k and 5ms min at 125k.

SCANport No MUT.

DPI Peripheral command messages (including Datalinks) are generated on change-of-state,

but not faster than Host MUT and at least every 250ms. Host will time out if >500ms.

SCANport Command messages are produced as a result of Host status message. If no command

response to Host status within 3 status scan times, Host will time out on that peripheral.

DPI Peer message requests cannot be sent any faster than 2x of MUT.

SCANport No Peer message support

DPI Host must ping every port at least one every 2 sec. Peripherals time out if >3 sec. Host will

wait maximum of 10ms (125k) or 5ms (500k) for peripheral response to ping. Peripherals typical response time is 1ms. Peripherals only allow one pending explicit message (e.g. ping response or peer request) at a time.

SCANport Host waits at least 10ms for response to ping. Host cannot send more than 2 event

messages (including ping) to a peripheral within 5ms. Peripherals typical response time is 1ms.

DPI Response to an explicit request or fragment must occur within 1 sec or device will time out

(applies to Host or Peripheral). Time-out implies retry from beginning. Maximum number of fragments per transaction is 16. Flash memory is exception with 22 fragments allowed.

SCANport Assume same 1 sec time-out. Maximum number of fragments is 16

DPI During Flash mode, host stops ping, but still supports status/command messages at a 1 –

5 sec rate. Drive will use 1 sec rate. Data transfer occurs via explicit message as fast as possible (e.g. peripheral request, host response, peripheral request, etc.) but only between two devices.

SCANport No Flash mode suppor t

The Minimum Update Time (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. Two successive Datalink commands or standard commands will still have to be separated by the MUT, however.

DriveGuard 39

DriveGuard Refer to “DriveGuard Safe-Off User Manual” publication PFLEX-UM001.

70EC

700VC

700H

✔

Drive Overload The drive overload function has two separate protection schemes, an inverse time

70EC

✔✔

protection based on current, and thermal manager based on measured power

700VC

700H

module temperature and operating conditions. The drive may fold back current limit when either of these methods detects a problem.

Any protection for the motor and associated wiring is provided by a Motor Thermal Overload feature.

The drive will monitor the temperature of the power module based on a measured temperature and a thermal model of the power module. As the temperature rises the drive may lower the PWM frequency to decrease the switching losses in the power module. If the temperature continues to rise, the drive may reduce current limit to try to decrease the load on the drive. If the drive temperature becomes critical, the drive will generate a fault.

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.

Normal Duty and Heavy Duty Operation

Applications require different amounts of overload current. Sizing a drive for Normal Duty provides 110% for 60 seconds and 150% for 3 seconds. For a heavy duty application, one larger rating of a drive is used (in comparison to the motor), and therefore provides a larger amount of overload current in comparison to the motor rating. Heavy duty sizing will provide at least 150% for 60 seconds and 200% for 3 seconds. These percentages are with respect to the connected motor rating.

Inverse Time Protection

The lower curve in Figure 2 shows the boundary of normal-duty operation, where the drive is rated to produce 110% of rated current for 60 seconds, 150% of rated current for three seconds, and 165% of rated current for 100 milliseconds. The maximum value for current limit is 150% so the limit of 165% for 100 milliseconds should never be crossed. If the load on the drive exceeds the level of current as shown on the upper curve, current limit may fold back to 100% of the drive rating until the 10/90 or 5/95 duty cycle has been achieved. For example, 60 seconds at 110% will be followed by 9 minutes at 100%, and 3 seconds at 150% will be followed by 57 seconds at 100%. With the threshold for where to take action slightly above the rated level the drive will only fold back when drive ratings are exceeded.

If fold back of current limit is not enabled in [Drive OL Mode], the drive will generate a F64 Drive Overload fault when operation exceeds the rated levels.

40 Drive Overload

Figure 2 Normal Duty Boundary of Operation

1.80

1.70

1.60

1.50

1.40

1.30

1.20

1.10

1.00

0.90

0.80

Current Level

0.70

0.60

0.50

0.40

0.30

0.20

0.10

0.00

1.00 10.00 100.00 1,000.00

Time (Seconds)

Heavy Duty operation follows the same algorithm as Normal Duty, but allows a larger percentage of rated current (one size smaller motor). The percentages are 150% for 60 seconds, 200% for 3 seconds and 220% for 100 milliseconds (see "Normal Duty and Heavy Duty Operation" on page 39

Figure 3 Heavy Duty Boundary of Operation

2.50

2.25

2.00

1.75

1.50

1.25

1.00

Current Level

0.75

0.50

0.25

0.00

1.00 10.00 100.00 1000.00 10000.00

Time (Seconds)

Thermal Manager

The thermal manager 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.

Figure 4 Thermal Manager Inputs/Outputs

Drive Overload 41

DT O S el e ct

(Off,PWM,ILmt,Both)

PWM Fr equ en cy

(2 - 12 kHz)

Curr ent Limit

(0 - 200%)

Temperature Analog Input

(Volts)

I_total

(Amp s)

Out pu t Frequency

Power Board Data

Driv e

Thermal

Overload

V_dc

(Volts)

DTO Fault

(On,Off)

Active PWM Frequency

(2 - 12 kHz)

Active Cu rrent Limit

(0 - 200%)

Drive Temperat ure

(x deg C)

IGBT Temp er ature

(x deg C)

KHz Alarm

(On, Off)

ILmt A lar m

(On, Off)

The following is a generalization of the calculations done by the thermal manager. The IGBT junction temperature T temperature T

, and a temperature rise that is a function of operating conditions.

Drive

is calculated based on the measured drive

When the calculated junction temperature reaches a maximum limit the drive will generate a fault. This fault cannot be disabled. This maximum junction temperature is stored on the power board along with other information to define the operation of the drive overload function. These values are not user adjustable. In addition to the maximum junction temperature, there are thresholds that select the point at which the PWM frequency begins to fold back, and the point at which current limit begins to fold back.

Alarm bits within [Drive Alarm 1] provide status as to when the fold back points are being reached (regardless of whether or not the drive is configured to fold back or not).

“Drv OL Lvl 1” is the alarm bit for PWM fold back. “Drv OL Lvl 2” is the alarm bit for current limit fold back.

Configuration

The [Drive OL Mode] allows the user to select the action(s) to perform with increased current or drive temperature. When this parameter is “Disabled,” the drive will not modify the PWM frequency or current limit. When set to “Reduce PWM” the drive will only modify the PWM frequency. “Reduce CLim” will only modify the current limit. Setting this parameter to “Both-PWM 1st” the drive will modify the PWM frequency first and then the current limit if necessary, to keep the drive from faulting with a Drive Overload or Overtemperature fault.

Temperature Display

The Drive’s temperature is measured (NTC in the IGBT module) and displayed as a percentage of drive thermal capacity in [Drive Temp]. This parameter is normalized to the thermal capacity of the drive (frame dependent) and displays thermal usage in % of maximum (100% = drive Trip). A test point, “Heatsink temperature” is available to read temperature directly in degrees C, but cannot be related to the trip point since “maximums” are only given in %.

42 Droop

Low Speed Operation

When operation is below 4 Hz, the IGBT duty cycle is such that heat will build up rapidly in the device. The thermal manager will increase the calculated IGBT temperature at low output frequencies and will cause corrective action to take place sooner.

When the drive is in current limit the output frequency is reduced to try to reduce the load. This works fine for a variable torque load, but for a constant 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. For example, if the thermal manager normally provides 150% for 3 seconds at high speeds, it may only provide 150% for one second before generating a fault at low speeds.

Some applications may benefit from the disabling of current limit fold back.

Droop Droop is used to “shed” load and is usually used when a soft coupling of two

70EC

✔✔

motors is present in an application. The master drive speed regulates and the

700VC

700H

follower uses droop so it does not oppose the master. The input to the droop block is the commanded motor torque. The output of the droop block reduces the speed reference. [Droop RPM @ FLA] sets the amount of speed, in RPM, that the speed reference is reduced when at full load torque. For example, when [Droop RPM @ FLA] is set to 50 RPM and the drive is running at 100% rated motor torque, the droop block would subtract 50 RPM from the speed reference.

Faults 43

Faults Faults are conditions occurring within and/or outside of the drive. These conditions

70EC

✔✔

are (by default) considered to be important enough that drive operation is

700VC

700H

discontinued. Faults are annunciated via the HIM, communications and/or digital outputs.

Once a fault occurs, it is latched, requiring a fault reset action. If the condition that caused fault still exists when the fault is reset, the drive will fault again and the fault will be latched again.

When a Fault Occurs

1. The drive is set as faulted, causing the drive output to be immediately disabled

and a “coast to stop” sequence to occur

2. The fault code is entered into the first buffer of the fault queue (see “Fault

Queue” below for rules).

3. Additional data on the status of the drive at the time that the fault occurred is

recorded. Note that there is only a single copy of this information which is always related to the most recent fault queue entry [Fault 1 Code], parameter

243. When another fault occurs, this data is overwritten with the new fault data. The following data/conditions are captured and latched into non-volatile drive memory:

– [Status 1 @ Fault] - drive condition at the time of the fault.

– [Status 2 @ Fault] - drive condition at the time of the fault.

– [Alarm 1 @ Fault], - alarm condition at the time of the fault.

– [Alarm 2 @ Fault] - alarm conditions at the time of the fault.

– [Fault Amps] - output amps at time of fault.

– [Fault Bus Volts] - DC Bus volts at time of fault.

– [Fault Frequency] or [Fault Speed] - drive output frequency (or speed) at

time of fault.

Fault Queue

Faults are also logged into a fault queue such that a history of the most recent fault events is retained. Each recorded event includes a fault code (with associated text) and a fault time of occurrence.

A fault queue will record the occurrence of each fault event that occurs while no other fault is latched. A new fault event will not be logged to the fault queue if a previous fault has already occurred, but has not yet been reset. Only faults that actually trip the drive will be logged. A fault that occurs while the drive is already faulted will be not be logged.

The fault queue is a first-in, first-out (FIFO) queue. Fault queue entry #1 will always be the most-recent entry (newest). As new faults are logged, existing entries will be shifted up by one. If the queue is full when a fault occurs, the oldest entry will be discarded.

The fault queue will be saved in nonvolatile storage at power loss, thus retaining its contents through a power off-on cycle.

44 Faul ts

Fault Code/Text [Fault Code x]

The fault code for each entry can be read in its respective read-only parameter. When viewed with a HIM, only the fault code (not text) is displayed. If viewed via a DPI peripheral (communications network), the queue is not accessed through parameters, and a text string of up to 16 characters is also available.

Fault Time [Fault x Time]

The drive has an internal drive-under-power timer that increments in value over the life of the drive and is saved in nonvolatile storage. Each time the drive is powered down and then repowered, the value of this timer is written to [Power Up Marker], parameter 242.

The time is presented in xxx.yyyy hours (4 decimal places). Internally it will be accumulated in a 32-bit unsigned integer with a resolution of 0.35 seconds, resulting in a rollover to zero every 47.66 years.

The time stamp value recorded in the fault queue at the time of a fault is the value of internal drive under power timer. By comparing this value to the [PowerUp Marker], it is possible to determine when the fault occurred relative to the last drive power-up.

Power Up Marker

This is a copy of the factory “drive under power” timer at the most recent power-up of the drive. It is used to provide relevance of [Fault x Time] values with respect to the power-up of the drive.

Resetting or Clearing a Fault

A latched fault condition can be cleared by the following:

1. An off to on transition on a digital input configured for fault reset or stop/reset.

2. Setting [Fault Clear] to “1.”

3. A DPI peripheral (several ways).

4. Performing a reset to factory defaults via parameter write.

5. Cycling power to the drive such that the control board goes through a power-up

sequence.

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. This can be done from a menu selection of the HIM or from a DPI command through the communications port.

Fault Configuration

The drive can be configured such that some conditions do not trip the drive.

[Fault Config 1] is a 16 bit parameter enabling or disabling specific fault conditions (see below).

Flux Braking 45

Following is a brief list of each configurable fault. Some of these faults are explained in more detail in their own section of this document.

Bit Fault Description

0 Power Loss

1 Undervoltage

2 Reserved

3 Motor Overload

4 Shear Pin

5 Auto Restart Tries

6 Decel Inhibit

7 Motor Thermistor

8 Input Phase Loss

9 Load Loss

10 Reserved

11 Shear Pin No Accel

12 Output Phase Loss

13 PTC Hardware

Flux Braking Flux braking is used to provide extra braking capability without the use of a brake

70EC

✔✔

resistor, by taking advantage of the losses in a motor. Flux braking can be used not

700VC

700H

only to brake a load to a complete stop, but also to brake a load from one speed to a lesser speed. For a complete list of methods that will bring the load to a complete stop, see "Stop Modes" on page 109

To enable flux braking:

1. [Bus Reg Mode A, B] must be set to “1” Adjust Freq to enable the bus regulator.

2. [Flux Braking] must be set to 1 “Enabled”.

When enabled, flux braking automatically increases the motor flux resulting in an increase of motor losses, but only when braking is required. 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.

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. Also consider using external motor thermal protection.

46 Flux Up

Flux Up AC induction motors require flux to be established before controlled torque can be

70EC

✔✔

developed. To build flux, voltage is applied. There are two methods to flux the

700VC

700H

motor.

The first method is during a normal start. Flux is established as the output voltage and frequency are applied to the motor. While the flux is being established, the unpredictable nature of the developed torque may cause the rotor to oscillate even though acceleration of the load may occur. In the motor, the acceleration profile may not follow the commanded acceleration profile due to the lack of developed torque.

Figure 5 Accel Profile during Normal Start - No Flux Up

Frequency

Reference

Rated Flux

Stator

Frequency

Oscillation due to flux being established

Time

Rotor

The second method is Flux Up Mode. In this mode, DC current is applied to the motor so that the flux is established before rotation. The flux up time period is based on the level of flux up current and the rotor time constant of the motor. The flux up current is not user adjustable.

Figure 6 Flux Up Current versus Flux Up Time

Flux Up Current = Maximum DC Current

Rated Flux

Current

Flux Up Current

Flux Up Time

Rated Motor Flux

Motor Flux

[Flux Up Time]

Once rated flux is reached in the motor, normal operation begins and the desired acceleration profile is achieved.

Figure 7 Rated Flux Reached

Ir Voltage - SVC

Greater of IR Voltage or

Flux Up

Voltage

Voltage Boost - V/Hz

Motor Flux

Flux Up

Normal

Operation

Stator Voltage

Rotor Speed

Motor Flux

Stator Freq

Time

Flying Start 47

Flying Start The Flying Start feature is used to start into a rotating motor, as quick as possible,

70EC

✔✔

and resume normal operation with a minimal impact on load or speed.

700VC

700H

When a drive is started in its normal mode it initially applies a frequency of 0 Hz and ramps to the desired frequency. If the drive is started in this mode with the motor already spinning, large currents will be generated. An overcurrent trip may result if the current limiter cannot react quickly enough. The likelihood of an overcurrent trip is further increased if there is a residual flux (back emf) on the spinning motor when the drive starts. Even if the current limiter is fast enough to prevent an overcurrent trip, it may take an unacceptable amount of time for synchronization to occur and for the motor to reach its desired frequency. In addition, larger mechanical stress is placed on the application.

In Flying Start mode, the drive’s response to a start command is to synchronize with the motors speed (frequency and phase) and voltage. The motor will then accelerate to the desired frequency. This process will prevent an overcurrent trip and significantly reduce the time for the motor to reach its desired frequency. Since the drive synchronizes with the motor at its rotating speed and ramps 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”

The gain can be adjusted to increase responsiveness. Increasing the value in [Flying StartGain] increases the responsiveness

of the Flying Start Feature

Application Example

In some applications, such as large fans, wind or drafts may rotate the fan in the reverse direction when the drive is stopped. If the drive were started in the normal manner, its output would begin at zero Hz, acting as a brake to bring the reverse rotating fan to a stop and then accelerating it in the correct direction.

This operation can be very hard on the mechanics of the system including fans, belts and other coupling devices.

Cooling Tower Fans

Draft/wind blows idle fans in reverse direction. Restart at zero damages fans, breaks belts. Flying start alleviates the problem

48 High Resolution Speed Reference

High Resolution Speed Reference

✔

70EC

700VC

The high resolution speed reference provides a 32 bit (as opposed to a 16 bit) speed reference from a communication network. The high resolution 32 bit reference is

700H

scaled so that a value of 2147483647 corresponds to [Maximum Freq], parameter 55 if [DPI Ref Select], parameter 298 = “0, Max Freq,” or 2147483647 corresponds to [Maximum Speed], parameter 82 if [DPI Ref Select] = “1, Max Speed.”

To use the high resolution reference, [Speed Ref A Sel] or [Speed Ref B Sel] is set to “30, HighRes Ref.” Then [HighRes Ref], parameter 308 is used as a reference through datalinks. A pair of datalinks (e.g. A1 and A2 or B1 and B2, etc.) must be set to write to [HighRes Ref].

Example

The following example writes the high resolution reference to a PF70EC on Ethernet from ControlLogix.

Drive Parameter Settings:

− [Speed Ref A Sel], parameter 90 = 30 “HighRes Ref”

− [DPI Ref Select], parameter 298 = 1 “Max Speed”

− [Data In A1], parameter 300 = 308

− [Data In A2], parameter 301 = 308

Data In A1 will contain the least significant word (LSW) of the speed reference and Data In A2 will contain the most significant word (MSW) of the speed reference.

ControlLogix Program

A PF70EC is added in I/O Configuration. Then a new tag of type DINT is created for the high resolution speed reference.

Input Phase Loss Detection

70EC

✔✔

Next, the speed reference is written to the DINT tag “PF70EC_HighResSpdRef.” Using the COP instruction, the DINT tag is copied to 2 UserDefinedData tags. The tag PF70EC:O:UserDefinedData[0] corresponds to Data In A1 in the drive and the tag PF70EC:O:UserDefinedData[1] corresponds to Data In A2.

Setting the tag PF70EC_HighResSpdRef to 2147483647 corresponds to [Max Speed] of the drive.

Important: In 16 bit processors such as the SLC and PLC-5, there are no DINT data types, so the high resolution speed reference remains split as 2 separate 16-bit words.

Occasionally, three-phase power sources can fail on one phase while continuing to deliver power between the remaining 2 phases (single-phase). Operating above

700VC

700H

50% output under this single-phase condition can damage the drive. If such a condition is likely, it is recommended that Input Phase Loss Detection be enabled. The drive can be programmed to simply turn on an alarm bit, or also fault the drive. The drive accomplishes this by interpreting voltage ripple on the DC bus.

Configuration

•

[Drive Alarm 1], parameter 259, bit 12 - “In Phase Loss” 0 = disabled, 1 = enabled.

• [Fault Config 1], parameter 238, bit 8 - “In Phase Loss” 0 = disabled, 1 =

enabled

Language 49

Language Seven languages are supported; English, Spanish, German, Italian, French,

70EC

✔✔

Portuguese and Dutch. All drive functions and information displayed on an LCD

700VC

700H

HIM are shown in the selected language. The desired language can be selected by any of the following methods.

• 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. This is accomplished by pressing the “Alt” key followed by the “Lang” key.

• The language can also be changed by selecting the [Language] parameter (201).

Load Loss Detection The output torque current is monitored by the drive and may be used to indicate a

70EC

✔✔

loss of load. This can be used to indicate a mechanical problem with load, or faulty

700VC

700H

wiring. Both the threshold level and amount of time the condition must be present before action is taken, is adjustable. The drive can be programmed to simply turn on an alarm bit, or also fault the drive.

Configuration

•

[Load Loss level], parameter 187, 0-800% of rated motor torque (based on entered nameplate data)

• [Load Loss Time], parameter 188, 0 - 300 seconds

• [Alarm Config 1], parameter 259, bit 13 - “Load Loss” 0 = disabled, 1 = enabled

• [Fault Config 1], parameter 238, bit 9 - “Load Loss” 0 = disabled, 1 = enabled

Masks A mask is a parameter that contains one bit for each of the possible communication

70EC

✔✔

ports. Masking (setting a bit's value to 0) stops the command from reaching the

700VC

700H

drive logic. Unmasking (setting a bit's value to 1) allows the command to pass through into the drive logic.

Example

A customer's process is normally controlled by a remote PLC, but the drive is mounted on the machine. The customer does not want anyone to reverse the drive by pressing “Reverse” on the locally mounted HIM (DPI port 1), because it would damage the process. To assure that only the PLC (connected to DPI port 5) has direction control, the [Direction Mask] can be set as follows:

Direction Mask

00100000

↑↑↑↑↑↑↑↑

Adapter # X6543210

This “masks out” the reverse function from all communication ports except port 5, making the local HIM (port 1) Reverse button inoperable. Also see "Owners" on page 59

50 MOP

MOP The Motor Operated Pot (MOP) function uses either digital inputs or network

70EC

✔✔

commands to increment or decrement the speed reference at a programmed rate.

700VC

700H

The MOP has three components:

• [MOP Rate] parameter

• [Save MOP Ref] parameter

• [MOP Frequency] parameter

MOP increment input

MOP decrement input

The MOP rate is the rate at which the MOP reference will change when commanded to increment or decrement. This rate is independent of acceleration and deceleration times.

MOP Dec

MOP Inc

MOP Reference

MOP rate is defined in Hz/sec. The MOP reference will increase/decrease linearly at that rate as long as the MOP inc or dec is asserted. Asserting both MOP inc and dec inputs simultaneously will result in no change to the MOP reference.

[Save MOP Ref] is a parameter that provides configurability of the initial MOP reference value after a power down or Stop command.

Bit 0 0 = Don’t save MOP reference on power-down (default) 1 = Save MOP reference on power-down

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.

Bit 1 0 = Reset MOP reference when STOP is asserted 1 = Don’t reset MOP reference when STOP is finished (default)

Important: The MOP reset only occurs when a stop event completes and is not

continuously cleared while the drive is stopped. The reset only applies to the stop edge and not when a fault is detected.

Incrementing or decrementing the MOP frequency is independent of whether or not MOP is being used as the speed reference. See "Speed Reference" on page 98

for

an explanation of activating a specific speed reference.

The [MOP Frequency] parameter shows the value of the MOP reference.

MOP handling with Direction Mode

If the Direction Mode is configured for “Unipolar,” then the MOP decrement will clamp at zero not allowing the user to generate a negative MOP reference that is clamped off by the reference generation. When Direction Mode = “Bipolar” the MOP reference will permit the decrement function to produce negative values. If the drive is configured for Direction Mode = “Bipolar” and then is changed to “Unipolar”, the MOP reference will also be clamped at zero if it was less than zero.

Motor Control Modes 51

Motor Control Modes [Motor Cntl Sel] selects the output mode of the drive. The choices are:

70EC

✔✔

• Custom Volts/Hertz

700VC

700H

Used in multi-motor or synchronous motor applications.

• Fan/Pump Volts/Hertz

Used for centrifugal fan/pump (variable torque) applications to achieve maximum energy savings.

• Sensorless Vector

Used for most constant torque applications. Provides excellent starting, acceleration and running torque.

• Sensorless Vector w/Economizer

Used for additional energy savings in constant torque applications that have constant speed reduced load periods.

• Flux Vector

Used when high performance speed regulation or torque regulation is required.

• Adjustable Voltage

Typically used for non-motor applications such as resistive loads, welding equipment and power supplies, but also linear motors.

The following table shows the performance differences between V/Hz, Sensorless Vector and Flux Vector.

700VC ONLY

Fan/Pump and

Torque Mode

Speed Regulation (% of base speed)

Operating Speed Range 40:1 80:1 80:1 120:1 1000:1 Speed Bandwidth 10 rad/sec 20 rad/sec 20 rad/sec 50 rad/sec ≥125 rad/sec Torque Regulation N/A N/A N/A ≤10% ≤5%

Custom V/Hz with Slip Comp

0.5% 0.5% 0.1% 0.1% 0.001%

SVC with Slip Comp

SVC with Feedback

Flux Vector without Feedback

Flux Vector with Feedback

Volts /He rt z

Volts/Hertz operation creates a fixed relationship between output voltage and output frequency. The relationship can be defined in two ways.

1. Fan/Pump

When this option is chosen, the relationship is 1/x for full frequency, full voltage is supplied and for 1/2 rated frequency, 1/4 voltage is applied, etc. This pattern closely matches the torque requirement of a variable torque load (centrifugal fan or pump – load increases as speed increases) and offers the best energy savings for these applications.

Maximum Voltage

Base Voltage

(Nameplate)

. Therefore;

Run Boost

Base Frequency

(Nameplate)

Maximum Frequency

52 Motor Control Modes

2. Custom

Custom Volts/Hertz allows a wide variety of patterns. The default configuration is a straight line from zero to rated voltage and frequency. As seen in the diagram below, the volts/hertz ratio can be changed to provide increased torque performance when required 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. The drive will lower the boost voltage to this level when running at low speeds (not accelerating). This reduces excess motor heating that could be caused if the higher start / accel boost level were used.

– Break Voltage/Frequency - Used to increase the slope of the lower portion

of the Volts / hertz curve, providing additional torque.

– Motor Nameplate Voltage/Frequency - sets the upper portion of the curve

to match the motor design. Marks the beginning of the constant power region

– Maximum Voltage/Frequency - Slopes the portion of the curve used above

base speed.

Maximum Voltage

Base Voltage

(Nameplate) Voltage

Break Voltage

Start/Accel Boost

Run Boost

Break

Frequency

Base Frequency

(Nameplate)

Maximum Frequency

Sensorless Vector

Sensorless Vector mode uses a V/Hz core enhanced by excellent current resolution, a slip estimator, a high performance current limiter and the vector algorithms.

CURRENT FEEDBACK - TOTAL

TORQUE I EST.

V/Hz Control

SPEED REF. FREQUENCY REF.

ELEC. FREQ. V REF.

Current

Limit

TORQUE I EST.

SLIP FREQUENCY

V/Hz

Vector

Control

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 identify the motor values (see "Autotune" on page 16

). Sensorless vector offers better torque production and a wider speed range than V/Hz. However, it may not be appropriate when more than one motor is connected to the same drive.

V VECTOR

Current

Resolver

Voltage Control

CURRENT FEEDBACK

GATE

SIGNALS

Inverter Motor

TORQUE I EST.

Slip

Estimator

Motor Control Modes 53

In sensorless vector control, the drive commands a specific amount of voltage to develop flux.

Maximum Voltage

Base Voltage

(Nameplate)

Appproximate Full Load Curve

Ir Voltage

Appproximate No Load Curve

Base Frequency

(Nameplate)

Maximum

Frequency

Sensorless Vector w/Economizer

Economizer mode consists of the sensorless vector control with an additional energy savings function.

When steady state speed is achieved, the economizer becomes active and automatically adjusts the drive output voltage based on applied load. By matching output voltage to applied load, the motor efficiency is optimized. Reduced load commands a reduction in motor flux current. The flux current is reduced as long as the total drive output current does not exceed 75% of motor rated current as programmed in [Motor NP FLA], parameter 42. The flux current is not allowed to be less than 50% of the motor flux current as programmed in [Flux Current Ref], parameter 63. During acceleration and deceleration, the economizer is inactive and sensorless vector motor control performs normally.

Maximum Voltage

Motor Nameplate Voltage

Rated Flux Current

Increasing Load

total

Reduced Flux Current, minimum of 50% of Rated Flux Current

Ir Voltage

Frequency

Motor Nameplate

Frequency

Maximum Frequency

Flux Vector Control

In flux vector mode, the flux and torque producing currents are independently controlled and speed is indirectly controlled by a torque reference. Alternatively, the drive can control torque instead of speed in flux vector mode. In either case, this mode can be operated either with or without feedback and will provide the fastest response to load changes.

54 Motor Nameplate Data

Figure 8 Flux Vector

SPEED REF.

Speed

Reg.

Flux

Reg.

TORQUE REF.

High Bandwidth Current Regulator

CURRENT FEEDBACK

V mag

Current

Reg.

V ang

Voltage Control

Inverter Motor

Motor Nameplate Data

70EC

✔✔

Adaptive

Controller

AUTOTUNE PARAMETERS

SLIP

SPEED FEEDBACK

These parameters provide motor information to the drive, so the drive can both protect the motor and also make internal adjustments to provide the best

700VC

700H

performance.

[Motor NP Volts] The rated voltage as stated on the motor nameplate.

[Motor NP FLA] The rated full load amps as stated on the motor nameplate.

[Motor NP Hz] The rated base frequency as stated on the motor nameplate.

[Motor NP RPM] The rated base speed in RPM as stated on the motor nameplate.

[Motor NP Power] The rated power as stated on the motor nameplate. This may be entered in horsepower or in kilowatts as selected in [Mtr NP Pwr Units], parameter 46.

Encoder

[Mtr NP Pwr Units] Determines the units for [Motor NP Power]. Possible settings are:

• 0 “Horsepower” - units are displayed in HP.

• 1 “kilowatts” - units are displayed in kW.

• 2 “Convert HP” - converts units to HP (from kW) by dividing [Motor NP

Power] by 0.746 (PowerFlex 700VC Only).

• 3 “Covert kW” - converts units to kW (from HP) by multiplying [Motor NP

Power] by 0.746 (PowerFlex 700VC Only).

[Motor Poles] Defines the number of poles in the motor. [Motor Poles] is calculated automatically if the user enters the motor nameplate data through the Assisted Start-up menu of an LCD HIM. The number of motor poles is defined by:

120f

---------=

where: P = motor poles f = base motor frequency (Hz) N = synchronous RPM at base motor frequency (f)

Motor Overload 55

Motor Overload The motor overload protection feature uses an IT (inverse time) algorithm to model

70EC

✔✔

the temperature of the motor and follows the same curve as a physical class 10

700VC

700H

overload device.

100000

10000

Motor Overload Curve

1000

Trip Time (Seconds)

100

100 125 150 175 200 225

Full Load Amps (%)

Cold Hot

250

[Motor NP FLA] is used by the overload feature to establish the 100% level (y axis) shown in the graph above.

Setting the correct bit in [Fault Config x] to zero disables the motor thermal overload. For multimotor applications (more than one motor connected to one drive), separate external overloads for each motor are required, and the drive’s motor overload can be disabled.

Operation of the overload is based on three parameters; [Motor NP FLA], [Motor OL Factor] and [Motor OL Hertz].

1. [Motor NP FLA] is the base value for motor protection.

2. [Motor OL Factor] is used to adjust for the service factor of the motor. Within

the drive, motor nameplate FLA is multiplied by motor overload factor to select the rated current for the motor thermal overload. This can be used to raise or lower the level of current that will cause the motor thermal overload to trip without the need to adjust the motor FLA. For example, if motor nameplate FLA is 10 Amps and motor overload factor is 1.2, then motor thermal overload will use 12 Amps as 100%.

Important: Some motors have a service factor that is only for use with sine

wave (non-drive) power. Check with the motor manufacturer to see if the nameplate service factor is valid or must be reduced when operated by a drive.

Changing Overload Factor

140

120

100

Continuous Rating

0 102030405060708090100

% of Base Speed

OL % = 1.20

OL % = 1.00

OL % = 0.80

56 Motor Overload

3. [Motor OL Hertz] is used to further protect motors with limited speed ranges.

Since many motors do not have sufficient cooling ability at lower speeds, the overload feature can be programmed to increase protection in the lower speed areas. This parameter defines the frequency where derating the motor overload capacity should begin. For all settings of overload Hz other than zero, the overload capacity is reduced to 70% when output frequency is zero. During DC injection braking, the motor current may exceed 70% of FLA, but this will cause the motor overload to trip sooner than when operating at base speed. At low frequencies, the limiting factor may be the drive overload rather than the motor overload.

Changing Overload Hz

120

100

Continuous Rating

0 102030405060708090100

OL Hz = 10

OL Hz = 25

OL Hz = 50

Duty Cycle for the Motor Overload

When the motor is cold, this function will allow 3 minutes at 150%. When the motor is hot, it will allow 1 minute at 150%. A continuous load of 102% is allowed to avoid nuisance faults. The duty cycle of the motor overload is defined as follows. If operating continuous at 100% FLA, and the load increases to 150% FLA for 59 seconds and then returns to 100%FLA, the load must remain at 100% FLA for 20 minutes to reach steady state.

1 Minute 1 Minute

150%

100%

20 Minutes

The ratio of 1:20 is the same for all durations of 150%. When operating continuous at 100%, if the load increases to 150% for 1 second the load must then return to 100% for 20 seconds before another step to 150%.

FLA%

Time

105 6320 5995 155 160 50 205 66 14

110 1794 1500 160 142 42 210 62 12

115 934 667 165 128 36 215 58 11

120 619 375 170 115 31 220 54 10

125 456 240 175 105 27 225 51 10

130 357 167 180 96 23 230 48 9

135 291 122 185 88 21 235 46 8

140 244 94 190 82 19 240 44 8

145 209 74 195 76 17 245 41 7

150 180 60 200 70 15 250 39 7

Cold Trip

Hot Trip Time FLA%

Cold Trip Time

Hot Trip Time FLA%

Cold Trip Time

Hot Trip Time

Notch Filter 57

Important: If the application requires high overload current for long durations

(e.g. 150% for 60 seconds), heavy duty sizing (between drive and motor) will be required. See "Normal Duty and Heavy Duty Operation" on page 39

Notch Filter A notch filter exists in the torque reference loop to reduce mechanical resonance

70EC

created by a gear train. [Notch Filter Freq] sets the center frequency for the 2 pole

700VC

700H

notch filter, and [Notch Filter K] sets the gain.

✔

Figure 9 Notch Filter Frequency

Gain

0 db

Notch Filter K

Notch Filter Frequency

Example

A mechanical gear train consists of two masses (the motor and the load) and spring (mechanical coupling between the two loads). See Figure 10

Figure 10 Mechanical Gear Train

Kspring

Jm Jload

The resonant frequency is defined by the following equation:

Jm Jload+()

resonance Kspring

-------------------------------

Jm Jload×

Jm is the motor inertia (seconds) Jload is the load inertia (seconds) Kspring is the coupling spring constant (rad2/sec)

BLBm

Figure 11 shows a two mass system with a resonant frequency of 62 radians/second

(9.87 Hz). One Hertz is equal to 2π radians/second.

58 Notch Filter

Figure 11 Resonance

Figure 12 represents the same mechanical gear train but with [Notch Filter Freq] set

to 10.

Figure 12 10 Hz Notch

Owners 59

Owners Owners are status parameters that show which peripheral devices (HIMs, comm

70EC

✔✔

ports, etc.) are commanding or have exclusive control of specific control functions.

700VC

700H

The list of devices also includes the drive’s control terminal block.

Exclusive

Only one device at a time can control the drive and only one owner bit will be high. The following owners are Exclusive:

• [Direction Owner]

• [Reference Owner]

• [Accel Owner]

• [Decel Owner]

• [Local Owner]

Non Exclusive

Multiple devices can simultaneously issue the same command and multiple owner bits may be high. The following owners are Not Exclusive:

• [Stop]

• [Start Owner]

• [Jog Owner]

• [Fault Clr Owner]

• [MOP Owner]

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.

Start Owner

00000010

↑↑↑↑↑↑↑↑

Adapter # X654321

When the local Start button is pressed, the display indicates that the command is coming from the HIM.

Stop Owner

00000001

↑↑↑↑↑↑↑↑

Adapter # X6543210

The operator then checks the Stop Owner. Notice that bit 0 is a value of “1,” indicating that the Stop device wired to the digital input terminal block is open, issuing a Stop command to the drive.Until this device is reclosed, a permanent Start Inhibit condition exists and the drive will not restart.

60 Password

Password By default the password is set to 00000 (password protection disabled).

70EC

700VC

700H

✔✔

Logging in to the Drive

Step Key(s) Example Displays

1. Press the Up or Down Arrow to enter your password. Press Sel to move from digit to digit.

Password

9999

2. Press Enter to log in.

Logging Out

Step Key(s) Example Displays

You are automatically logged out when the User Display appears. If you want to log out before that, select “log out” from the Main Menu.

To change a password

Step Key(s) Example Displays

1. Use the Up Arrow or Down Arrow to scroll to Operator Intrfc. Press Enter.

2. Select “Change Password” and press Enter.

3. Enter the old password. If a password has not been set, type “0.” Press Enter.

4. Enter a new password (1- 65535). Press Enter and verify the new password. Press Enter to save the new password.

Operator Intrfc:

Change Password

User Display

Parameters

Password:

Old Code: 0

New Code: 9999

Position Indexer/Speed Profiler 61

Position Indexer/ Speed Profiler

70EC

700VC

✔

Overview

700H

The profile/indexer may be configured as a velocity regulator or a position regulator. If position control is desired, encoder feedback is required. Parameter 088, [Speed/Torque Mod] is used to select the “Pos/Spd Prof” mode. Sixteen steps are available with this feature.

Common Guidelines for all step types

Direction Control - The drive must be configured to allow the profile to control the direction. This is accomplished by setting [Direction Mode], parameter 190 to “Bipolar.”

- Many threshold values can affect the performance of the profile/indexer. To

Limits help minimize the possibility of overshooting a position, ensure that the following parameters are set for the best performance.

[Regen Power Limit] - default is –50% and will likely require a greater negative value. A brake or other means of dissipating regenerative energy is recommended.

[Current Lmt Sel] & [Current Lmt Value] - By default these parameters are set to provide 150% of drive rating. If lowered, the performance may be degraded.

[Bus Reg Mode A] - The default setting will adjust frequency to regulate the DC bus voltage under regenerative conditions. This will most likely cause a position overshoot. To resolve this, select “Dynamic Brak” and size the load resistor for the application.

[Bus Reg Mode B] - The default setting will adjust frequency to regulate the DC bus voltage under regenerative conditions. This will most likely cause a position overshoot. To resolve this, select “Dynamic Brak” and size the load resistor for the application.

Speed Regulator

- The bandwidth of the speed regulator will affect the performance. If the connected inertia is relatively high, the bandwidth will be low and therefore a bit sluggish. When programming the acceleration and deceleration rates for each step, do not make them too aggressive or the regulator will be limited and therefore overshoot the desired position.

Position Loop Tuning

Two parameters are available for tuning the position loop. [Pos Reg Filter], parameter 718 is a low pass filter at the input of the position regulator. [Pos Reg Gain], parameter 719 is a single adjustment for increasing or decreasing the responsiveness of the regulator. By default these parameters are set at roughly a 6:1 ratio (filter = 25, gain = 4). It is recommended that a minimum ratio of 4:1 be maintained.

Jogging

A jog function is compatible with profiling but the drive must be in a stopped condition. If the drive is presently running a profile, the jog will be ignored. The direction of the jog is controlled by the sign of the jog speed. This can be manipulated via analog input scaling, from a network communication device or with the HIM module.

62 Position Indexer/Speed Profiler

Profile Command Control Word

The profile/indexer is controlled with [Profile Command], parameter 705. The bit definitions are as follows:

Bit Name Description

0 Start Step 0 The binary value of these bits determines which step will be the starting step

1 Start Step 1

2 Start Step 2

3 Start Step 3

4 Start Step 4

5-7 Reserved Not used

8 Hold Step When set, this command will inhibit the profile from transitioning to the next

9 Pos Redefine This bit is used to set the present position as Home. When this bit is set,

10 Find Home This bit is used to command the Find Home routine.

11 Vel Override When this bit is set the velocity of the present step will be multiplied by the

12-31 Reserved Not used.

for the profile when a start command is issued. If the value of these bits are not 1-16 the drive will not run since it does not have a valid step to start from. Valid Examples: 00011 = step 3, 01100 = step 12

step when the condition(s) required are satisfied. When the Hold command is released, the profile will transition to the next step.

[Profile Status] bit “At Home” will be set and the [Units Traveled] will be set to zero.

value in [Vel Override].

The bits in [Profile Command] can be set via DPI interface (HIM or Comm) or digital inputs. When digital input(s) are programmed for “Pos Sel 1-5,” the starting step of the profile is exclusively controlled by the digital inputs. The DPI interface value for bits 0-4 will be ignored.

If a digital input is configured for bit 8-11 functions of the [Profile Command], the DPI interface or the digital input can activate the command.

Velocity Regulated Step Parameters

Each of the Velocity Regulated steps has the following associated parameters or functions:

Step Type

Digital

Time Time Blend

Val ue To ta l Mo v e

Veloc ity Speed &

Accel Time Accel Rate Accel Rate Accel Rate Accel Rate Accel Rate X

Decel Time Decel Rate Decel Rate Decel Rate Decel Rate Decel Rate Decel Rate

Next Step Condition

Dwell Dwell Time X Dwell Time X Compare

Batch Batch

Next Next Step Next Step Next Step Next Step Next Step X (Stop)

X = Function not applicable to this step type

Time

Direction

Time greater than [Step Value]

Number

Total Time Digital Input

Speed & Direction

Time greater than [Step Val ue]

XBatch

Input

Number

Speed & Direction

Digital Input logic

Number

Encoder Incremental Blend

Position & Direction Parameter

Speed Speed &

At Position [Step Val ue]

XXX

Parameter Level End

Number ±

Direction

[Step Value] > or < [Step Dwell]

Val ue

At Zero transition

Dwell Time

Position Indexer/Speed Profiler 63

Position Regulated Step Parameters

Each of the Position Regulated steps has the following associated parameters or functions:

Step Type

Encoder Absolute Encoder Incremental End Hold Position

Value Position & Direction Position & Direction X

Velocity Speed Speed X

Accel Time Accel Rate Accel Rate X

Decel Time Decel Rate Decel Rate X

Next Step Condition At Position = 1 At Position =1 At Position =1

Dwell Dwell Time Dwell Time Dwell Time

Batch X Batch Number X

Next Next Step Next Step X (Stop)

X = Function not applicable to this step type

Homing Routine

Each time the profile/indexer is enabled, the drive requires a home position to be detected. The following options are available:

Homing to Marker Pulse with Encoder Feedback

- When “Find Home” is commanded, the homing routine is run when a start command is issued. The Homing bit (11) in [Profile Status], parameter 700 will be set while the homing routine is running. The drive will ramp to the speed and direction set in [Find Home Speed], parameter 713 at the rate set in [Find Home Ramp], parameter 714 until the digital input defined as Home Limit is activated. The drive will then ramp to zero and then back up to first marker pulse prior to the Home Limit switch at 1/10th the [Find Home Speed]. When on the marker pulse, the At Home bit (13) is set in the [Profile Status] and the drive is stopped.

The diagram below shows the sequence of operation for homing to a marker pulse. [Encoder Z Chan], parameter 423 must be set to “Marker Input” or “Marker Check” for this type of homing.

Homing to Marker

250

200

150

Units Traveled

100

Encoder Spee d

2 7 12 17 22 27 42

-50

Find Home Command

-100

Homing

Start Command

[Encoder Speed], 415 [Units Traveled], 701 [Dig In Status], 216[Profile Status], 700

Home Limit Input

3732

At Home

Profile Status

Digital In Statu s

64 Position Indexer/Speed Profiler

Homing to Limit Switch with Encoder Feedback - When “Find Home” is commanded, the homing routine is run when a start command is issued. The Homing bit (11) in [Profile Status], parameter 700 will be set while the homing routine is running. The drive will ramp to the speed and direction set in [Find Home Speed], parameter 713 at the rate set in [Find Home Ramp], parameter 714 until the digital input defined as Home Limit is activated. The drive will then reverse direction at 1/10th the [Find Home Speed] to the point where the Home Limit switch activated and stop.

The diagram below shows the sequence of operation for homing to a limit switch with encoder feedback (without a marker pulse). [Encoder Z Chan], parameter 423 must be set to “Pulse Input” or “Pulse Check.”

Homing to Limit Switch

At Home

6015 65

Profile Status

Digital In Statu s

250

200

150

Units Traveled

100

Encoder Spee d

20 25 30 35 40 45 50 55

Find Home Command

-50

[Encoder Speed], 415 [Units Traveled], 701 [Dig In Status], 216[Profile Status], 700

Homing

Home Limit Input

Start Command

Homing to Limit Switch w/o Encoder Feedback - When “Find Home” is commanded, the homing routine is run when a start command is issued. The Homing bit (11) in [Profile Status], parameter 700 will be set while the homing routine is running. The drive will ramp to the speed and direction set in [Find Home Speed], parameter 713 at the rate set in [Find Home Ramp], parameter 714 until the digital input defined as Home Limit is activated. The drive will then decelerate to zero. If the switch is no longer activated, the drive will reverse direction at 1/10th the [Find Home Speed] to the switch position and then stop. The Home Limit switch will be active when stopped.

The diagram below shows the sequence of operation for homing to a limit switch without encoder feedback.

Homing to Limit Switch (No Feedback)

200

150

100

-50

Home Limit Input

Find Home Command

20 25 30 450 35

[Speed Feedback], 25 [Dig In Status], 216[Profile Status], 700

Start Command

At HomeHoming

Position Redefine – When “Pos Redefine” is set, the present position is established as home and [Units Traveled] is set to zero.

Position Indexer/Speed Profiler 65

Disable Homing Requirement – If a home position is not required, the routine can be disabled by clearing [Alarm Config 1] bit 17 “Prof SetHome” to “0.” This will disable the alarm from being set when “Pos/Spd Prof” mode is configured in [Speed/Torque Mod] and will set the present position as home.

Once Homing is complete the “Find Home” command must be removed to allow the profile to be run. If the “Find Home” command is not removed, when the drive is started, the routine will see that it is At Home and the drive will stop.

Velocity Regulator Step Types

End – The drive ramps to zero speed and stops the profile. It clears the current step bits and sets the Complete bit (14) in [Profile Status], parameter 700 word.

Time

– When started, the drive will ramp to the desired velocity, hold the speed,

and then ramp to zero in the programmed time for the given step.

The example below shows a five step profile. The first 3 are Time steps followed an Encoder Abs step to zero then an End step. For each Time step the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Velocity]. The drive then decelerates at [Step X DecelTime] to zero. The [Step X Value] is programmed to the desired time for the total time of the accel, run and decel of the step. Each step has a 1 second time programmed in [Step X Dwell] which is applied to the end of each step. After the dwell time expires, the profile transitions to the next step. The absolute step is used to send the profile back to the home position. This is done by programming [Step 4 Value] to zero.

Timed Steps

Step 5

Step X Value

Units Traveled

Current Step

Step X Dwell

Step X Batch

Step X Next

350

250

150

Profile Status (Scaled)

-50

-150

Encoder Spee d

-250

-350

-450

Note: there is no "At Position"

indication when using timed steps

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step # Step X Type

53 73 93 153113 133

Step 2

Step X Velocity

Step 3

Time

Step X AccelTime

Step 4

Step X DecelTime

1 Time 100 0.5 0.5 5.00 1.00 1 2

2 Time 200 0.5 0.5 5.00 1.00 1 3

3 Time 300 0.5 0.5 5.00 1.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

66 Position Indexer/Speed Profiler

Time Blend - When started the drive will ramp to the desired velocity and hold speed for the programmed time at which point it will transition to the next step and ramp to the programmed velocity without going to zero speed.

The example below shows a five step profile. The first three are Time Blend steps followed by an Encoder Abs step to zero then an End step. For each Time Blend step the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Velocity]. The [Step X Value] is programmed to the desired time for the total time of the accel and run of the step. When the value programmed in [Step X Value] is reached, the profile transitions to the next step. The absolute step is used to send the profile back to the home position. This is done by programming [Step 4 Value] to zero.

Timed Steps Blended

Step 5

Units Traveled

Current Step

-9

350

250

150

Profile Status (Scaled)

35 55 75 95 115 135

-50

Note: there is no "At Position"

indication when using

-150

Encoder Spee d

-250

-350

-450

timed steps

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 2

Step 3

Time

Step 4

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Time Blend 100 0.5 0.5 5.00 0.00 1 2

2 Time Blend 200 0.5 0.5 5.00 0.00 1 3

3 Time Blend 300 0.5 0.5 5.00 0.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Digital Input - When started, the drive will ramp to the desired velocity and hold speed until the digital input programmed in the value transitions in the direction defined. When this occurs, the profile will transition to the next step and ramp to the programmed velocity without going to zero speed.

The example below shows a six step profile. In each step, the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Velocity] until a digital input is detected. When the input is detected it transitions to the next step in the profile. This continues through DigIn6 activating step 5. Step 5 is defined as a Parameter Level step. Digital Inputs used in the profile must be defined as “Prof Input.”

Digital Inputs

350

250

150

Profile Status (Scaled)

30 50 70 90 110 130 150 170

-50

Encoder Spee d

-150

-250

-350

[Encoder Speed], 415 [Units Traveled], 701 Current Step Dig In Status, 216[Profile Status], 700

Digital Input #4

Digital Input #3

Step 1

Step 2

Digital Input #5

Dwell

Digital Input #6

Step 3

Time

Position Indexer/Speed Profiler 67

Step 6

Step 4

Step 5

Note: Step 5 is a Parameter Level Step.

Units Traveled

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Digital Input 300 0.5 0.5 3.00 0.00 1 2

2 Digital Input 50 0.5 0.5 4.00 5.00 1 3

3 Digital Input -300 0.5 0.5 5.00 0.00 1 4

4 Digital Input -100 0.5 0.5 6.00 1.00 1 5

5 Param Level -50 0.5 0.5 701 0.00 1 6

6 End N/A N/A 0.5 N/A 0.00 N/A N/A

Encoder Incremental Blend (EncIncrBlend) - When started, the drive will ramp to the desired velocity and hold speed until the units of travel programmed is reached (within tolerance window). The profile will then transition to the next step and the drive will ramp to the speed of the new step without first going to zero speed.

The example below shows a five step profile. The first three are “EncIncrBlend” steps followed an “Encoder Abs” step to zero then an “End” step. For each “EncIncrBlend” step the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Value]. The [Step X Value] is programmed to the desired units of travel for the step. When the value programmed in [Step X Value] is reached, the profile transitions to the next step. The absolute step is used to send the profile back to the home position. This is done by programming [Step 4 Value] to zero.

Encoder Incremental Blend

350

250

150

Profile Status (Scaled)

-50

-150

-250

Encoder Speed

-350

-450

30 50 70 90 110

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 2

Step 3

Time

Step 4

Complete

Step 5

Units Traveled

Current Step

68 Position Indexer/Speed Profiler

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 EncInc Blend 100 0.5 0.5 10.00 0.00 1 2

2 EncInc Blend 200 0.5 0.5 10.00 0.00 1 3

3 EncInc Blend 300 0.5 0.5 10.00 0.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Encoder Incremental Blend with Hold - This profile is the same as the previous, but contains the Hold function. While the Hold is applied, the step transition is inhibited. When the Hold is released the step can then transition if the conditions to transition are satisfied.

Encoder Incremental Blend w/Hold

350

250

150

Profile Status (Scaled)

-50

-150

Encoder Spee d

-250

-350

-450

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Hold Input

3919 59 79 99 119 139 159

Step 1

Step 2

Step 3

Time

Step 4

Complete

Step 5

Units Traveled

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 EncInc Blend 100 0.5 0.5 10.00 0.00 1 2

2 EncInc Blend 200 0.5 0.5 10.00 0.00 1 3

3 EncInc Blend 300 0.5 0.5 10.00 0.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Encoder Incremental Blend with Velocity Override - This profile is the same as the “EncIncrBlend,” but contains the Velocity Override function. While the “Vel Override” is applied, the velocity of the step will be multiplied by [Vel Override], parameter 711. In the example below during step 1 the Vel Override was toggled. The speed was multiplied by 150% causing the speed to be 150 RPM rather than

100. When released the speed resumed to the programmed [Step 1 Velocity] of 100rpm.

Encoder Incremental Blend w/Velocity Override

Position Indexer/Speed Profiler 69

350

250

150

Profile Status

10 80

-50

-150

-250

Encoder Speed

-350

-450

Velocity Override

20 30 40 50 60 70 90 100

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 2

Step X

Step # Step X Type

Velocity

Step 3

Time

Step X AccelTime

Complete

Step 4

Step X DecelTime

Step 5

110

Step X Value

Units Traveled

Current Step

Step X Dwell

Step X Batch

Step X Next

1 EncInc Blend 100 0.5 0.5 10.00 0.00 1 2

2 EncInc Blend 200 0.5 0.5 10.00 0.00 1 3

3 EncInc Blend 300 0.5 0.5 10.00 0.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Parameter Level (Param Level) - When started the drive will ramp to the desired velocity, hold speed and compare the programmed step value to the step dwell level. The sign of the step value defines “less than or greater than” step dwell. When true, the profile will transition to the next step.

The example below shows a five step profile using “Param Level” steps followed by an “Encoder Abs” then an “End” step. For each “Param Level” step the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Velocity]. The [Step X Value] is programmed to the parameter number to monitor. The [Step X Dwell] is the value used to compare against the [Step X Value]. The sign of [Step X Value] sets a less than or greater than comparison (– equals < and + equals >). When the comparison of [Step X Value] and [Step X Dwell] is satisfied the profile transitions to the next step. The “Encoder Abs” step is used to send the profile back to the home position. This is done by programming [Step 4 Value] to zero.

In the example [Step 1,2,3 Value] is set to “701.” The value of [Units Traveled], parameter 701 is now a greater than comparison with the step dwell parameters. [Step 1 Dwell] = 10, [Step 2 Dwell] = 20, and [Step 3 Dwell] = 30. When step 1 is beyond 10 Units Traveled, the profile transitions to step 2. When step 2 is greater than 20 Units Traveled the profile transitions to step 3. The transition from step 3 to step 4 happens when Units Traveled is above 30.

70 Position Indexer/Speed Profiler

Parameter Level

Step 3 Dwell Level, 745

350

250

150

Profile Status (Scaled)

13 18 23 28 33 43 48 53

-50

-150

Encoder Spee d

Step 1 Dwell Level, 725

-250

-350

-450

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 1

Step 2

Time

Step 3

Step 2 Dwell Level, 735

Step 4

Step 5

58388

Units Traveled

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Param Level 100 0.5 0.5 701 10.00 1 2

2 Param Level 200 0.5 0.5 701 20.00 1 3

3 Param Level 300 0.5 0.5 701 30.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Note: A negative number in the [Step X Value] will transition when the comparison is less than the [Step X Dwell].

Position Regulator Step Types

Encoder Incremental (Encoder Incr) - This is a move increment from the current position in the direction, distance and speed programmed. When started the drive ramps to the desired velocity, holds the speed, then ramps to zero speed at the position desired within the tolerance window.

The example below shows a five step profile. The first three are “Encoder Incr steps” followed by an “Encoder Abs” step to zero then an “End” step. For each “Encoder Incr” step the drive ramps at [Step X AccelTime] to [Step X Velocity] in the direction of the sign of [Step X Value] then decelerates at the rate of [Step X DecelTime] to the position programmed in [Step X Value] which sets the desired units of travel for the step. When the value programmed in [Step X Value] is reached within the tolerance window programmed in [Encoder Pos Tol], the “At Position” bit is set in [Profile Status]. In this example a dwell value held each of the first three steps “At Position” for 1 second. After the [Step X Dwell] time expires the profile transitions to the next step. The absolute step is used to send the profile back to the home position. This is done by programming [Step 4 Value] to zero.

Encoder Incremental w/Dwell

350

250

150

Profile Status

-50

-150

-250

Encoder Speed

-350

-450

90 110 130 150 190

70 210

At Position

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 2

Time

Step 3

170

Step 4

Position Indexer/Speed Profiler 71

Units Traveled

Complete

Step 5

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Encoder Incr 100 0.5 0.5 10.00 1.00 1 2

2 Encoder Incr 200 0.5 0.5 10.00 1.00 1 3

3 Encoder Incr 300 0.5 0.5 10.00 1.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

Encoder Incremental with Hold - This profile is the same as Encoder Incr, but contains the “Hold” function. During step 3 the “Hold” bit was set. After some time “At Position” the “Hold” was removed which allowed the profile to transition to the next step.

Encoder Incremental w/Dwell and Hold

350

250

150

Profile Status

30 50 90 110 130

At Position

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Encoder Spee d

-50

-150

-250

-350

-450

Step 2

Time

Hold

Step 3

Complete

Step 4

Step 5

15010 70

Units Traveled

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Encoder Incr 100 0.5 0.5 10.00 1.00 1 2

2 Encoder Incr 200 0.5 0.5 10.00 1.00 1 3

3 Encoder Incr 300 0.5 0.5 10.00 1.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

72 Position Indexer/Speed Profiler

Encoder Incremental with Velocity Override - This profile is the same as Encoder Incr, but contains the “Velocity Override” function. During step 3 the “Vel Override” bit was set. While active the [Step 3 Velocity] is multiplied by [Vel Override]. In this example [Vel Override] is 150% causing the speed to be 450rpm rather than 300.

Encoder Incremental w/Dwell and Velocity Override

500

400

300

200

100

Profile Status

-100

-200

-300

Encoder Speed

-400

-500

30 50 70 90 110 130

10 150

Step 1

[Encoder Speed], 415 [Units Traveled], 701 Current Step[Profile Status], 700

Step 2

Time

Velocity Override

Step 3

Complete

Step 4

Step 5

Units Traveled

Current Step

Step # Step X Type

Step X Velocity

Step X AccelTime

Step X DecelTime

Step X Value

Step X Dwell

Step X Batch

Step X Next

1 Encoder Incr 100 0.5 0.5 10.00 1.00 1 2

2 Encoder Incr 200 0.5 0.5 10.00 1.00 1 3

3 Encoder Incr 300 0.5 0.5 10.00 1.00 1 4

4 Encoder Abs 400 0.5 0.5 0.00 1.00 1 5

5 End N/A N/A 0.5 N/A 0.00 N/A N/A

End Hold Position – The drive holds the last position and stops the profile after dwell time expires.

Encoder Absolute

– This is a move to an absolute position, which is referenced from the home position. When started the drive ramps to the desired velocity in the direction required, holds the speed, then ramps to zero speed at the position desired within the tolerance window.

Powe r L oss 73

Power Loss The drive contains a sophisticated algorithm to manage initial application of power

70EC

✔✔

as well as recovery from a partial power loss event. The drive also has

700VC

700H

programmable features that can minimize the problems associated with a loss of power in certain applications.

Terms

The following terms are used internally by the drive and are defined below for a complete understanding of power loss functionality.

Term Definition

Vbus The instantaneous DC bus voltage.

Vmem The average DC bus voltage. A measure of the “average” bus voltage determined by

heavily filtering bus voltage. Just after the pre-charge relay is closed during the initial power-up bus pre-charge, bus memory is set equal to bus voltage. Thereafter it is updated by ramping at a very slow rate toward V DC per minute (for a 480VAC drive). An increase in V to prevent a false high value due to the bus being pumped up by regeneration. Any change to V

Vslew The rate of change of V

is blocked during inertia ride through.

mem

in volts per minute.

mem

Vrecover The threshold for recovery from power loss.

Vtrigger The threshold to detect power loss.

PowerFlex 700VC The level is adjustable. The default is the value in the PF700 Bus Level table. If “Pwr Loss Lvl” is selected as an input function AND energized, V [Power Loss Level]. Vopen is normally 60V DC below V V

open

and V

are limited to a minimum of V

trigger

Level] is set to a large value.

PowerFlex 70EC This is a fixed value.

WARNING:

When using a value of Parameter #186 [Power Loss Level] larger than default, the customer must provide a minimum line impedance to limit inrush current when the power line recovers. The input impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 5 times the drive’s input VA rating.

Vinertia The software regulation reference for V

during inertia ride through.

bus

Vclose The threshold to close the pre-charge contactor.

Vopen The threshold to open the pre-charge contactor.

Vmin The minimum value of V

open

Voff The bus voltage below which the switching power supply falls out of regulation.

. The filtered value ramps at 2.4V

bus

is blocked during deceleration

mem

is set to Vmem minus

trigger

(in a 480VAC drive). Both

trigger

. This is only a factor if [Power Loss

min

Table E PF70EC Bus Levels

Class 200/240 VAC 400/480 VAC 600/690 VAC

slew

recover

trigger1

trigger2

open Vmem

min

off

1.2V DC 2.4V DC 3.0V DC

– 30V V

mem

– 60V V

mem

– 60V V

mem

– 90V V

mem

– 90V V

– 60V V

mem

– 120V V

mem

– 120V V

mem

– 180V V

mem

– 180V V

mem

– 75V

– 150V

– 225V

204V DC 407V DC 509V DC

? 300V DC ?

74 Power L os s

700

650

600

550

DC Bus Volts

500

450

400

Line Loss Mode = Decel

Recover Close Trigger Open

350 400 450

AC Input Volts

700

650

600

550

DC Bus Volts

500

450

400

Line Loss Mode = Coast

Recover Close Trigger Open

350 400 450

AC Input Volts

Table F PF700VC Bus Levels

Class 200/240V AC 400/480V AC 600/690V AC

slew

recover

trigger1,2

trigger1,3

open

open4

min

off 5

1.2V DC 2.4V DC 3.0V DC

– 30V V

mem

– 60V V

mem

– 60V V

mem

– 90V V

mem

– 90V V

mem

– 60V V

mem

– 120V V

mem

– 120V V

mem

– 180V V

mem

– 180V V

mem

– 75V

– 150V

– 225V

153V DC 305V DC 382V DC

– 200V DC –

700

650

600

550

500

DC Bus Volts

450

400

350

300

Line Loss Mode = Coast

Recover Close Trigger Open

350 400 450

AC Input Volts

Note 1:Vtrigger is adjustable, these are the standard values.

700

650

600

550

500

DC Bus Volts

450

400

350

300

Line Loss Mode = Decel

Recover Close Trigger Open

350 400 450

AC Input Volts

700

650

600

550

500

DC Bus Volts

450

400

350

300

Line Loss Mode = Continue

Recover Close Trigger Open

350 400 450

AC Input Volts

Restart after Power Recovery

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.

Powe r L oss 75

Power Loss Actions

The drive is designed to operate at a nominal input voltage. When voltage falls below this nominal value by a significant amount, action can be taken to preserve the bus energy and keep the drive logic alive as long as possible. The drive has three methods of dealing with low bus voltages:

• “Coast” - Disable the drive and allow the motor to coast.

• “Decel” - Decelerate the motor at a rate which will regulate the DC bus until the

load’s kinetic energy can no longer power the drive.

• “Continue” - Allow the drive to power the motor down to 50% of the nominal

DC bus voltage.

When power loss occurs, the “Power Loss” alarm bit in [Drive Alarm 1] turns on if the respective bit in [Alarm Config 1] is enabled.

If the “Power Loss” bit in [Fault Config 1] is enabled, the drive will fault with a F003-Power Loss Fault when the power loss event exceeds [Power Loss Time].

The drive faults with a F004-UnderVoltage fault if the bus voltage falls below V

min

and the UnderVoltage bit in [Fault Config 1] is set.

The pre-charge relay opens if the bus voltage drops below V bus voltage rises above V

If the bus voltage rises above V

recover

for 20 ms, the drive determines the power

and closes if the

open

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.

Coast

This is the default mode of operation. The drive determines a power loss has occurred if the bus voltage drops below V output is disabled and the motor coasts.

Bus Voltage

Motor Speed

. If the drive is running, the inverter

trigger

680V 620V 560V 500V

407V

305V

Power Loss

Output Enable

Pre-Charge

Drive Fault

480V example shown, see Tab l e F for further information.

76 Power L os s

Decel

This mode of operation is useful if the mechanical load is high inertia and low friction. By recapturing the mechanical energy, converting it to electrical energy and returning it to the drive, the bus voltage is maintained. As long as there is mechanical energy, the ride through time is extended and the motor remains fully fluxed. If AC input power is restored, the drive can ramp the motor to the correct speed without the need for reconnecting.

The drive determines a power loss has occurred if the bus voltage drops below

trigger

If the drive is running, the inertia ride through function is activated.

The load is decelerated at the correct rate so that the energy absorbed from the mechanical load regulates the DC bus to the value V

The inverter output is disabled and the motor coasts if the output frequency drops to zero or if the bus voltage drops below V

or if any of the “run permit” inputs are

open

de-energized.

If the drive is still in inertia ride through operation when power returns, the drive immediately accelerates at the programmed rate to the set speed. If the drive is coasting and it 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.

Bus Voltage

inertia

680V 620V 560V 500V

407V

305V

Motor Speed

Power Loss

Output Enable

Pre-Charge

Drive Fault

480V example shown, see Ta b l e F for further information.

Half Voltage

This mode provides the maximum power ride through. The input voltage can drop to 50% and the drive is still able to supply drive rated current (not drive rated power) to the motor.

ATTENTION: To guard against drive damage, a minimum line impedance must be provided to limit inrush current when the power line

recovers. The input impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive’s input VA rating.

Process PID Loop 77

Bus Voltage

Motor Speed

Power Loss

Output Enable

Pre-Charge

Drive Fault

480V example shown, see Ta b l e F for further information.

Coast Input and Decel Input

700VC ONLY

680V 620V 560V

365V 305V

These modes operate similarly to their “non-input” versions, but provide additional ride through time. This is accomplished by early sensing of the power loss via an external device that monitors the power line. This device provides a hardware signal which is connected to the drive through the “pulse” input (because of its high-speed capability). Normally this hardware power loss input will provide a power loss signal before the bus drops to less than V

open.

Process PID Loop The internal PID function provides closed loop process control with proportional

70EC

✔✔

and integral control action. The function is designed to be used in applications that

700VC

700H

require simple control of a process without the use of a separate stand-alone loop controller.

The PID function reads a process variable input to the drive and compares it to a desired setpoint stored in the drive. The algorithm will then adjust the output of the PID regulator, changing drive output frequency to attempt zero error between the process variable and the setpoint.

The Process PID can be used to modify the commanded speed or can be used to trim torque. There are two ways the PID Controller can be configured to modify the commanded speed.

• Speed Trim - The PID Output can be added to the master speed reference.

• Exclusive Control - PID can have exclusive control of the commanded speed.

The mode of operation between speed trim, exclusive control, and torque trim is selected in the [PI Configuration] parameter.

Speed Trim Mode

In this mode, the output of the PID regulator is summed with a master speed reference to control the process. This mode is appropriate when the process needs to be controlled tightly and in a stable manner by adding or subtracting small amounts directly to the output frequency (speed). In the following example, the master speed reference sets the wind/unwind speed and the dancer pot signal is used as a PID Feedback to control the tension in the system. An equilibrium point is programmed as PID Setpoint, and as the tension increases or decreases during winding, the master speed is trimmed to compensate and maintain tension near the equilibrium point.

78 Process PID Loop

0 Volts

Equilibrium Point

[PI Reference Sel]

10 Volts

Dancer Pot [PI Feedback Sel]

Master Speed Reference

When the PID is disabled the commanded speed is the ramped speed reference.

Slip

Slip Adder

Spd Ref

PI Ref

PI Fbk

Process PI

Controller

Linear Ramp

& S-Curve

PI Disabled

Comp

Open

Loop

Process

Speed Control

Spd Cmd

When the PID is enabled, the output of the PID Controller is added to the ramped speed reference.

Slip

Slip Adder

Spd Ref

PI Ref

PI Fbk

Process PI

Controller

Linear Ramp

& S-Curve

PI Enabled

Comp

Open

Loop

Process

Speed Control

Spd Cmd

Exclusive Mode

In this mode, the output of PID regulator is the speed reference, and does not “trim” a master speed reference. This mode is appropriate when speed is unimportant and the only thing that matters is satisfying the control loop. In the pumping application example below, the reference or setpoint is the required pressure in the system. The input from the transducer is the PID feedback and changes as the pressure changes. The drive output frequency is then increased or decreased as needed to maintain system pressure regardless of flow changes. With the drive turning the pump at the required speed, the pressure is maintained in the system.

Process PID Loop 79

Motor

PI Feedback

Pump

Desired Pressure

Pressure

Transducer

[PI Reference Sel]

However, when additional valves in the system are opened and the pressure in the system drops, the PID error will alter its output frequency to bring the process back into control. When the PID is disabled the commanded speed is the ramped speed reference.

Slip

Slip Adder

Spd Ref

PI Ref

PI Fbk

Process PI

Controller

Linear Ramp

& S-Curve

PI Disabled

Comp

Open Loop

Process

Speed Control

Spd Cmd

When the PID is enabled, the speed reference is disconnected and PID Output has exclusive control of the commanded speed, passing through the linear ramp and s-curve.

Slip

Slip Adder

Spd Ref

PI Ref

PI Fbk

Process PI

Controller

Linear Ramp

& S-Curve

PI Enabled

Comp

Open

Loop

Process

Speed Control

Spd Cmd

80 Process PID Loop

PID Configuration

[PI Configuration] is a set of bits that select various modes of operation. The value of this parameter can only be changed while the drive is stopped.

• Exclusive Mode - see page 78.

• Invert Error - This feature changes the “sign” of the error, creating a decrease

in output for increasing error and an increase in output for decreasing error. An example of this might be an HVAC system with thermostat control. In Summer, a rising thermostat reading commands an increase in drive output because cold air is being blown. In Winter, a falling thermostat commands an increase in drive output because warm air is being blown.

The PID has the option to change the sign of PID Error. This is used when an increase in feedback should cause an increase in output. The option to invert the sign of PID Error is selected in the PID Configuration parameter.

• Preload Integrator - This feature allows the PID Output to be stepped to a

preload value for better dynamic response when the PID Output is enabled. Refer to the diagram below. If PID is not enabled the PID Integrator may be initialized to the PID Pre-load Value or the current value of the commanded speed. The operation of Preload is selected in the PID Configuration parameter.

By default, Pre-load Command is off and the PID Load Value is zero, causing a zero to be loaded into the integrator when the PID is disabled. As shown in diagram A below, when the PID is enabled the PID output will start from zero and regulate to the required level. When PID is enabled with PID Load Value is set to a non-zero value the output begins with a step as shown in Diagram B below. This may result in the PID reaching steady state sooner, however if the step is too large the drive may go into current limit which will extend the acceleration.

PI Enabled

PI Output

Spd Cmd

Diagram A

PI Pre-load Value

PI Pre-load Value = 0 PI Pre-load Value > 0

Diagram B

Pre-load command may be used when the PID has exclusive control of the commanded speed. With the integrator preset to the commanded speed there is no disturbance in commanded speed when PID is enabled. After PID is enabled the PID output is regulated to the required level.

Process PID Loop 81

PI Enabled

Start at Spd Cmd

PI Output

Spd Cmd

Pre-load to Command Speed

When the PID is configured to have exclusive control of the commanded speed and the drive is in current limit or voltage limit the integrator is preset to the commanded speed so that it knows where to resume when no longer in limit.

• Ramp Ref - The PID Ramp Reference feature is used to provide a smooth

transition when the PID is enabled and the PID output is used as a speed trim (not exclusive control). When PID Ramp Reference is selected in the PID Configuration parameter, and PID is disabled, the value used for the PID reference will be the PID feedback. This will cause PID error to be zero. Then when the PID is enabled the value used for the PID reference will ramp to the selected value for PID reference at the selected acceleration or deceleration rate. After the PID reference reaches the selected value the ramp is bypassed until the PID is disabled and enabled again. S-curve is not available as part of the PID linear ramp.

• Zero Clamp - This feature limits the possible drive action to one direction only.

Output from the drive will be from zero to maximum frequency forward or zero to maximum frequency reverse. This removes the chance of doing a “plugging” type operation as an attempt to bring the error to zero. This bit is active only in trim mode.

The PID has the option to limit operation so that the output frequency will always have the same sign as the master speed reference. The zero clamp option is selected in the PID Configuration parameter. Zero clamp is disabled when PID has exclusive control of speed command.

For example, if master speed reference is +10 Hz and the output of the PID results in a speed adder of –15 Hz, zero clamp would limit the output frequency to not become less than zero. Likewise, if master speed reference is –10 Hz and the output of the PID results in a speed adder of +15 Hz, zero clamp would limit the output frequency to not become greater than zero.

• Feedback Square Root - This feature uses the square root of the feedback

signal as the PID feedback. This is useful in processes that control pressure, since centrifugal fans and pumps vary pressure with the square of speed.

The PID 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. The result of the square root is normalized back to full scale to provide a consistent range of operation. The option to take the square root is selected in the PID Configuration parameter.

82 Process PID Loop

• Stop Mode - When Stop Mode is set to “1” and a Stop command is issued to the

drive, the PID loop will continue to operate during the decel ramp until the PID output becomes more than the master reference. When set to “0,” the drive will disable PID and perform a normal stop. This bit is active in Trim mode only.

100.0

75.0

50.0

25.0

0.0

-25.0

-50.0

-75.0

Normalized SQRT(Feedback)

-100.0

-100.0 -75.0 -50.0 -25.0 0.0 25.0 50.0 75.0 100.0

Normalized Feedback

• Anti-Wind Up - When Anti-Windup is set to “1” the PID loop will

automatically prevent the integrator from creating an excessive error that could cause loop instability. The integrator will be automatically controlled without the need for PID Reset or PID Hold inputs.

• To rq ue Tr im - When Torque Trim is set to “1” the output of the process PID

loop will be added to Torque Reference A and B, instead of being added to the speed reference. Torque Trim is only active in Flux Vector mode.

• % of Ref - When using Process PID control the output can be selected as

percent of the Speed Reference. This works in Speed trim mode only, not in Torque Trim or Exclusive Mode.

Examples

% of Ref selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum Frequency = 130 Hz.

4.3 Hz will be added to the final speed reference.

% of Ref not selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum Frequency = 130 Hz. 13.0 Hz will be added to the final speed reference.

PID Control

[PI Control] is a set of bits to dynamically enable and disable the operation of the process PID controller. When this parameter is interactively written to from a network it must be done through a data link so the values are not written to EEprom.

• PI Enable - The PID loop can be enabled/disabled. The Enabled status of the

PID loop determines when the PID regulator output is part or all of the commanded speed. The logic evaluated for the PID Enabled status is shown in the following ladder diagram.

The drive must be in Run before the PID Enabled status can turn on. The PID will remain disabled when the drive is jogged. The PID is disabled when the drive begins a ramp to stop, except when it is in Trim mode and the Stop mode bit in [PI Configuration] is On.

Process PID Loop 83

When a digital input is configured as “PI Enable,” the PID Enable bit of [PI Control] must be turned On for the PID loop to become enabled. If a digital input is not configured as “PI Enable” and the PID Enable bit in [PI Control] is turned On, then the PID loop may become enabled. If the PID Enable bit of [PI Control] is left continuously, then the PID may become enabled as soon as the drive goes into Run. If analog input signal loss is detected, the PID loop is disabled.

Stopping

DigInCfg

.PI_Enable

DigInCfg

.PI_Enable

DigIn

.PI_Enable

PI_Control .PI_Enable

PI_Control

.PI_Enable

Signal LossRunning

PI_Status

.Enabled

• PI Hold - The Process PID Controller has the option to hold the integrator at the

current value so if some part of the process is in limit the integrator will maintain the present value to avoid windup in the integrator.

The logic to hold the integrator at the current value is shown in the following ladder diagram. There are three conditions under which Hold will turn On.

– If a digital input is configured to provide PID Hold and that digital input is

turned on then the PID integrator will stop changing. Note that when a digital input is configured to provide PID Hold that takes precedence over the PID Control parameter.

– If a digital input is not configured to provide PID Hold and the PID Hold bit

in the PID Control parameter is turned On then the PID integrator will stop changing.

– If the current limit or voltage limit is active then the PID is put into Hold.

DigInCfg

.PI_Hold

DigIn

.PI_Hold

PI_Status

.Hold

DigInCfg .PI_Hold

Current Lmt

or Volt Lmt

PI_Control

.PI_Hold

• PI Reset - This feature holds the output of the integral function at zero. The

term “anti windup” is often applied to similar features. It may be used for integrator preloading during transfer and can be used to hold the integrator at zero during “manual mode.”

For example: a process whose feedback signal is below the reference point, creating error. The drive will increase its output frequency in an attempt to bring the process into control. If, however, the increase in drive output does not zero the error, additional increases in output will be commanded. When the drive reaches programmed Maximum Frequency, it is possible that a significant amount of integral value has been “built up” (windup). This may cause undesirable and sudden operation if the system were switched to manual operation and back. Resetting the integrator eliminates this windup.

84 Process PID Loop

PID Status

[PI Status] parameter is a set of bits that indicate the status of the process PID controller

• Enabled - The loop is active and controlling the drive output.

• Hold - A signal has been issued and the integrator is being held at its current

value.

• Reset - A signal has been issued and the integrator is being held at zero.

• In Limit - The loop output is being clamped at the value set in [PI Upper/Lower

Limit].

PID Reference and Feedback

The selection of the source for the reference signal is entered in the PID Reference Select parameter. The selection of the source for the feedback signal is selected in the PID Feedback Select parameter. The reference and feedback have the same limit of possible options.

Options include DPI adapter ports, MOP, preset speeds, analog inputs, pulse input, encoder input and PID setpoint parameter.

The value used for reference is displayed in PID Reference as a read only parameter. The value used for feedback is displayed in PID Feedback as a read only parameter. These displays are active independent of PID Enabled. Full scale is displayed as ±100.00.

PID Reference and Feedback Scaling

The PID reference can be scaled by using [PI Reference Hi] and [PI Reference Lo]. [PI Reference Hi] determines the high value, in percent, for the PID reference. [PI Reference Lo] determines the low value, in percent, for the PID reference.

The PID feedback can be scaled by using [PI Feedback Hi] and [PI Feedback Lo]. [PI Feedback Hi] determines the high value, in percent, for the PID feedback. [PI Feedback Lo] determines the low value, in percent, for the PID feedback.

Example:

The PID reference meter and PID 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.

− [PI Reference Sel] = 0 “PI Setpoint”

− [PI Setpoint] = 50%

− [PI Feedback Sel] = 2 “Analog In 2"

− [PI Reference Hi] = 100%

− [PI Reference Lo] = –100%

− [PI Feedback Hi] = 100%

− [PI Feedback Lo] = 0%

− [Analog In 2 Hi] = 10V

− [Analog In 2 Lo] = 0V

PI Feedback Scaling

[Torque Ref A Sel] = “Analog In 1”

[Analog In 2 Hi] 10V

[Analog In 1 Lo] 0V

[PI Feedback Hi] 100%

[PI Feedback Lo] 0%

Now 5V corresponds to 50% on the PID Feedback, and we will try to maintain a PID setpoint of 50% (5V).

Process PID Loop 85

Using Scale Blocks with PID Reference and Feedback

Scale Blocks are included in the Reference and Feedback selections of the Process PID controller. This selects the output of the scale block for use as Reference or Feedback to the Process PID.

PID Setpoint

This parameter can be used as an internal value for the setpoint or reference for the process. If [PI Reference Sel] points to this parameter, the value entered here will become the equilibrium point for the process.

PID Error

The PID Error is then sent to the Proportional and Integral functions, which are summed together.

PID Error Filter

[PI BW Filter] sets up a filter for the PID Error. This is useful in filtering out unwanted signal response, such as noise in the PID loop feedback signal. The filter is a Radians/Second low pass filter.

PID Gains

The [PI Prop Gain], [PI Integral Time] and [PI Deriv Time] parameters determine the response of the PID.

Proportional control (P) adjusts output based on size of the error (larger error = proportionally larger correction). If the error is doubled, then the output of the proportional control is doubled. Conversely, if the error is cut in half then the output of the proportional output will be cut in half. With only proportional control there is always an error, so the feedback and the reference are never equal. [PI Prop Gain] is unit less and defaults to 1.00 for unit gain. With [PI Prop Gain] set to 1.00 and PID Error at 1.00% the PID output will be 1.00% of maximum frequency.

Integral control (I) adjusts the output based on the duration of the error. (The longer the error is present, the harder it tries to correct). The integral control by itself is a ramp output correction. This type of control gives a smoothing effect to the output and will continue to integrate until zero error is achieved. By itself, integral control is slower than many applications require and therefore is combined with proportional control (PI). [PI Integral Time] is entered in seconds. If [PI Integral Time] 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.

Derivative Control (D) adjusts the output based on the rate of change of the error and, by itself, tends to be unstable. The faster that the error is changing, the larger change to the output. Derivative control is usually used in torque trim mode and is usually not needed in speed mode.

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.

86 PTC Motor Thermistor Input

PID Lower and Upper Limits/ Output Scaling

The output value produced by the PID is displayed as ±100% in [PI Output Meter].

[PI Lower Limit] and [PI Upper Limit] are set as a percentage. In exclusive or speed trim mode, they scale the PID Output to a percentage of [Maximum Freq]. In torque trim mode, they scale the PID Output as a percentage of rated motor torque.

Example

Set the PID lower and Upper limits to ±10% with Maximum Frequency set to 100 Hz. This will allow the PID loop to adjust the output of the drive ±10 Hz.

[PI Upper Limit] must always be greater than [PI Lower Limit].

Once the drive has reached the programmed Lower and Upper PID limits, the integrator stops integrating and no further “windup” is possible.

PID Output Gain

[PI Output Gain] allows additional scaling of the PID loop output.

Example

The application is a velocity controlled winder. As the roll builds up, the output gain can be reduced to allow the dancer signal to be properly reacted to by the PID loop without changing tuning of the PID loop.

PTC Motor Thermistor Input

70EC

✔✔

A PTC (Positive Temperature Coefficient) device (also know as a motor thermistor) embedded in the motor windings, can be monitored by the drive for motor thermal

700VC

700H

protection.

Configuration and Operation

The PTC is connected to either the dedicated PTC input (PF700VC only) or Analog input 1 along with a pull-up resistor of 3.32k ohms (see the specific product manual for a connection diagram). Note: Analog Input 2 does not support this function.

For connection to analog input 1, the drive can be configured as follows to either fault or alarm:

• [Fault Config 1], parameter 238, Bit 7 = 1 (enabled)

• [Alarm Config 1], parameter 259, Bit 11 = 1 = (enabled)

• Fault and alarm message = “Motor Therm”

For connection to the dedicated PTC input (PF700VC only), the drive can be configured as follows to either fault or alarm:

• [Fault Config 1], parameter 238, Bit 13 = 1 (enabled)

• [Alarm Config 1], parameter 259, Bit 18 = 1 = (enabled)

• Fault and alarm message = “PTC HW”

Note: If the drive is configured for both alarm and fault, the alarm condition is ignored.

Alarm Operation

An alarm will occur when the PTC resistance increases above 3230 ohms (5V DC), but must decrease below 2153 ohms (4Vdc) for the alarm condition to clear.

PWM Frequency 87

Fault Operation

A fault will occur when the PTC resistance increases above 3230 ohms (5V DC), and must be cleared (reset) by a fault clear command (see "Faults" on page 43

) after

the resistance has decreased below 3230 ohms (5V DC).

The drive will also fault if the PTC voltage drops below 0.2V DC, indicating a shorted PTC.

PWM Frequency In general, it is best to use the lowest possible PWM (switching) frequency that is

70EC

✔✔

acceptable for the application. There are some benefits to increasing the PWM

700VC

700H

frequency. Refer to Figure 13

and Figure 14. Note the output current at 2 kHz and 4 kHz. The “smoothing” of the current waveform continues as the PWM frequency is increased.

Figure 13 Current at 2 kHz PWM Frequency

Figure 14 Current at 4 kHz PWM Frequency

Higher PWM frequencies may result in less motor heating and lower audible noise. The decrease in motor heating is considered negligible and motor failure at lower PWM frequencies is very remote. The higher PWM frequency creates less vibration in the motor windings and laminations thus, lower audible noise. This may be desirable in some applications.

Some 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.

See derating guidelines in the Appendix. Also see the Wiring and Grounding document for PWM frequency limitations versus motor cable length.

A very large majority of all drive applications will perform adequately at 2-4 kHz.

88 Regen Power Limit

Regen Power Limit The [Regen Power Lim] is programmed as a percentage of the rated power. The

70EC

✔✔

mechanical energy that is transformed into electrical power during a deceleration or

700VC

700H

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%. When using dynamic braking or a regenerative supply, [Regen Power Lim] can be set to the most negative limit possible (–800%). When the user has dynamic braking or regenerative supply, but wishes to limit the power to the dynamic brake or regenerative supply, [Regen Power Lim] can be set to a level specified by the user.

Reset Parameters Resetting all drive parameters at once (in the active memory being used by the

70EC

✔✔

drive) is accomplished by choosing “Reset To Defalts” through the “Memory

700VC

700H

Storage” area of the HIM main menu. This command can also be executed from [Reset To Defalts], parameter 197 which also offers the following three choices:

• 0, “Ready” - Parameter 197 returns to this value after the reset to defaults is

completed.

• 1, “Factory” - All active parameters are reset to values that match the voltage

code (e.g. 400V or 480V) that was shipped.

• 2, “Low Voltage” - All active parameters are reset to values that match the

lowest voltage within its class (e.g. 400V)

• 3, “High Voltage” - All active parameters are reset to values that match the

highest voltage within its class (e.g. 480V)

Reset command 2 would only be used if, for example, a 480V drive (catalog code D) was to be used on a 400V system and motor.

Reset command 3 would only be used if for example, a 400V drive (catalog code C) was to be used on a 480V system and 460V motor.

Since reset commands 2 and 3 also reset all drive parameters, they would normally only be used to initialize the drive for the proper voltage prior to making all other parameter settings. Note that the setting for [Voltage Select] is also affected by reset commands 2 and 3, but using [Voltage Select] instead of [Reset To Defalts] will not initialize parameters such as [Motor NP Volts] and [Motor NP Hertz].

When a reset command is executed, it resets all parameters within the active parameter set (normally used by the drive to operate). User Sets (additional memory areas for alternate parameter settings) are unaffected by parameter reset functions. Transferring a default set of parameters into a user set requires a parameter reset command followed by a [Save To User Set] command (see "User Sets" on page 114

S Curve 89

S Curve The S Curve function provides control of the rate of change of acceleration and

70EC

✔✔

deceleration (also known as “jerk”). S Curve helps control the transition from

700VC

700H

steady state speed to a change in speed. By adjusting the percentage of S Curve applied, the ramp takes the shape of an “S.” This allows a smoother transition and produces less mechanical stress.

Example with No S Curve

80.0

60.0

40.0

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

When S Curve is enabled, it adds time to the overall acceleration by a percentage of the programmed acceleration time. This is shown in the curves below, which represent 0%, 25%, 50% and 100% S Curve. Note that half of the “S” is added to beginning and half is added to the end of the ramp.

70.0

60.0

50.0

40.0

30.0

20.0

10.0

0.0

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5

Seconds

4.0

The acceleration and deceleration times are independent but the same S Curve percentage is applied to both as shown in the following example.

70.0

60.0

50.0

40.0

30.0

20.0

10.0

0.0

0.0 1.0 2.0 3.0 4.0 5.0

Seconds

6.0

90 S Curve

Time to Accelerate

When accelerating from 0 to maximum speed, with maximum speed set to 60 Hz, Ta = 2.0 sec, and S Curve = 25%, acceleration time is extended by 0.5 seconds (2.0 x 25%). When accelerating to only 30 Hz the amount of jerk control (S Curve) is the same, but the extended amount of acceleration time is different.

70.0

60.0

50.0

40.0

30.0

20.0

10.0

0.0

0.0 0.5 1.0 1.5 2.0 2.5 3.0

Seconds

Crossing Zero Speed

When the commanded frequency passes through zero, the frequency will S Curve to zero and then S Curve to the commanded frequency as shown.

80.0

60.0

40.0

20.0

0.0

-20.0

-40.0

-60.0

-80.0

0.0 1.0 2.0 3.0 4.0 5.0

Seconds

The following graph shows an acceleration time of 1.0 second. After 0.75 seconds, the acceleration time is changed to 6.0 seconds. When the acceleration rate is changed, the commanded rate is reduced to match the requested rate based on the initial S Curve calculation. After reaching the new acceleration rate, the S Curve is then changed to be a function of the new acceleration rate.

70.0

60.0

50.0

40.0

30.0

20.0

10.0

0.0

0.0 1.0 2.0 3.0 4.0 5.0

Seconds

Safe-Off 91

Safe-Off Refer to “DriveGuard Safe-Off User Manual” publication PFLEX-UM001.

70EC

700VC

700H

✔

Scale Blocks See also "Analog Scaling" on page 4 and page 10.

70EC

700VC

700H

✔

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] and [ScaleX In Lo] determine the high and low values for the input to the scale block. [ScaleX Out Hi] and [ScaleX Out Lo] determine the corresponding high and low values for the output of the scale block. [ScaleX Out Value] is the resulting output of the scale block.

There are (3) ways to use the output of the scale block:

1. A destination parameter can be linked to [ScaleX Out Value].

2. [PI Reference Sel] and [PI Feedback Sel] can also use the output of the scale

block by setting them to:

– 25, “Scale Block1 Out”

– 26, “Scale Block2 Out”

Note that when [PI Reference Sel] and [PI Feedback Sel] are set to use the scale blocks, the [Scale X Out Hi] and [Scale x Out Lo] parameters are not active. Instead, [PI Reference Hi] and [PI Reference Lo], or [PI Feedback Hi] and [PI Feedback Lo], determine the scaling for the output of the scale block.

3. [Analog Outx Sel] can be set to:

– 20, “Scale Block1”

– 21, “Scale Block2”

– 22, “Scale Block3”

– 23, “Scale Block4”

Note that when the Analog Outputs are set to use the scale blocks, the [Scale x Out Hi] and [ScaleX Out Lo] parameters are not active. Instead, [Analog OutX Hi] and [Analog OutX Lo] determine the scaling for the output of the scale block. See "Analog Outputs" on page 10

Example Configuration

In this configuration Analog In 2 is a –10V to +10V signal which corresponds to – 800% to +800% motor torque from another drive. We want to use the –200% to +200% range (–2.5V to +2.5V) of that motor torque and correspond it to –100% to +100% of the PI Reference.

2.5

1.5

0.5

-0.5

-1.5

Scale1 In Value =

-2.5

Analog In2 Value (Volts)

-80 -60 -40 -20 0 20 40 60 80 100

-100

PI Reference

92 Security

Parameter Settings

Parameter Value Description

[Scale 1 In Hi] 2.5 V 2.5 V = 200% torque from other drive

[Scale 1 In Lo] –2.5V –2.5 V = –200% torque from other drive

[PI Reference Sel] 25, Scale

Block1 Out

[PI Reference Hi] 100 % 100% PI Reference corresponds to 200% torque from other drive

[PI Reference Lo] –100 % –100% PI Reference corresponds to –200% torque from other drive

The PI Reference becomes the output of the scale block

Parameter Links

Scale1 In Hi PI Reference Hi

Analog In2 Value

Destination Parameter Source Parameter Description

[Scale1 In Value] [Analog In2 Value] Scaling Analog In 2 value

477

476

478

Scale1 In Value

Scale1 In Lo

Scale1 Out

PI Reference Lo

Value

460

481

461

= Link

PI Reference

Security This feature provides write access protection for individual communication ports in

70EC

✔✔

a drive. In addition, the following drive peripherals and software tools support this

700VC

700H

security technology.

Communication Peripherals

•

20-COMM-E EtherNet/IP v2.002 (or higher)

• 20-COMM-C/-Q ControlNet v2.001 (or higher)

• 20-COMM-D DeviceNet v2.001 (or higher)

• 20-COMM-S DF1 v1.003 (or higher)

Software Tools

•

DriveExplorer v4.04 (or higher)

• DriveTools SP v4.01 (or higher)

By default, every DPI port in the drive is configured to allow write access. For additional information on DPI port locations and their assignments, refer to “HIM Overview” in Appendix B of the User Manual.

To change write access on an individual DPI port, change the bit setting of the associated port in [Write Mask Cfg], parameter 596.

• Bit 0 = Host (drive)

• Bit 1 = DPI Port 1

• Bit 2 = DPI Port 2

• Bit 3 = DPI Port 3

• Bit 4 = DPI Port 4 (PF700VC only)

• Bit 5 = DPI Port 5

Bit value of 0 = masked (read only access)

Bit value of 1 = not masked (read/write access)

Security 93

Any changes to [Write Mask Cfg] will not take effect until one of the following three events occur:

• Power is removed and reapplied.

• A drive reset (not reset to defaults) is performed.

• [Write Mask Act], parameter 597, bit 15 transitions from “1” to “0.”

The status of a port’s write access may be verified at [Write Mask Act]. For example, to verify that write access was disabled on “DPI Port 1”, bit 1 should equal bit 1 in [Write Mask Cfg].

The port that is being used to make security changes (e.g. if using a network adapter connected to Port 5), can only change other ports (not itself) to “Read Only.” This is to prevent the complete lockout of a drive with no future way to regain write access.

The figure on the left shows how DriveExplorer will respond when connected to a PowerFlex 70 EC drive that has security enabled on DPI Port 5. The “ ” icon will also appear in the program window to indicate that the adapter you are communicating through has its port write access disabled. The figure on the right shows how a HIM will respond when a write is attempted on a port that does not have write privileges.

F-> Stopped Auto

Security Enabled Access Denied

When connected to a port configured for “Read Only” with programming tools that do not have security functionality, errors will occur for any write attempt. Examples of such tools are HIMs with older firmware, earlier versions of Drive Tools or Drive Explorer, and third party software. See the following example messages when using tools that do not support the security function:

F-> Stopped Auto

Device State Has Disabled Function

94 Shear Pin

Shear Pin As a default, the drive will fold back when the output current exceeds the current

70EC

✔✔

limit level. However, the shear pin feature can be used to instantly fault the drive

700VC

700H

when output current exceeds a programmed amount. Additionally, the drive can be programmed to ignore this condition during acceleration and deceleration which often requires current that would otherwise cause a shear pin fault. Also, the condition can be completely ignored for a programmable amount of time. There are situations where a fast acceleration of the motor will cause the drive to output current to the motor near or at the current limit value for shear pin and fault the drive while in acceleration. To avoid this condition set bit 11 in parameter 238 to “1”. Using bit 11 in parameter 238 without bit 4 being “1” has no effect. In addition a shear pin time needs to be set in parameter 189. This will allow current limit for [shear pin time] before faulting the drive.

A unique fault (Shear Pin, F63) will be generated if the function is activated and the condition occurs.

Configuration

• P238 [Fault Config 1], bit 4 (Shear Pin) = “1” - this enables the shear pin fault).

• P238 [Fault Config 1], bit 11 (ShearPNo Acc) = “1” - this enables the ignore

feature during accelerations.

• P189 [Shear Pin Time] = desired amount of time to ignore the shear pin

condition before a fault occurs (e.g. 0.5 sec).

• P147 [Current Lmt Sel] = “Cur Lim Val” - specifies the source of the current

limit level. Can also com from analog inputs.

• P148 [Current Lmt Val] = desired value for current limit and shear pin fault (e.g.

15 amps).

Application Example

By programming the Shear Pin feature, the drive will fault, stopping the excess torque before mechanical damage occurs.

Skip Frequency Figure 15 Skip Frequency

70EC

700VC

✔✔

700H

Skip + 1/2 Band

Skip Frequency

Skip – 1/2 Band

Frequency

Command Frequency

Drive Output Frequency

Time

(A)

(B)

(A)

(B)

35 Hz

30 Hz

25 Hz

Skip Frequency 95

Some machines may have a resonant operating frequency (vibration speed) that is undesirable or could cause equipment damage. To guard against continuous operation at one or more resonant points, parameters 084-086, ([Skip Frequency 1-3]) can be programmed.

The value programmed into a skip frequency parameter, sets the center point for an entire “skip band” of frequencies. The width of the band (range of frequency around the center point) is determined by [Skip Freq Band], parameter 87. The range is split, half above and half below the skip frequency parameter.

If the commanded frequency is greater than or equal to the skip (center) frequency and less than or equal to the high value of the band (skip plus 1/2 band), the drive will set the output frequency to the high value of the band. See (A) in Figure 15

If the commanded frequency is less than the skip (center) frequency and greater than or equal to the low value of the band (skip minus 1/2 band), the drive will set the output frequency to the low value of the band. See (C) in Figure 15

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 Frequency 2

Skip Band 1

Skip Band 2

If skip bands overlap or touch, the center frequency is recalculated based on the highest and lowest band values.

If a skip band(s) extend beyond the max frequency limits, the highest band value will be clamped at the max frequency limit. The center frequency is recalculated based on the highest and lowest band values.

If the band is outside the limits, the skip band is inactive.

0 Hz

400 Hz.

Skip Frequency 1 Skip Frequency 2

0 Hz

400 Hz.

Max.Frequency

Skip

0 Hz

400 Hz.

Skip Frequency 1

60 Hz. Max.

Frequency

Adjusted Skip Band w/Recalculated Skip Frequency

Inactive Skip Band

0 Hz

Acceleration and deceleration are not affected by the skip frequencies. Normal accel/decel will proceed through the band.

96 Sleep Mode

Sleep Mode The purpose of the Sleep-Wake function is to Start (wake) the drive when an

70EC

✔✔

analog signal is greater than or equal to the specified [Wake Level], and Stop

700VC

700H

(sleep) the drive when an analog signal is less than or equal to the specified [Sleep Level]. Setting [Sleep-Wake Mode] to “Direct” enables the sleep-wake function to work as described.

An “Invert” mode also exists, which changes the logic so that an analog value less than or equal to [Wake Level] starts the drive and an analog value greater than or equal to [Sleep Level] stops the drive.

Sleep/Wake Operation

Drive

Run

Sleep-Wake

Function

Start

Stop

Sleep Timer

Satisfied

Sleep Level

Satisfied

Wake Timer

Satisfied

Wake Level

Satisfied

Wake Up

Go to Sleep

Wake Time

Sleep

Time

Wake Time

Sleep

Time

Wake Level

Sleep Level

Analog Signal

Example Conditions Wake Time = 3 Seconds Sleep Time = 3 Seconds

Requirements

In addition to enabling the sleep function with [Sleep-Wake Mode], at least one of the following assignments must be made to a digital input: Enable, Stop-CF, Run, Run Fwd or Run Rev, and the input must be closed. All normal Start Permissives must also be satisfied (Not Stop, Enable, Not Fault, Not Alarm, etc.).

Conditions to Start/Restart

ATTENTION: Enabling the Sleep-Wake function can cause unexpected machine operation during the Wake mode. Equipment damage and/or

personal injury can result if this parameter is used in an inappropriate application. Do Not use this function without considering the table below and applicable local, national & international codes, standards, regulations or industry guidelines.

Rockwell Automation 20A-70EC, 20A-700VC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Overview

Manual Conventions This manual covers the PowerFlex 70EC and the PowerFlex 700VC Drives. Some

Reference Materials In addition to the User Manual for your drive, the following manuals are

General Precautions

Detailed Drive Operation

Accel/Decel Time [Accel Time 1, 2]

Reference Information

Alarms Alarms are indications of situations that are occurring within the drive or

4 Analog Inputs

10 Analog Outputs

Auto/Manual 13

Auto Restar t 15

16 Autotune

18 Bus Regulation

Copy Cat 23

24 Current Limit

Datalinks A Datalink is one of the mechanisms used by PowerFlex drives to transfer data to

DC Bus Voltage / Memory

Digital Inputs Digital Input Configuration

Digital Outputs 33

36 Direction Control

DriveGuard 39

Drive Overload The drive overload function has two separate protection schemes, an inverse time

42 Droop

Faults 43

Flux Braking 45

Flux Up

Flying Start 47

High Resolution Speed Reference

Input Phase Loss Detection

Language 49

Load Loss Detection The output torque current is monitored by the drive and may be used to indicate a

Masks A mask is a parameter that contains one bit for each of the possible communication

Motor Control Modes 51

Motor Nameplate Data

Motor Overload 55

Notch Filter 57

Owners 59

Password

Position Indexer/ Speed Profiler

Powe r L oss 73

Process PID Loop 77

PTC Motor Thermistor Input

PWM Frequency 87

88 Regen Power Limit

Reset Parameters Resetting all drive parameters at once (in the active memory being used by the

S Curve 89

Safe-Off 91

Scale Blocks See also "Analog Scaling" on page 4 and page 10.

92 Security

94 Shear Pin

Skip Frequency

96 Sleep Mode