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

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✔✔

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

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✔✔

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

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

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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

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situations:

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• 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

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

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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

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[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

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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

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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.

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