Rockwell Automation 20G-750 User Manual

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Page 1

Reference Manual

PowerFlex 750-Series AC Drives

Catalog Numbers 20F, 20G, 21G

Original Instructions

Page 2

Important User Information

IMPORTANT

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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.

ATTENTION: 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 a hazard, and recognize the consequence.

Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Page 3

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table lists the topics added to this revision.

Top ic Pag e

Adjusta ble Voltage 17

Droop Feature 53

Owners 70

Process PID Loop 76

PTC Motor Thermistor Input 152

Alarms 155

Current Limi t 156

Drive Overload 158

Faul ts 162

Motor Overload 168

Pass word 173

Reflected Wave 179

Security 185

Shear Pin 188

Slip Compensation 192

Carrier (PWM) Frequency 196

Flux Braking 216

High Resolution Feedback 220

Inertia Adaption 221

Load Observer 225

Motor Control Modes 226

Motor Types 235

Torque Reference 262

Speed Torque Position 266

This table lists other changes made to this revision.

Top ic Pag e

Studio 5000™ Logix Designer application is the rebranding of RSLogix™ 5000 software

Block diagrams updated to firmware revision 9.xxx. 375

Block diagrams added:

Position Control – Spindle Orient 11-Series Inputs and Outputs – Digital 11-Series Inputs and Outputs – Analog 11-Series Inputs and Outputs – ATEX

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 3

395 410 411 412

Page 4

Summary of Changes

Notes:

4 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 5

Overview

Preface

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Allen-Bradley Drives Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Product Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Studio 5000 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Chapter 1

Drive Configuration

Accel/Decel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Adjustable Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Auto Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Auto/Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Automatic Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Auxiliary Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Bus Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Configurable Human Interface Module Removal . . . . . . . . . . . . . . . . . . . 52

Droop Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Duty Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Feedback Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Hand-Off-Auto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Process PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Reset Parameters to Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Sleep/Wake Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Start Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Stop Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Voltage Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Feedback and I/O

Chapter 2

Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

PTC Motor Thermistor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 5

Page 6

Table of Contents

Chapter 3

Diagnostics and Protection

Motor Control

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

DC Bus Voltage/Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Drive Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Input Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Overspeed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Reflected Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Shear Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Slip Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Slip Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Chapter 4

Carrier (PWM) Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Dynamic Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Flux Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Flux Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Flux Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

High Resolution Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Inertia Adaption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Inertia Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Load Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Motor Control Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Motor Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Regen Power Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Speed Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Speed Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Speed Torque Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Chapter 5

Drive Features

6 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

High Speed Trending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Position Homing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Page 7

Chapter 6

Table of Contents

Integrated Motion on the EtherNet/ IP Network Applications for PowerFlex 755 AC Drives

Additional Resources for Integrated Motion on the

EtherNet/IP Network Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Coarse Update Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Control Modes for PowerFlex 755 Drives Operating on the Integrated

Motion on the EtherNet/IP Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Drive Nonvolatile (NV) Memory for Permanent Magnet Motor

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Dual Loop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Dual-Port EtherNet/IP Option Module (ETAP) . . . . . . . . . . . . . . . . . . 315

Hardware Over Travel Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

Integrated Motion on EtherNet/IP Instance to PowerFlex 755 Drive

Parameter Cross-Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Motor Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Network Topologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

PowerFlex 755 and Kinetix 7000 Drive Overload

Rating Comparison for Permanent Magnet Motor Operation. . . . . . . 345

PowerFlex 755 Drive Option Module

Configuration and Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Regenerative/Braking Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Safe Speed Monitor Option Module (20-750-S1) Configuration . . . . 350

Speed Limited Adjustable Torque (SLAT) . . . . . . . . . . . . . . . . . . . . . . . . 353

Supported Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

System Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Using an Incremental Encoder with an MPx Motor . . . . . . . . . . . . . . . . 372

PowerFlex 755 Integrated Motion on the

EtherNet/IP Network Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Appendix A

Index

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 7

Page 8

Table of Contents

8 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 9

Overview

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

Preface

Who Should Use This Manual

What Is Not in This Manual

Additional Resources

This manual is intended for qualified personnel. You must be able to program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.

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

The following table lists publications that provide information about PowerFlex 750-Series drives.

Resource Description

PowerFlex 750-Series Drive Installation Instruction, 750-

IN001

PowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001

PowerFlex 750-Series AC Drives Technical Data, publication 750-TD001

PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001

PowerFlex 750-Series AC Drives Hardware Service Manual

- Frame 8 and Larger, publication 750-TG001

PowerFlex 755 Drive Embedded EtherNet/IP Adapter User Manual, publication 750COM-UM001

PowerFlex 750-Series Drive DeviceNet Option Module User Manual, publication 750COM-UM002

PowerFlex 7-Class Network Communication Adapter User Manuals, publications 750COM-UMxxx

Provides the basic steps required to install a PowerFlex® 750-Series AC drive.

Provides detailed information on:

• I/O, control, and feedback options

• Parameters and programming

• Faults, alarms, and troubleshooting

Provides detailed information on:

• Drive specifications

• Option specifications

• Fuse and circuit breaker ratings

Provides detailed information on HIM components, operation, features.

Provides detailed information on:

• Preventive maintenance

• Component testing

• Hardware replacement procedures

These publications provide detailed information on configuring, using, and troubleshooting PowerFlex 750-Series communication option modules and adapters.

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 9

Page 10

Preface

Resource Description

PowerFlex 750-Series Safe Torque Off User Manual, publication 750-UM002

Safe Speed Monitor Option Module for PowerFlex 750-Series AC Drives Safety Reference Manual, publication

750-RM001

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001

PowerFlex AC Drives in Common Bus Configurations, publication DRIVES-AT002

Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-1.1

A Global Reference Guide for Reading Schematic Diagrams, publication 100-2.10

Guarding Against Electrostatic Damage, publication 8000-

4.5.2

Product Certifications website, http://ab.com

These publications provide detailed information on installation, set up, and operation of the 750-Series safety option modules.

Provides basic information needed to properly wire and ground PWM AC drives.

Provides basic information needed to properly wire and ground common bus PWM AC drives.

Provides general guidelines for the application, installation, and maintenance of solid-state control.

Provides a simple cross-reference of common schematic/ wiring diagram symbols used throughout various parts of the world.

Provides practices for guarding against Electrostatic damage (ESD)

Provides declarations of conformity, certific ates, and other certification details.

The following publications provide necessary information when applying the Logix Processors.

Resource Description

Logix5000 Controllers Common Procedures, publication

1756-PM001

Logix5000 Controllers General Instructions, publication

1756-RM003

Logix5000 Controllers Process Control and Drives Instructions, publication 1756-RM006

This publication links to a collection of programming manuals that describe how you can use procedures that are common to all Logix5000 controller projects.

Provides a programmer with details about each available instruction for a Logix-based controller.

The following publications provide information that is useful when planning and installing communication networks.

Resource Description

ContolNet Coax Tap Installation Instructions, publication

1786-5.7

ContolNet Fiber Media Planning and Installation Guide, publication CNET-IN001

Provides procedures and specifications for the installation of ControlNet coaxial taps.

Provides basic information for fiber cable planning and installation.

You can view or download publications at

http://www.rockwellautomation.com/literature

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

10 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 11

Preface

Allen-Bradley Drives Technical Support

Product Certification

Manual Conventions

Use one of the following methods to contact Automation and Control Technical Support.

Online Email Telephone

www.ab.com/support/abdrives support@drives.ra.rockwell.com 262-512-8176

Title Online

Rockwell Automation Technical Support

http://support.rockwellautomation.com/knowledgebase

Product Certifications and Declarations of Conformity are available on the internet at www.rockwellautomation.com/products/certification

• In this manual we refer to PowerFlex 750-Series Adjustable Frequency AC Drives as: drive, PowerFlex 750, PowerFlex 750 drive or PowerFlex 750 AC drive.

• Specific drives within the PowerFlex 750-Series can be referred to as: – PowerFlex 753, PowerFlex 753 drive or PowerFlex 753 AC drive – PowerFlex 755, PowerFlex 755 drive or PowerFlex 755 AC drive

• To help differentiate parameter names and LCD display text from other

text, the following conventions are used: – Parameter Names appear in [brackets] after the Parameter Number.

For example: P308 [Direction Mode].

– Display text appears in “quotes.” For example: “Enabled.”

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

action.

Word Meani ng

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

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 11

Page 12

Preface

General Precautions

Qualified Personnel

ATT EN TI ON : 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.

Personal Safety

ATT EN TI ON : To avoid an electric shock hazard, verify that the voltage on the

bus capacitors has discharged completely before servicing. Check the DC bus voltage at the Power Terminal Block by measuring between the +DC and -DC terminals, between the +DC terminal and the chassis, and between the -DC terminal and the chassis. The voltage must be zero for all three measurements.

Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.

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.

The drive start/stop/enable control circuitry includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exists, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required.

Hazard of personal injury or equipment damage due to unexpected machine operation exists if the drive is configured to automatically issue a Start or Run command. Do not use these functions without considering applicable local, national and international codes, standards, regulations or industry guidelines.

12 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 13

Product Safety

ATT EN TI ON : An incorrectly applied or installed drive can result in component

damage or a reduction in product life. Wiring or appl ication errors such as under sizing the motor, incorrect or inadequate AC supply, or excessive surrounding air temperatures may result in malfunction of the system.

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 Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook.

Configuring an analog input for 0-20 mA operation and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.

A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals to start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.

Preface

Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere.

Class 1 LED Product

ATT EN TI ON : Hazard of permanent eye damage exists when using optical

transmission equipment. This product emits intense light and invisible radiation. Do not look into module ports or fiber optic cable connectors.

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 13

Page 14

Preface

Studio 5000 Environment

The Studio 5000™ Engineering and Design Environment combines engineering and design elements into a common environment. The first element in the Studio 5000 environment is the Logix Designer application. The Logix Designer application is the rebranding of RSLogix™ 5000 software and will continue to be the product to program Logix5000™ controllers for discrete, process, batch, motion, safety, and drive-based solutions.

The Studio 5000 environment is the foundation for the future of Rockwell Automation® engineering design tools and capabilities. This environment is the one place for design engineers to develop all of the elements of their control system.

14 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 15

Chapter 1

Drive Configuration

Top ic Pag e

Accel/Decel Time 16

Adjusta ble Voltage 17

Auto Restart 25

Auto/Manual 27

Automatic Device Configuration 34

Autotune 35

Auxiliary Power Supply 41

Bus Regulation 41

Configurable Human Interface Module Removal 52

Droop Feature 53

Duty Rating 53

Feedback Devices 54

Flying Star t 54

Hand-Off-Auto 64

Masks 67

Owners 70

Power Loss 72

Process PID Loop 76

Reset Parameters to Factor y Defaults 88

Sleep/Wake Mode 90

Start Permissives 94

Stop Modes 96

Vol tage Clas s 10 4

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 15

Page 16

Chapter 1 Drive Configuration

Accel/Decel Time

You can configure the drive’s acceleration time and deceleration time.

Acceleration Time

P535[Accel Time 1] and P536 [Accel Time 2] set the acceleration rate for all speed changes. Defined as the time to accelerate from 0 to motor nameplate frequency P27 [Motor NP Hertz] or to motor nameplate rated speed P28 [Motor NP RPM]. The setting of Hertz or RPM is programmed in P300 [Speed Units]. Selection between Acceleration Time 1 and Acceleration Time 2 is controlled by a digital input function (see Digin Functions in the PowerFlex 750Series Programming Manual, publication 750-PM001 (sent over a communication network or DeviceLogix™ software).

Adjustment range is 0.00 to 3600.00 seconds.

) or by Logic Command

Deceleration Time

P537 [Decel Time 1] and P538 [Decel Time 2] set the deceleration rate for all speed changes. Defined as the time to decelerate from motor nameplate frequency P27 [Motor NP Hertz] or from motor nameplate rated speed P28 [Motor NP RPM] to 0. The setting of Hertz or RPM is programmed in P300 [Speed Units]. Selection between Deceleration Time 1 and Deceleration Time 2 is controlled by a digital input function (see Digin Functions in the PowerFlex 750-Series Programming Manual, publication 750-PM001 Command (sent over a communication network or DeviceLogix software).

) or by Logic

Adjustment range is 0.00 to 3600.00 seconds.

16 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 17

Drive Configuration Chapter 1

Rated Voltage

Volt age

Frequenc y

Max Frequency

Adjustable Voltage

As standard AC drive applications are expanding into new markets, new control methods are required to meet these market demands for electromagnetic applications. Some of these applications, listed below, use non-motor or nonstandard motors that require independent control of load frequency and voltage.

• Vibration welding

• Induction heating

• Power supplies

• Vibratory feeders or conveyors

• Electromagnetic stirring

• Resistive loads

Standard inverter control modes consist of volts per hertz (V/Hz), with boost selections, speed feedback selection, fan, pump, and economize, flux vector (FV), with encoder and encoder less modes. The control of the output voltage/ frequency relationship of the variable frequency inverter must be maintained in the linear and nonlinear (over-modulation) regions. Voltage linearity is achieved by maintaining a constant voltage/frequency ratio over the entire operating region. The variable frequency inverter must deliver an adjustable-frequency alternating voltage whose magnitude is related to the output frequency. As the linear-to-nonlinear transition begins, the control must compensate for the lost voltage and deliver a linear output voltage profile.

In adjustable voltage control mode, the output voltage is controlled independently from the output frequency. The voltage and frequency components have independent references and acceleration/deceleration rates.

The adjustable voltage control mode operation enables separate control of the output voltage and the output frequency for use on applications that are typically non-motor types. The voltage and frequency components have independent references and independent acceleration and deceleration rates. Both the voltage and frequency can be set to any point within their respective range. The following graph illustrates these functional ranges.

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Page 18

Chapter 1 Drive Configuration

Overview

Adjustable voltage control is enabled by setting P35 [Motor Ctrl Mode] to option 9 “Adj VltgMode.” This feature provides either three-phase and singlephase output voltage. The default mode is three-phase output voltage and is selected by P1131 [Adj Vltg Config]. In single-phase mode the drive is not designed to operate single phase motors, but rather the output load is considered to have a lagging or unity power factor consisting of resistance and inductance for specially designed motor or non-motor application.

Input reference sources can be configured from P1133 [Adj Vltg Select]. The input source can be scaled and upper when lower limits are applied. A trim source can be selected reference from P1136 [Adj Vltg TrimSel] with the trim voltage added or subtracted from the voltage reference.

The scalar frequency selection and scalar frequency ramp are the same components as used in all other control modes. The exception being the frequency command and ramp are decoupled from the voltage generation for the adjustable voltage control mode to provide an independent frequency ramp. Acceleration and deceleration rates and S Curve are the same as used in all other modes. Upper and lower limits are applied to the value of the output command frequency.

The adjustable voltage control voltage ramp provides an independent voltage ramp decoupled from the scalar frequency ramp and controlled by user selectable acceleration and deceleration ramp times. There is also an adjustable percent S Curve feature.

The current limit function reduces the output voltage when the current limit is exceeded. Minimum and maximum voltage limits are applied so the output voltage is never operated outside that range.

Adjustable Voltage Control Setup

The following examples of setups for the Adjustable Voltage Control mode are a starting point for configuration. Applications can be unique and require specific parameter settings. These examples are base case only.

Table 1 - Basic Adjustable Voltage Control Parameters

Parameter No. Parameter Name Setting Description

35 Motor Ctrl Mode 9 “Adj VltgMode” Adjustable Voltage feature is used in non-motor

1131 Adj Vltg Config 1 1 = 3-Phase Operation, 0 = 1-Phase Operation

1133 Adj Vltg Select Preset 1

1134 Adj Vltg Ref Hi 100 Percent

1140 Adj Vltg AccTim e n Secs Application dependent

applications.

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Page 19

Drive Configuration Chapter 1

Parameter No. Parameter Name Setting Description

1141 Adj Vltg DecTime n Secs Application dependent

1142 Adj Vltg Preset1 n VAC Application dependent

1153 Dead Time Comp n % Vary from 0% to 100%. Dead Time Comp is best set

to 0% when output of the Sine wave Filter is fed into a transformer, to prevent or minimize DC Offset voltage s.

Refer to the PowerFlex 750-Series Programming Manual, publication 750-

PM001, for parameter descriptions and defaults.

When using sine wave or dv/dt filters, the PWM frequency must match the filter design. The drive’s thermal protection changes the PWM frequency if over temperature conditions are detected. Set P420 [Drive OL Mode] to option 1 “Reduce CLmt” and P38 [PWM Frequency] to the filter instructions.

Additional Parameter Changes

When using adjustable voltage control it is necessary to change additional parameters beyond the feature itself. Use this table to assist in setting these parameters.

Table 2 - Adjustable Voltage Applications Parameter Settings

Parameter No. Parameter Name Setting Description

38 PWM Frequency 2 kHz or 4 kHz Match the setting with filter tuning.

40 Mtr Options Cfg Bit 5 = 0 Reflected wave is turned off so that there are no

Bit 8 = 1 AsyncPWMLock is on because the filter is tuned to

Bit 9 = 1 PWM Freq Lock is on because the filter is tuned to

Bit 11 = 0 The “Elect Stab” bit affects angle stability and

Bit 12 = 0 Transistor diagnostics is turned off because that

43 Flux Up Enable 0 Leave at the “Manual” setting.

44 Flux Up Time Default Leave at 0.0000 seconds.

missing pulses in the output voltage waveform and to minimize any offsets that can appear.

the carrier frequency. The carrier frequency must be fixed, if it changes the filter will not work. Also, set the PWM frequency match filter tuning, either 2 kHz or 4 kHz.

voltage stability. Angle stability gain is set for 0 so it does not

compensate for the current going into the filter’s caps. Voltage stability gain is set for 0 for the same reason.

sequence of turning transistors on and off charges the caps in the filter and can cause an IOC trip.

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Page 20

Chapter 1 Drive Configuration

IMPORTANT

Parameter No. Parameter Name Setting Description

60 Start Acc Boost 0 Set if there are DC offset voltages at load

61 Run Boost 0

62 Break Voltage 0

63 Break Frequency 0

420 Drive OL Mode 1 “Reduce CLmt” Drive OL mode is set for reduce current limit, and

1154 DC Offset Ctrl 1 “Enable” This turns off any offset control programmed in the

transformer input windings.

not the PWM frequency as it must remain fixed.

firmware.

Modulation mode is default at space vector only because 2-phase modulation will degrade the filter’s performance.

Do not autotune.

Application Considerations

Whatever the device the user wants to connect to the drive by using the adjustable voltage feature, that device has some type of rating associated with it. As a minimum it needs to have a current rating and voltage rating. Drive selection is based on those ratings.

Sizing

First, consider the voltage rating of the drive. Determine what the available line voltage is and select a drive voltage rating to match. Next, select a drive that supplies the current necessary for the device’s rating.

Single Phase Output

Consult Rockwell Automation before configuring a drive for single phase adjustable voltage output. Derating of the drive is necessary because of stress on the DC bus capacitor or the IGBT switching losses. When PWM is applied to a resistor, the current changes state following the voltage. For each PWM voltage pulse the current is pulsing the same way. This rapid change in current is not designed into the IGBT selection for the drive. Therefore, some sort of derating needs to be applied. Somewhere around 67% derating. When in this mode, actual losses must be measured to determine a derating percentage. Adding a reactor in series with the resistor can help by adding inductance and rounding off the corners of the current pulses. Depending on how much inductance is added, the waveform can look like a sine wave.

20 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 21

Drive Configuration Chapter 1

Single Phase - PWM into Resistor - No Reactor

Vol tag e DC Bus Curren t

Single Phase - PWM into Resistor - No Reactor

Vol tag e Curren t

This is a plot showing output voltage, output current, and DC Bus voltage. Here you can see the current following the voltage in a typical PWM output.

This plot enlarges some of the pulses to see the current and its shape.

Notice the tops have an abrupt change to them. Any rounding of the wave form at the top is due to the type of resistor used. The resistors used for this plot are the grid type resistors where the resistor element is coiled along its length, adding a certain amount of inductance. This inductance helps round over the leading edge of the current.

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Chapter 1 Drive Configuration

Single Phase - PWM into Resistor - No Reactor

Vol tag e DC Bus Curren t

Below is the same plot with a reactor added in series. These waveform look like a sine wave and that is a function of how much inductance is added. However, the increased voltage drop must be accounted for.

Another option is to have a sine wave filter in the circuit. This lets unshielded cable to be used without the worry of PWM generated noise being injected into the facility. The cost of shielded cable versus a sine wave filter, Among other factors, has to be weighed.

When using single phase operation, connect the load to the U and V phases. The W phase is energized but is not used.

Enter your maximum current into the Motor NP Amps parameter. Also use this value in the Current Limit parameter. When started the drive attempts to ramp to the commanded voltage. If current limit is hit, the drive levels off or reduce the voltage to satisfy the current limit.

Notice the DC Bus voltage ripple in two of the plots above. If this ripple is high enough in magnitude, it can cause the drive to trip on an Input Phase Loss fault. This is due to the drive monitoring the bus ripple and if a certain delta between max volts and min volts exists for a certain amount of time, the drive assumes an input phase was lost. This fault can be disabled by setting P462 [InPhase LossActn] to option 0 “Ignore.”

Three Phase Output

If you are driving as resistive load, configure it in a three phase arrangement to avoid using the single phase mode of adjustable voltage. Use a sine wave filter to keep PWM off the resistors. If the resistors are of the ceramic type, it is possible to crack the resistor using PWM.

22 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 23

Drive Configuration Chapter 1

XL 2 pi× f× H×=

XL12pi× 60× 1.2 1000⁄()× 0.45ohm==

XL22pi× 60× 5 1000⁄()× 1.88ohm==

XL32pi× 60× 5 1000⁄()× 1.88ohm==

XL42pi× 60× 3 1000⁄()× 1.13ohm==

IVXL 3×()⁄=

VIXL× 3×=

The following is a plot of voltage and current at the reactor. The output of the drive is sent through a sine wave filter then to the reactor. The shape of the waveform is determined by the amount of capacitance in the sine wave filter.

If you wanted to know what voltage you can expect at the three phase reactor, consider an example where the user has four reactors in series. The inductance of each is 1.2mH, 5mH, 5mH and 3mH. First item to calculate is XL for each

reactor. .

Now total it. XL1 + XL2 + XL3 + XL4 = 5.35 ohm.

For a three phase reactor the current is represented by the

equation,

Isolate the voltage.

The current value can be what the least rating of the reactors are or if the rating are greater than the drive rating, use the drive rating. In this case the drive is rated for 14 amps.

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Page 24

Chapter 1 Drive Configuration

V 14 5.35× 1.73× 129.8==

DC Voltage

Resistor Current

Times

DC Voltage

Resistor Current

So plug in the numbers.

So 14 amps is realized when the voltage is 129.8 on the output. A drive with a voltage rating of 240V AC could be selected.

Below is a waveform of voltage and current at a resistor. The output of the drive runs through a sine wave filter. Then this is connected to a one to one transformer. This output is then sent to a bridge rectifier giving us pure DC. With the use of a feedback board and the drives PI loop, the voltage at the resistor was steady even if the resistance changed while running.

Other

Setting the frequency acceleration time to zero results in the drive outputting a DC voltage waveform.

If the frequency accel time is set between 0 and 1, this could trigger and anomaly

24 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

where the drive outputs a frequency not equal to the commanded frequency. The

Page 25

40 Mtr Options Cfg

Options

Reserved

Jerk Select

Not Used

Common Mode

Xsistor Diag

Elect Stab

DB WhileStop

PWM FreqLock

AsyncPWMLock

PWM Type Sel

RS Adaption

Reflect Wave

Mtr Lead Rev

EnclsTrqProv

(1)

(1) 755 drives only.

Trq ModeJog

Trq ModeStop

Zero TrqStop

Default00000000000000000001100011100111

Bit 323029282726252423222120191817161514131211109876543210

Mtr Ctrl Options

MOTOR CONTROL

Drive Configuration Chapter 1

cause of this anomaly is the introduction of the jerk function. This bit needs to be off during this condition.

RW 32-bit

Motor Options Configuration

Configuration of motor control-related functions. For motors abo ve 200 Hz, a carrier frequency of 8 kHz or higher is recommended. Consider drive derate and motor lead distance restrictions.

Integer

When using single phase operation, connect the load to the U and V phases. The W phase is energized but is not used.

Using a DC output can result in thermal issues. The drive may need to be derated.

Auto Restart

Investigate Possible Derating

Derate drive for sine wave filter.

Motor or drive overload is not affected by adjustable voltage mode.

The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. Provided the drive has been programmed with a 2 wire control scheme and the Run signal is maintained. This enables remote or unattended operation. Only certain faults are allowed to be reset. Faults listed as NonResettable in the programming manual indicate possible drive component malfunction and are not resettable.

Use caution when enabling this feature, because the drive attempts to issue its own start command based on user selected programming.

Configuration

Setting P348 [Auto Rstrt Tries] to a value greater than zero enables the Auto Restart feature. Setting the number of tries equal to zero disables the feature.

ATT EN TI ON : Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.

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Chapter 1 Drive Configuration

P349 [Auto Rstrt Delay] sets the time, in seconds, between each reset/run attempt.

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

• P936 [Drive Status 2] Bit 1 “AuRstrCntDwn” provides indication that an Auto Restart attempt is presently counting down and the drive attempts to start at the end of the timing event.

• P936 [Drive Status 2] Bit 0 “AutoRstr Act” indicates that the auto restart has been activated.

Operation

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

1. The drive is running and an Auto Reset Run fault occurs, thus initiating the fault action of the drive.

2. After the number of seconds in P349 [Auto Rstrt Delay], the drive automatically performs an internal Fault Reset, resetting the faulted condition.

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

4. If another Auto Reset Run fault occurs, the cycle repeats itself up to the

number of attempts set in P348 [Auto Rstrt Tries].

5. If the drive faults repeatedly for more than the number of attempts set in P348 [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. If the drive remains running for five minutes or more because the last reset/run without a fault, or is otherwise stopped or reset, the Auto Reset/ Run is considered successful. The Auto Restart status parameters are reset, and the process repeats if another auto resettable fault occurs.

See Aborting an Auto-Reset/Run Cycle for information on how the Reset/Run cycle can be aborted.

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 type must be Auto Reset Run.

• P348 [Auto Rstrt Tries] setting must be greater than zero.

• The drive must have been running, not jogging, not auto tuning, and not

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

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Page 27

Drive Configuration Chapter 1

Aborting an Auto-Reset/Run Cycle

During an Auto Reset/Run cycle the following actions/conditions abort the reset/run attempt process.

• A stop command is issued from any source. (Removal of a 2-wire run-fwd or run-rev command is considered a stop assertion.)

• A fault reset command is issued from any source.

• The enable input signal is removed.

• P348 [Auto Rstrt Tries] is set to zero.

• A Non-Resettable fault occurs.

• Power to the drive is removed.

• The Auto Reset/Run Cycle is exhausted.

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 is considered exhausted and therefore unsuccessful. In this case the Auto Reset/Run cycle terminates and an F33 “AuRsts Exhaust” fault is indicated by P953 [Fault Status B] Bit 13 “AuRstExhaust.”

Auto/Manual

The purpose of the Auto/Manual function is to permit temporary override of speed control and/or exclusive ownership of logic (start, run, direction) control. A manual request can come from any port, including HIM, digital input or other input module. However, only one port can own manual control and must release the drive back to auto control before another port can be granted manual control. When in Manual mode, the drive receives its speed reference from the port that requested manual control, unless otherwise directed by the Alternate Manual Reference Select.

The HIM can request Manual control by pressing the Controls key followed by the Manual key. Manual control is released by pressing the Controls key followed by Auto. 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.

Manual control can also be requested through a digital input. To do this, a digital input has to be set to request Manual control through P172 [DI Manual Ctrl]. Digital Input Manual control requests can be configured to use their own alternative speed reference to control the drive. Digital inputs can also be used in conjunction with Hand-Off-Auto Start to create a three way HOA switch that incorporates Manual mode.

The Safe Speed Monitor Option Module uses Manual mode to control the speed of the drive when entering Safe Limited Speed monitoring.

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Chapter 1 Drive Configuration

Auto/Manual Masks

The port configuration of the Auto/Manual feature is performed through a set of masks. Together, these masks set which ports can control the speed and/or logic control of the drive as well as which ports can request Manual control. The masks are configured by setting a 1 or 0 in the bit number that corresponds to the port (Bit 1 for port 1, Bit 2 for port 2, and so forth). Digital Inputs are always configured through Bit 0, regardless of what port the module physically resides in. If both [Manual Ref Mask] and [Manual Cmd Mask] for a particular port are set to 0, that port is unable to request manual control.

P324 [Logic Mask]

Logic Mask enables and disables the ports from issuing logic commands (such as start and direction) in any mode. Stop commands from any port are not masked and still stop the drive.

P325 [Auto Mask]

Auto Mask enables and disables the ports from issuing logic commands (such as start and direction) while in Auto mode. Stop commands from any port are not masked and still stop the drive.

P326 [Manual Cmd Mask]

Manual Command Mask enables and disables the ports from exclusively controlling logic commands (such as start and direction) while in Manual mode. If a port assumes Manual control, and the corresponding bit for the port in the [Manual Cmd Mask] is set, no other port is able to issue logic commands. Stop commands from any port are not masked and still stops the drive.

P327 [Manual Ref Mask]

Manual Reference Mask enables and disables the ports from controlling the speed reference while in Manual mode. If a port assumes manual control, and the corresponding bit for the port in the [Manual Ref Mask] is set, the drive is commanded to the speed reference from that port. An alternate speed reference can be commanded using P328 [Alt Man Ref Sel]. If the respective bit for the manual control port is not set, then the drive follows its normal automatic speed reference, even in Manual mode.

Alternate Manual Reference Select

By default, the speed reference used in Manual mode comes from the port that requested manual control (For example, if a HIM in port 1 requests manual control, the speed reference in Manual mode comes from port 1). If instead it is desired to use an a different speed reference, P328 [Alt Man Ref Sel], can be used. The port selected in the parameter is used for manual reference regardless of which port requested manual control, as long as the port in manual control is allowed to set the manual reference per P327 [Manual Ref Mask]. If P328 [Alt Man Ref Sel] is an analog input, the maximum and minimum speeds can be configured through P329 [Alt Man Ref AnHi] and P330 [Alt Man Ref AnLo].

28 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 29

Drive Configuration Chapter 1

ESC

REF



MANUAL

FBKREF

REMOVE

HIM

EDIT

REF

 FWDREV 



REF

JOG HELP

Control Sc reen Key Functio n Map

corresponds to Navigation/Number Keys

Stopped

0.00 Hz

AUTO

Stopped

0.00 Hz

MAN

Stopped

0.00 Hz

AUTO

Host Drive 240V 4.2A 20G...D014

ESC REF TEXT

PAR#

For analog input between the minimum and maximum, the drive derives the speed from these parameters through linear interpolation.

The P328 [Alt Man Ref Sel] manual reference overrides all other manual speed references, including P563 [DI ManRef Sel].

HIM Control

Manual Control can be requested through an HIM device attached to port 1, 2, or 3. The proper bits must be set in the masks (P324 [Logic Mask], P326 [Manual Cmd Mask], and P327 [Manual Ref Mask]) for the port that the HIM

is attached. To request control through the HIM, press the (Controls) key to display the Control screen.

Press the (Manual) key.

Press the (Edit) key to confirm that you want to switch to Manual mode.

If the request is accepted, the HIM displays “MAN” in the top right corner. The display does not indicate if the drive is in Manual, but rather if that particular HIM has Manual control. A HIM still displays “AUTO” if it does not have ownership of the Manual mode, even if the drive itself is in Manual mode. To see if the drive is in Manual mode, check P935 [Drive Status 1] Bit 9.

When a HIM has Manual control of the drive, the drive uses the speed reference from the HIM unless overridden by P328 [Alt Man Ref Sel]. To change the speed reference on the HIM, navigate to the Status screen and press the middle soft key labeled REF.

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 29

Page 30

Chapter 1 Drive Configuration

ESC

REF



MANUAL

FBKREF

REMOVE

HIM

EDIT

REF

 FWDREV 



REF

JOG HELP

Control Scre en Key Function Map

corresponds to Navigation/Number Keys

Stopped

0.00 Hz

AUTO

Current Speed

With Manual Preload

Without Manual Preload

Desired Speed

Set in HIM

Manual Mode

Requested

Desired Manual Speed

Last Speed Used in HIM

If the request is not accepted, a message indicates that “Manual Control is not permitted at this time.” The most likely causes are that manual control is disabled for the port or that another port currently has manual control. To check which port has manual control, look at P924 [Manual Owner].

To release Manual mode from the HIM, press the (Controls) key to display the Control screen.

Press the (Auto) key.

Press the (Edit) key to confirm that you want to switch to Auto mode.

HIM Preload

Before taking a manual control speed reference from a HIM, the drive can preload its current speed into the HIM to provide a smooth transition. Without this feature, the drive immediately transitions to whatever speed was last used in the HIM, before the operator has a chance to make their adjustment. With this feature, the drive maintains its current speed until the operator sets the speed to the desired manual reference.

30 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

The Auto/Manual HIM Preload is configured through P331 [Manual Preload]. Ports 1, 2, and 3 can be configured to have the speed reference preloaded into the HIM by setting bits 1, 2, and 3 respectively.

Page 31

Drive Configuration Chapter 1

Manual Speed Reference HIM (DPI Port 1)

Manual Control (Port 5, Input 3)

Automatic Speed Reference (Port 14)

Example Scenario

The drive has a HIM in port 1 and a 24V DC I/O module in port 5. You want to select manual control from a digital input 3 on the I/O module. You want the embedded EtherNet/IP port to be the source for the speed reference in Automatic mode, and the HIM to be the source for the speed reference in Manual mode.

Required Steps

1. Set P172 [DI Manual Ctrl] to Port 5-I/O Module > 1-Dig In Sts > 3 –

Input 3.

2. Set P328 [Alt Man Ref Sel] = 871 Port 1 Reference 3. Set P331 [Manual Preload] = 0000 0000 0000 0010, Bit 1 enables the preloading of the speed feedback value to the HIM at port 1 when the HIM is granted manual control.

Digital Input Control

A Digital Input can be configured to request manual control through P172 [DI Manual Ctrl]. When setting up the Auto/Manual masks, digital inputs are configured through Bit 0, regardless of what port the module physically resides in.

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Chapter 1 Drive Configuration

+24V

+10V

XOO

OOX

XOO

DI 0: Stop

DI 1: HOA Start and Manual Control

Analog IN 0: DI Manual Speed Reference

Speed Potentiometer

A speed reference for Manual mode from a digital input can be set by selecting a port in P328 [Alt Man Ref Sel]. This however causes all manual requests to use that port as a reference, whether the request was from the digital input or from a HIM. A separate manual reference port for use only when the request comes from a digital input can be configured through P563 [DI ManRef Sel]. (To see P564 [DI ManRef AnlgHi], set P301 [Access Level] to 1 “Advanced.”) If P328 [Alt Man Ref Sel] is configured, it overrides P563 [DI ManRef Sel] and provides the manual reference.

If P563 [DI ManRef Sel] is an analog input, the maximum and minimum speeds can be configured through P564 [DI ManRef AnlgHi] and P565 [DI ManRef AnlgLo]. For analog input between the minimum and maximum, the drive derives the speed from these parameters through linear interpolation.

Hand-Off-Auto

The Auto/Manual feature can be used in conjunction with a Hand-Off-Auto Start to create a H-O-A switch that starts the drive and requests manual control at the same time, allowing for a local speed reference to control the drive. See

Hand-Off-Auto

on page 64 for more details on the Hand-Off-Auto Start feature.

In the circuit below, a speed potentiometer was added to the analog input to provide a speed reference to the drive. When the H-O-A switch is moved from Auto to Hand, the digital input block requests manual control and issues a start command to the drive. If the digital input port receives manual control, the drive accelerates to the reference speed from the analog input. All attempts to change the speed except from the analog input are blocked. If the drive is stopped while in Hand, switch the H-O-A switch to Off and then back to Hand to restart the drive.

If another port has manual control of the drive, but does not have exclusive ownership of the logic commands (due to P326 [Manual Cmd Mask]), turning the switch to Hand causes the drive to begin moving but for the analog input to have no control over the speed.

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Drive Configuration Chapter 1

For this circuit, set the following parameters (P301 [Access Level] must be set to 1 “Advanced” to see P563 [DI ManRef Sel]).

Number Parameter Name Value

158 DI Stop Digital Input 0

172 DI Manual Ctrl Digital Input 1

176 DI HOA Start Digital Input 1

324 Logic Mask xxxxxxxxxxxxxxx1 (Digital In)

326 Manual Cmd Mask xxxxxxxxxxxxxxx1 (Digital In)

327 Manual Ref Mask xxxxxxxxxxxxxxx1 (Digital In)

563 DI ManRef Sel Anlg In0 Value

The drive requests Manual mode, start, and tracks the reference speed coming from the Analog Input when the H-O-A switches to Hand. (The HIM still reads Auto. This display changes only when the HIM has control of Manual mode).

Safe Limited Speed

Safe Limited Speed through the PowerFlex Safe Speed Monitor option module uses Manual mode to control the speed of the drive. When Safe Limited Speed monitoring is enabled, the safety module requests manual control of the drive. If the drive does not reach a safe speed, as defined on the option module by P55 [Safe Speed Limit] and within P53 [LimSpd Mon Delay], the drive faults.

While the option module uses the Manual mode, it has no way to provide a speed reference or start the drive. The following parameters must thus be configured.

P326 [Manual Cmd Mask]

Turn off the bit corresponding to the safety option’s port to allow modules installed in other ports to continue to control the drive when it is operating in Manual mode. For example, if the safety option is installed in port 6, then turn off Bit 6 in this parameter.

P327 [Manual Ref Mask]

Turn on the bit corresponding to the safety option’s port to allow the safety option to command the drive to use its Manual Speed Reference when it is operating in Manual mode. For example, if the safety option is installed in port 6, then turn on Bit 6 in this parameter.

P328 [Alt Man Ref Sel]

Set this parameter to select the desired speed reference when the drive is operating in Manual mode. For example, set this parameter to the value Port 0: Preset Speed 1 to configure the drive to use P571 [Preset Speed 1] as the Manual Speed Reference. In this case, P571 [Preset Speed 1] must be less than P55 [Safe Speed Limit] in the safety option to avoid causing an SLS Speed Fault.

See the Safe Speed Monitor Option Module for PowerFlex 750-Series AC Drives Safety Reference Manual, publication 750-RM001

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 33

, for more information.

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Chapter 1 Drive Configuration

Automatic Device Configuration

Automatic Device Configuration (ADC) supports the automatic download of configuration data to a Logix controller that has an EtherNet/IP connection to a PowerFlex 755 drive (firmware 4.001 or later) and its associated peripherals ADC is supported in the following:

• RSLogix 5000 software, version 20 or later

• Studio 5000 environment, version 21 or later

Project files (.ACD files) created with this software contain the configuration settings for PowerFlex drives in the project. When the project is downloaded to the controller, the configuration settings are transferred to controller memory. Earlier programming software required a manual process to download configuration settings to the controller.

ADC can also work in tandem with Firmware Supervisor. If Firmware Super visor is set up and enabled for a drive (Exact Match keying must be used), the drive/ peripheral is automatically upgraded (if necessary) prior to any ADC operation for that port.

Information on Automatic Device Configuration (ADC) can be found in the PowerFlex 755 Embedded EtherNet/IP Adapter User Manual, publication

750COM-UM001

topics:

• Description of the ADC functionality

• How the Drive Add-On Profiles (AOPs) affect ADC

• Configuring a PowerFlex 755 Drive (firmware 4.001 or later) for ADC

• ADC and Logix Memory

• Storing the Drive’s and Peripherals’ Firmware in the Logix Controller

(Firmware Supervisor)

• Special Considerations When Using a DeviceLogix software Program

• Special Considerations When Using a 20-750-S1 Safe Speed Monitor

Module

• Monitoring the ADC Progress

• Examples of potential issues and solutions

, Chapter 4, Configuring the I/O includes the following

34 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

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Drive Configuration Chapter 1

Autotune

The Autotune feature is used to measure motor characteristics. The Autotune feature is made up of several individual tests, each of which is intended to identify one or more motor parameters. These tests require motor nameplate information to be entered into the drive parameters. Although some of the parameter values can be changed manually, measured values of the motor parameters provide the best performance. Each motor control mode requires its own set of tests to be performed. The information obtained from these measurements is stored in the drives non volatile memory for use during operation of the drive. The feature lets these tests to be separated into tests that don’t require motor rotation (Static Tune), all tests within the selected control mode (Rotate Tune), or if the control mode requires the Inertia (Inertia Tune).

The Autotune tests are selected through the P70 [Autotune]. The feature provides a manual or automatic method for setting P73 [IR Voltage Drop], P74 [Ixo Voltage Drop] and P75 [Flux Current Ref ]. Valid only when P35 [Motor Ctrl Mode] is set to 1 “Induction SV,” 2 “Induct Econ,” or 3 “Induction FV.”

Other motor control modes such as Permanent Magnet and Interior Permanent magnet, populate other parameters associated with those control modes. See the autotune parameter set below.

Tes ts

Four Autotune selections are available in the PowerFlex 755 drive control. All four selections are selected from the Autotune parameter.

P70 [Autotune]

• 0 = Ready

• 1 = Calculate

• 2 = Static Tune

• 3 = Rotate Tune

• 4 = Inertia Tune

Ready

Parameter returns to this setting following a Static Tune or Rotate Tune, at which time another start transition is required to operate the drive in Normal mode. It also permits manually setting P73 [IR Voltage Drop], P74 [Ixo Voltage Drop], and P75 [Flux Current Ref ].

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Chapter 1 Drive Configuration

IMPORTANT

Calcula te

When the Autotune parameter is set to Calculate (default), the drive uses motor nameplate data to automatically set P73 [IR Voltage Drop], P74 [Ixo Voltage Drop], P75 [Flux Current Ref ] and P621 [Slip RPM at FLA].

P73 [IR Volt Drop], P87 [PM IR Voltage], P79 [Encdrlss VltComp], P74 [Ixo Voltage Drop], P75 [Flux Current Ref ], P93 [PM Dir Test Cur], and the Slip Frequency parameters are updated based on nameplate parameter values. When a nameplate parameter value is changed, the Autotune parameters are updated based on the new nameplate values.

When using Calculate, updated values come from a lookup table.

Static Tune

When the Autotune parameter is set to Static, only tests that do not create motor movement are run. A temporary command that initiates a non-rotational motor stator resistance test for the best possible automatic setting of P73 [IR Voltage Drop] in all valid modes and a non-rotational motor leakage inductance test for the best possible automatic setting of P74 [Ixo Voltage Drop] in a Flux Vector (FV) mode. A start command is required following initiation of this setting. Used when motor cannot be rotated.

Rotate Tune

The actual tests performed when Static and Rotate Tune selections are made, differ for the available motor control modes, Feedback Type and motor type selected. The tests performed are dependent on the settings of P35 [Motor Ctrl Mode], P125 [Pri Vel Fdbk Sel], and P70 [Autotune]. The parameters that are updated are then dependent on the tests run and in some cases calculated values for some parameters are used to update other parameters. Refer to Ta b l e 3

A temporary command initiates a Static Tune and is then followed by a rotational test for the best possible automatic setting of P75 [Flux Current Ref ]. In Flux Vector (FV) mode, with encoder feedback, a test for the best possible automatic setting of P621 [Slip RPM at FLA] is also run. A start command is required following initiation of this setting.

If using rotate tune for a Sensorless Vector (SV) mode, uncoupled the motor from the load or results can be invalid. With a Flux Vector (FV) mode, either a coupled or uncoupled load produces valid results. Caution must be used when connecting the load to the motor shaft and then performing an autotune. Rotation during the tune process can exceed machine limits.

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Drive Configuration Chapter 1

Table 3 - Autotune Value Source

Control Mode

VF Induction NA Static ON OFF OFF OFF OFF ON OFF OFF OFF OFF

FV Induction Encoder Static ON ON ON OFF OFF OFF OFF OFF OFF OFF

Motor Type

PM NA Static ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

Reluctance NA Static ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

PM Encoder Static OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Reluctance Encoder Static OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Feedback Select

EncoderlessStaticONONONONOFFOFFOFFOFFOFFOFF

Encoderless Static ON ON OFF OFF OFF OFF OFF OFF OFF OFF

Encoderless Static OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Autotune Rs Xo Idlt Rslt Id Rsld Slip Encrls Cemf PmOffset

Dynamic ON OFF OFF OFF ON ON OFF OFF OFF OFF

Dynamic ON OFF OFF OFF OFF OFF OFF OFF OFF OFF

Dynamic ON OFF OFF OFF ON OFF OFF OFF OFF OFF

Dynamic ON ON OFF OFF ON OFF ON OFF OFF OFF

DynamicONONONONONONOFFONOFFOFF

Dynamic ON ON OFF OFF OFF OFF OFF OFF ON ON

Dynamic ON ON OFF OFF OFF OFF OFF OFF ON OFF

Dynamic OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Inertia Tune

The Inertia Autotune selection involves only one test. Several parameters are updated from the test results. Refer to the tables in the Individual Tests section.

A temporary command initiates an inertia test of the motor/load combination. The motor ramps up and down while the drive measures the amount of inertia. This option applies only to FV modes selected in P35 [Motor Ctrl Mode]. Obtain final test results with the load coupled to the motor as long as the rotation won’t damage the machine.

Test Dependencies

When running the flux test, the selected accel rate is used unless it is less than 10 seconds. In this case, 10 seconds is forced. In the case of the Inertia test, a 0.1 second accel rate is used. The selected direction used during normal operation is used for all rotation tests. Also, during any rotate test, the normal speed limits are enforced.

The thermal manager is always being run in the 2 ms loop, which provides protection during all of the Autotune tests.

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Chapter 1 Drive Configuration

Tacc

WK2ΔN×

308 t()

-------------------------=

Tacc 308 t()××

ΔN

--------------------------------------=

Individual Tests

Some of the following tests are executed during an Autotune.

Resistance Test

This test is a Static test whether Static or Rotate is selected. Used to measure Stator resistance.

Inductance Tests

This test is a Static test whether Static or Rotate is selected. One test is used for Induction motors and a another is used for PM motors. The result from the Induction test is placed into the Ixo parameter and the PM test is placed into the IXd and IXq parameters.

Flux Test

This test is a Rotate test that measures the current under a no load condition. The results are used for the flux current. If a Static test is used, the resulting value is from a lookup table.

Slip Test

This test is a Rotate test that measures the difference between the rotor speed and the stator speed. This measurement is taken during acceleration.

PM Offset Test

This test can create a small amount of motor movement so it needs to be performed with the Rotate selection. The test reads the encoder position when the drive outputs zero hertz.

Inertia Test

This test is a stand alone test that is used to measure the system inertia.

The drive sets this value in P76 [Total Inertia] as seconds of inertia. This reflects the time it takes to accelerate the load at 100% torque to base speed. This

information can be very useful in determining the total inertia (in lb•ft connected to a motor shaft.

) that is

Using the following formula,

and rearranging it to

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Drive Configuration Chapter 1

T Speed×

5252

-------------------------=

HP 5252×

Speed

-----------------------=

10 5252×

1785

------------------- -=

Tacc 308× t()×

ΔN

--------------------------------------=

we have a formula that isolates the connected inertia.

For the variables, Tacc is the 100% rating of the drive in lb•ft. Let’s say I’m using a 10 Hp drive with a 10 Hp motor. We can rearrange the Horsepower formula below to solve for torque in lb•ft.

My motor is 10hp, 1785RPM,

and rearranging it to

So let’s plug in the numbers. T = lb•ft

And (t) comes from what the drive reports as seconds of inertia after running the inertia tune. Let’s say that the drive reported 2.12 seconds of inertia. And now organizing the variables we have

Tacc = 29.42 (t) = 2.12 N = 1785

plugging these into the formula, WK

After these calculations, one can conclude that the connected inertia is equal to

10.76 lb•ft

What effect can P71 [Autotune Torque] have on these calculations? Regardless of the value entered here, the drive interpolates as if this value was 100%. So the seconds of inertia reported by the drive always reflects 100% torque.

. Multiplying by 0.04214011 you get 0.453 kg•m2.

= 10.76

CEMF Test

This is a Rotate test used to measure a PM motors CEMF.

Autotune Parameters Information about some other Autotune Parameters not covered above.

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Chapter 1 Drive Configuration

Autotune Parameters

P71 [Autotune Torque]

Typically the default value of 50% is sufficient for most applications. You have the option of increasing this value or decreasing the value.

P73 [IR Voltage Drop]

The voltage drop due to resistance.

P74 [Ixo Voltage Drop]

The voltage drop due to Inductance.

P75 [Flux Current Ref ]

The current necessary to flux up the motor. This value come from a lookup table for Static tunes and is measured during a Rotate tune. Obviously a rotate tune gives more accurate results.

P76 [Total Inertia]

Reported as seconds of inertia. See description above.

P77 [Inertia Test Lmt]

A number entered in this parameter limits the inertia tune test to a maximum number of revolutions. If violated, the drive faults on F144 “Autotune Inertia.” Also, when a value is entered and the drive determines that the number of revolutions will be exceeded it goes into a decel and stops before the value is exceeded.

P78 [Encdrlss AngComp] and P79 [Encdrlss VltComp] These parameters are valid only for Flux Vector motor control mode and open loop. P78 is populated only by a rotate tune. P79 is populated by a Static measurement.

P80 [PM Cfg]

This configuration parameter enables certain tests to be performed based on the motor connected.

Permanent Magnet Motors

Parameters P81 through P93 and P120 are all populated by an autotune when the motor selected is permanent magnet. The value for these parameters are determined only by a rotate tune.

Interior Permanent Magnet Motors

Parameters P1630 through P1647 are all populated by an autotune when the motor selected is interior permanent magnet. The value for these parameters are determined only by a rotate tune.

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Drive Configuration Chapter 1

Motoring Regenerating

Auxiliary Power Supply

Bus Regulation

The optional Auxiliary Power Supply module, 20-750-APS, is designed to provide power to a single drive’s control circuitry in the event incoming supply power to the drive is removed or lost.

When connected to a user supplied 24V DC power source, the communication network functions remain operational and on-line. A DeviceNet program can also continue to run and control any associated input and outputs.

The auxiliary power supply module is designed to power all peripherals, I/O, and connected feedback devices.

Some applications create an intermittent regeneration condition. The following example illustrates such a condition. The application is hide tanning, in which a 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, of dissipating the energy, such as a dynamic braking chopper/resistor, or the drive takes some corrective action prior to the overvoltage fault value.

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Chapter 1 Drive Configuration

Drive Output Shut Off

0V Fault @ V

bus

Max

DB Bus

Motor Speed

Output Frequency

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

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.

The bus voltage regulator takes precedence over acceleration/deceleration.

42 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Select bus voltage regulation in the Bus Reg mode parameter.

Page 43

Drive Configuration Chapter 1

Current Limit

Derivative Gain

Block

Magnitude

Calculator

PI Gain Block

Current Limit Level

U Phase Motor Current

W Phase Motor Current

SW 3

I Limit,

No Bus Reg

Proportional Channel

Integral Channel

Acc/Dec Rate

Jerk

Ramp

Jerk

Clamp

No Limit

SW 2

I Limit,

No Bus Reg

Bus Reg

Frequenc y

Ramp

(Integrator)

Output Frequency

Frequency

Limits

Frequenc y Reference

SW 5

Speed

Control

Mode

Frequency Setpoint

Maximum Frequency, Minimum Speed, Maximum Speed, Overspeed Limit

Frequency Reference (to Ramp Control, Speed Ref, and so forth.)

Speed Control (Slip Comp, Process PI, and so forth.)

Bus Voltage Regulation Point, V

reg

Bus Voltage Regulator

Bus Voltage (V

bus

)

Integral Channel

Proportional Channel

SW 4

Bus Reg On

Derivative Gain Block

PI Gain Block

Limit

No Limit

SW 1

Operation

Bus voltage regulation begins when the bus voltage exceeds the bus voltage regulation setpoint V

shown.

Bus Regulation Limit Bus Reg Open Closed Don’t Care

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

and the switches shown in Figure 1 move to the positions

reg

SW 1SW 2SW 3SW 4SW 5

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Chapter 1 Drive Configuration

The derivative term senses a rapid rise in the bus voltage and activates the bus regulator prior to actually reaching the bus voltage regulation setpoint V

reg

. The

derivative term is important because it minimizes overshoot in the bus voltage when bus regulation begins thereby attempting to avoid an overvoltage 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.

ATT EN TI ON : 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 occurs if the speed reaches [Max Speed] + [Overspeed Limit]. If this condition is unacceptable, take action to 1) limit supply voltages within the specification of the drive and, 2) limit fast positive input voltage changes to less than 10%. If this operation is unacceptable and the necessary actions cannot be taken, the “adjust freq” portion of the bus regulator function must be disabled (see parameters 372 and 373).

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 372 and 373). In addition, installing a properly sized dynamic brake resistor provides 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.

Bus Regulation Modes

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

P372 [Bus Reg Mode A] is the mode normally used by the drive unless the “DI BusReg Mode B” digital input function is used to switch between modes instantaneously, in which case P373[Bus Reg Mode B] becomes the active bus regulation mode.

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Drive Configuration Chapter 1

DB Turn On

DB Turn Off

AC Volts

DC Volts

Mem

DC Bus Voltage Speed Feedback

Over Voltage Trip Point

Stop Pressed Motor Coasts

Seconds

DC Bus Volts

10 Volts = Base Speed

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

480

<685V DC 750V DC

>685V DC Memory + 65V DC

880

815

750

685

650

On - 8V DC

509

453

320 360 460 484 528 576

Option 0 “Disabled”

If [Bus Reg Mode n] is set to 0 “Disabled” The Voltage Regulator is off and the DB transistor is disabled. Energy returning to the DC bus increases the voltage unchecked and trips the drive on over voltage once the voltage threshold is reached.

Figure 2 - PowerFlex 750-Series Bus Regulation – Disabled

900

800

700

600

500

400

300

200

100

-0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

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Chapter 1 Drive Configuration

DC Bus Voltage Speed Feedback

DC bus is regulated under the over voltage trip point.

Motor stops in just under 7 seconds instead of the programmed 1 second decel.

Seconds

DC Bus Volts

10 Volts = Base Speed

Option 1 “Adjust Freq”

If [Bus Reg Mode n] is set to 1 “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 (Ta b l e 5 DC, the adjust frequency setpoint is 750V DC.

Below you can see the DC bus is being regulated as the speed is sacrificed to be sure the drive does not trip on over voltage.

Figure 3 - PowerFlex 750-Series Bus Regulation – Adjust Frequency

). For example, with a DC Bus Memory at 684V

900

800

700

600

500

400

300

200

100

-1 0 1 2 3 4 5 6 7 8 9

Option 2 “Dynamic Brak”

If [Bus Reg Mode n] is set to 2 “Dynamic Brak” The Dynamic Brake Regulator is enabled. In Dynamic Brake 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 turns on at 750V DC and turns back off at 742V DC. The Dynamic Brake mode can operate differently depending upon the setting of P382 [DB Resistor Type] either External or Internal.

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Drive Configuration Chapter 1

DC Bus Voltage DC Current

DC Bus

Seconds

DC Bus Volts

10 Volts = Base Speed

Speed Fdbk

Over Voltage Trip

Motor Speed

Brake Current

DC Bus Voltage DC Current

DC Bus

Seconds

DC Bus Volts

10 Volts = Base Speed

Speed Fdbk

Motor Speed

Brake Current

Internal Resistor

If the drive is set up for an internal resistor, there is a protection scheme built into the firmware such that if it is determined that too much power has been dissipated into the resistor the firmware does not allow the DB transistor to fire any longer. Thus the bus voltage rises and trips on over voltage.

Figure 4 - PowerFlex 750-Series Bus Regulation – Internal Dynamic Brake Resistor

900

800

700

600

500

400

300

200

100

-0.1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7

External Resistor

If the drive is set up for an external resistor and the resistor has been sized correctly and the regenerative power limit is set to a value that enables the regenerative power to be fully dissipated, the DB transistor continues to fire throughout the decel time.

Figure 5 - PowerFlex 750-Series Bus Regulation – External Dynamic Brake Resistor

800

780

760

740

720

700

680

660

-0.2 0 0.2 0.4 0.6 0.8 1 1.2

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 47

-2

Page 48

Chapter 1 Drive Configuration

The DB current seems as if it is decreasing toward the end of the decel. This is just a result of the sweep time of the oscilloscope and instrumentation. After all, it’s not known as “Ohm’s Suggestion.” The point is evident that the DB transistor is pulsing through the decel.

Option 3 “Both DB 1st”

If [Bus Reg Mode n] is set to 3 “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 750V DC and the Dynamic Brake Regulator turns on at 742V DC and back off at 734V DC.

It is possible that the drive can react differently between Flux Vector mode and Sensorless Vector mode. The important thing to remember here is that in SV control, the drive does not use the value entered into P426 [Regen Power Lmt]. If left at default (-50%) and the decel is such that it creates a large amount of regen power, the drive again attempts to protect the resistor.

Consider the plots below.

Option 4 “Both Frq 1st”

If [Bus Reg Mode n] is set to 4 “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 (Ta b l e 4 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 turns on at 750V DC and back off at 742V DC.

Figure 6

shows that upon a stop command the bus voltage rises immediately to a point where the DB transistor turns on briefly bringing the voltage down to a point where the bus regulator can regulate the bus by adjusting the output frequency (speed).

). The Dynamic Brake

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Page 49

Figure 6 - PowerFlex 750-Series Bus Regulation – Both Adj First

DC Bus Voltage DC Current

DC Bus

Seconds

DC Bus Volts

10 Volts = Base Speed

Speed Fdbk

Motor Speed

Brake Current

DC Bus Voltage DC Current

DC Bus

Seconds

DC Bus Volts

10 Volts = Base Speed

Speed Fdbk

Motor Speed

Brake Curren t

Drive Configuration Chapter 1

800

780

760

740

720

700

680

660

-0.2 0 0.2 0.4 0.6 0.8 1 1.2

-2

Flux Vector (FV) Control

With the Regen Power Limit left at default, and a decel time of 0.1 seconds, the drive is limiting the amount of power to a point where the resistor could be heating up due to duty cycle considerations. So the drive stops the DB transistor from firing and switches to “Adjust Frequency” to regulate the bus and then enables another DB pulse and then back to adjust frequency and so on until the bus voltage remains below the trigger level.

Figure 7 - PowerFlex 750-Series Bus Regulation – Both DB First FV

900

800

700

600

500

400

300

200

100

-0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8

-2

If the Regen Power Limit is opened up to 100% for instance, the plot will look exactly the same as the Sensorless Vector mode plot show below.

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Chapter 1 Drive Configuration

DC Bus Voltage DC Current

DC Bus

PowerFlex 750-Series Bus Regulation – Both DB First SV

Seconds

DC Bus Volts

10 Volts = Base Speed

Speed Fdbk

Motor Speed

Brake Current

Sensorless Vector (SV) Control

Because the drive is not limiting the regen power the DB is able to dissipate the power the entire decel time before duty cycle considerations limits the DB capability.

900

800

700

600

500

400

300

200

100

-0.15 0.05 0.25 0.45 0.65 0.85 1.05 1.25 1.45

Table 4 - Bus Regulation Curves

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

< 650V DC Memory + 100V DC

480

> 685V DC Memory + 65V DC

Curve 1 - 8V DC650V DC ≤ DC Bus Memory ≤ 685V DC 750V DC

Level/Gains

The following parameters are Level/Gains related to bus regulation.

50 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

P374 [Bus Reg Lvl Cfg]

Bus Regulation Level Configuration - Selects the reference used to determine the bus voltage regulation level for the bus voltage regulator and the reference used for the dynamic brake.

• “Bus Memory” (0) – References are determined based on P12 [DC Bus Memory].

• “BusReg Level” (1) – References are determined based on the voltage set in P375 [Bus Reg Level].

If coordinated operation of the dynamic brakes of a common bus system is desired, use this selection and set the P375 [Bus Reg Level] to coordinate the brake operation of the common bus drives.

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Drive Configuration Chapter 1

P375 [Bus Reg Level]

Bus Regulation Level - Sets the turn-on bus voltage level for the bus voltage regulator and the dynamic brake.

Table 5 - Turn On Bus Voltage

P20 [Rated Volts] = Default Turn On Volts = Min/Max Setting =

< 252V 375V 375V / 389V

252…503V 750V 750 / 779V

504…629V 937V 937 / 974V

> 629V 1076V 1076 / 1118V

While the following parameters are listed and editable in the drive, they typically do not need to be adjusted in any way. Take care when adjusting because undesired operation can occur in another aspect of motor control.

P376 [Bus Limit Kp]

Bus Limit Proportional Gain - Enables a progressively faster decel when the drive is behind the programmed decel time by making the bus limiter more responsive. A higher value means the drive tries to decrease decel time.

This parameter is valid only in NON-Flux Vector modes.

P377 [Bus Limit Kd]

Bus Limit Derivative Gain - Lets you force the bus limit sooner. The higher the value the quicker the bus limit is hit and regulation starts. This can cause regulation below the typical setpoint (750VDC for 460V drive). Too high a value and normal operation of the motor can be affected. (60…60.5 Hz oscillation.)

This parameter is valid only in NON-Flux Vector modes.

P378 [Bus Limit ACR Ki]

Bus Limit Active Current Regulator Integral Gain - If you find your system makes the regulator unstable or oscillatory, a lower value in this parameter settles out the oscillations.

This parameter is valid only in NON-Flux Vector modes.

P379 [Bus Limit ACR Kp]

Bus Limit Active Current Regulator Proportional Gain - Determines the responsiveness of the active current and therefore, regenerated power and bus voltage. Raising this value can cause the output frequency (when in bus limit) to become noisy or jittery. Too low a value can cause the bus limit function to malfunction and result in a over voltage fault.

This parameter is valid only in NON-Flux Vector modes.

P380 [Bus Reg Ki]

Bus Regulator Integral Gain - When regulating the DC bus, the voltage tends to swing above and below the voltage setpoint in what looks like a ringing oscillation. This parameter affects that behavior. A lower the value reduces oscillation.

This parameter is valid only in Flux Vector modes.

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P381 [Bus Reg Kp]

Bus Regulator Proportional Gain - This determines how fast the bus regulator is activated. The higher the value the faster the drive reacts once the DC voltage setpoint is reached.

This parameter is valid only in Flux Vector modes.

Once again, the likelihood of these parameters needing adjustment is highly unlikely. In fact, some descriptions related to the functionality of these parameters are intentionally left out of this text to eliminate undesired motor operation when they are adjusted unwisely.

Configurable Human Interface Module Removal

With the PowerFlex 750-Series the drives response to a HIM communication loss (removal) is configurable. This feature is available in drives with firmware revision 3.0 or later.

It is used to prevent unintended stopping of the drive by disconnecting the HIM. However, the HIM cannot be the sole source of a Stop command to enable this feature.

The configuration is similar to the communication adapter communication loss selections:

• 0 = Fault

• 1 = Stop

• 2 = Zero Data

• 3 = Hold Last

• 4 = Send Fault Config

The default setting is 0 “Fault.”

The HIM can be connected to one 1 of 3 ports per the parameters below. Each port is configured separately:

• P865 [DPI Pt1 Flt Actn] to determine the fault action at port 1.

• P866 [DPI Pt2 Flt Actn] to determine the fault action at port 2.

• P867 [DPI Pt3 Flt Actn] to determine the fault action at port 3.

If “Send Flt Cfg” is to be selected for the fault action, then configure the appropriate parameter below.

• P868 [DPI Pt1 Flt Ref ] to set the speed reference if the HIM at port 1 is disconnected.

• P869 [DPI Pt2 Flt Ref ] to set the speed reference if the HIM at port 2 is disconnected.

• P870 [DPI Pt3 Flt Ref ] to set the speed reference if the HIM at port 3 is disconnected.

A constant value must be entered as the fault speed reference in this instance.

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Drive Configuration Chapter 1

Droop Feature

Duty Rating

Droop is used to shed load and is usually used when a soft coupling of two motors is present in an application. The master drive speed regulates and the follower uses droop so it does not oppose the master. The input to the droop block is the commanded motor torque. The output of the droop block reduces the speed reference. P620 [Droop RPM at FLA] sets the amount of speed, in RPM, that the speed reference is reduced when at full load torque. For example, when P620 [Droop RPM at FLA] is set to 50 RPM and the drive is running at 100% rated motor torque, the droop block subtracts 50 RPM from the speed reference.

Applications require different amounts of overload current.

Normal Duty

Sizing the drive for Normal Duty enables the use of the highest continuous output current rating of the drive and an overload rating of 110% for 60 seconds (every 10 minutes) and 150% for 3 seconds (every minute).

Heavy Duty

For heavy duty applications, a drive one size larger than is required for the motor is used in the application and therefore provides a larger amount of overload current in comparison to the motor rating. Heavy Duty sizing provides at least 150% for 60 seconds (every 10 minutes) and 180% for 3 seconds (every minute).

Light Duty

The light duty setting, for a given normal duty rated drive, provides a higher continuous output current but with limited overload capability. When in light duty, the drive provides 110% for 60 seconds (every 10 minutes). The light duty setting is only available on PowerFlex 755 drives, frame 8 and larger.

The overload percentages are with respect to the connected motor rating.

The duty rating is programmed in P306 [Duty Rating]. This parameter is reset to the default setting if a Set Defaults “ALL” is executed. For drives rated under 7.5 kW (10 Hp) the normal duty and heavy duty continuous current ratings are the same, and have the heavy duty overload settings.

When changing the [Duty Rating], review P422 [Current Limit 1] and P423 [Current Limit 2].

Refer to the PowerFlex 750-Series AC Drives Technical Data, publication 750-

TD001, for continuous and overload current ratings for each catalog number.

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Chapter 1 Drive Configuration

Feedback Devices

Flying Start

There are three different feedback option modules available for PowerFlex 750Series AC Drives:

• Single Incremental Encoder (20-750-ENC-1)

• Dual Incremental Encoder (20-750-DENC-1)

• Universal Feedback (20-750-UFB-1)

The Dual Incremental Encoder and Universal Feedback modules each support up to two encoders while the Single Incremental Encoder supports one encoder. Multiple feedback option modules can be installed in the drive, however there is a limit of two feedback modules if using Integrated Motion on EtherNet/IP.

For more information on the option modules, including specifications and wiring information, see the PowerFlex 750-Series AC Drives Installation Instructions, publication 750-IN001

For more information on encoder feedback options, including connections and compatibility, see Appendix E of the PowerFlex 750-Series Programming Manual, publication 750-PM001

The Flying Start feature is used to start into a rotating motor, as quick as possible, and resume normal operation with a minimal impact on load or speed.

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 are generated. An over current trip can result if the current limiter cannot react quickly enough. The likelihood of an over current 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 over current trip, it can 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 then accelerates to the commanded frequency. This process prevents an over current trip and significantly reduce the time for the motor to reach its commanded frequency. Because the drive synchronizes with the motor at its rotating speed and ramps to the proper speed, little or no mechanical stress is present.

The Sweep function is currently not in the PowerFlex 750-Series drives frame 8 and larger.

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Drive Configuration Chapter 1

Configuration

Flying Start can be configured by setting P356 [FlyingStart Mode] to the following:

• 0 “Disabled”

• 1 “Enhanced”

• 2 “Sweep”

Disabled

Disables the feature.

Enhanced

An advanced mode that performs the motor reconnect quickly by using the motor’s CEMF as a means of detection. This mode is the typical setting for this feature.

Sweep

The Frequency Sweep mode is used with output sine wave filters. It attempts a reconnect by outputting a frequency starting at P520 [Max Fwd Speed]+ P524 [Overspeed Limit] and decreasing according to a slope that is modified by P359 [FS Speed Reg Ki] until there is a change in the monitored current indicating the speed of the spinning motor has been found. If the motor was not found from the forward sweep, the drive sweeps in the reverse direction from P521 [Max Rev Speed]+ P524 [Overspeed Limit].

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Chapter 1 Drive Configuration

PowerFlex 753 Flying Start - Sweep Mode - Decelerating Load

Coasti ng Motor

Frequency Sweep

Start Pressed

Detection

Slope determined by P359

Frequenc y

Speed

Curren t

Scope Plots

Flying Start - Sweep Mode

This plot shows a coasting motor. When a start is commanded, the output frequency jumps up to P520 [Max Fwd Speed]+ P524 [Overspeed Limit] at some current. As the sweep frequency decreases the current is monitored. When the sweep frequency matches the frequency of the coasting motor, the current reverses and detection is complete. The motor is accelerated back to commanded speed.

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Drive Configuration Chapter 1

PowerFlex 753 Flying Start - Sweep Slope A

Note the slope of the frequency sweep.

Adjust P359 [FS Speed Reg Ki]

Frequenc y

Speed

Curren t

PowerFlex 753 Flying Start - Sweep Slope B

Note the slope of the frequency sweep.

Adjust P359 [FS Speed Reg Ki]

Frequenc y

Speed

Curren t

Flying Start - Sweep Slope A

This plot shows when the drive starts to sweep for the spinning motor, the frequency sweep has a certain slope associated with it. By modifying P359 [FS Speed Reg Ki] you can change the slope of this sweep.

Flying Start - Sweep Slope B

This plot shows the result of increasing P359 [FS Speed Reg Ki]. The slope is extended.

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Chapter 1 Drive Configuration

PowerFlex 753 Flying Start - Rotating Load - P360 = 1, Default = 75

Note current dip.

Frequency

Speed

Curren t

In the two samples shown above, the motor was decelerating. The sweep function and slope manipulation work the same if the motor was spinning at some constant speed.

Flying Start - Sweep Dip A

This plot shows the effect of modifying P360 [FS Speed Reg Kp]. In this plot a motor is spinning at some constant speed when the drive is issued a start command and the sweep routine is started. Note the current dip when the parameter is set to its lowest value and the drive has determined the frequency of the rotating motor. See the next plot when this parameter set to its highest setting.

Flying Start - Sweep Dip B

This plot shows the effect of modifying P360 [FS Speed Reg Kp]. In this plot a motor that is spinning at some constant speed when the drive is issued a start

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command and the sweep routine is started. Note the current dip when the parameter is set to its highest value and the drive has determined the frequency of

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Drive Configuration Chapter 1

PowerFlex 753 Flying Start - Rotating Load - P360 = 9000, Default = 75

Note current dip.

Frequenc y

Speed

Curren t

PowerFlex 753 Flying Start - Rotating Reverse - Sweep Mode

Speed and Direction determined

Frequenc y

Speed

Current

Sweep Forward

Acceleration to Commanded Speed

Controlled Decel

Sweep Reverse

Motor Spinning Reverse Drive is off

the rotating motor. See the previous plot when this parameter set to its lowest setting.

Flying Start - Sweep Reverse Rotating Motor

This plot shows the Sweep mode when the motor is rotating opposite from the commanded frequency. It starts the same as explained above. If it didn't detect the motor’s speed as it reaches 3 Hz it begins to sweep in the opposite direction. From here the process continues the same as before.

Flying Start - Enhanced Mode

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Chapter 1 Drive Configuration

PowerFlex 753 Flying Start - Enhanced Mode

Frequenc y

Speed

TP 138 Current

Current pulses, motor excitation

Attempt to mea sure

counter EMF

Output Current

Motor “caught,” Normal Accel

This plot shows a very short time base of the Enhanced mode. If the drive detects the counter EMF of the motor it can instantly re-connect to the motor and accelerate to the commanded speed. If the drive cannot measure the CEMF (this is where the plot picks up) it sends current pulses to the motor in an attempt to excite the motor allowing the drive to detect the speed of the motor. This usually happens only at very low speeds. Once the drive has detected the motor it accelerates to the commanded speed.

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Drive Configuration Chapter 1

PowerFlex 753 Flying Start - Rotating Reverse - Enhanced Mode

Frequenc y

Speed

Current

No Sweep necessary in Enhanced Mode

Flying Start - Enhanced Mode Reverse

Here is a motor spinning in the opposite direction of the commanded speed. In Enhanced mode the detection takes a very short time and the motor is controlled to zero speed and accelerated to the commanded speed.

P357 [FS Gain]

Sweep mode - The amount of time the detection signal (current) must be below the setpoint. A very short time entered could cause false detections. Too long of a time and detection could be missed.

Enhanced mode - It’s the Kp in the current regulator used in the detection process. Used along with P358.

P358 [FS Ki]

Sweep mode - Integral term in voltage recovery, indirectly connected to time; higher value can shorten recovery time but can cause unstable operation.

Enhanced mode - It’s the Ki in the current regulator used in the detection process. Used along with P357.

P359 [FS Speed Reg Ki]

Sweep mode - The amount of time to sweep the frequency. A short time entered produces a steep slope on the frequency. A higher value (longer time) produces a flatter frequency sweep. Shown above.

Enhanced mode - It’s the Ki in the speed regulator used in the detection process. Used along with P358.

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Chapter 1 Drive Configuration

P360 [FS Speed Reg Kp]

Sweep mode - Sets level the current must drop below. A larger value requires less change in current to indicate detection.

Enhanced mode - It’s the Kp in the speed regulator used in the detection process. Used along with P357.

P361 [FS Excitation Ki]

Sweep mode - Integral term used to control the initial output voltage

Enhanced mode - Integral term used in the current regulator, which controls the motor excitation if the detection process deemed it necessary to excite the motor.

P362 [FS Excitation Kp]

Sweep mode - Proportional term used to control the initial output voltage

Enhanced mode - Proportional term used in the current regulator, which controls the motor excitation if the detection process deemed it necessary to excite the motor.

P363 [FS Reconnect Dly]

Delay time used between the issued start command and the start of the reconnect function. This is mainly used for power loss situations so the restart doesn't occur too quickly causing possible faults.

P364 [FS Msrmnt CurLvl]

There are two different measurement methods used when in Enhanced mode. If this parameter is set to zero the second method is cancelled and reconnect is attempted after the first measurement. Any other level change in this parameter could help the second measurement routine. Usually a higher number helps more.

Cooling Tower Fans Application Example

In some applications, such as large fans, wind or drafts can rotate the fan in the reverse direction when the drive is stopped. If the drive were started in the normal manner, its output begins 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.

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Drive Configuration Chapter 1

Draft/wind blows idle fans in reverse direction. Restarting at zero speed and accelerating damages fans and could break belts. Flying start alleviates the problem.

There could be occasions when the sweep as well as the CEMF detection fails at low speeds. This is due to the low levels of motor detection signals. It has been discovered that Sweep mode is more successful in these cases than Enhanced mode.

When in Sweep mode the frequency is always swept in the direction of the commanded frequency first.

Motor detection at low speeds can be difficult. Rather than get a false detection, the sweep reverses at 3 Hz.

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Chapter 1 Drive Configuration

+24V

XOO

OOX

DI 0: Stop

DI 1: Start

Hand-Off-Auto

Many legacy drive installations included a circuit (such as a Hand-Off-Auto switch) that provided 3-wire start and stop signals simultaneously to the drive. PowerFlex 750-Series drives do not start unless there is a full input cycle between the stop and start signals. P176 [DI HOA Start] adds a delay to the start signal, allowing the required time interval between the start and stop signals. This enables the use of a single 3-wire control circuit to start and stop the drive.

Hand-Off-Auto Start

If P161 [DI Start] and P176 [DI HOA Start] are both configured, a “DigIn Cfg B” alarm results. You cannot use both Digital Input Start and Digital Input Hand-Off-Auto Start at the same time.

Hand-Off-Auto Example

A Motor Control Cabinet has an Hand-Off-Auto switch wired as shown in the figure below.

When the switch is turned to Off, the switch is open between the source and Stop (DI:0) and between Stop and Start (DI:1). This causes the drive to be in an asserted stop. When the switch is turned to Auto, the control signal reaches the Stop input but not the Start. The drive can be stopped and started by another location. When the switch is turned to Hand, both the Stop and Start ports are energized.

In order for the drive to start, the Stop signal must be received prior to the Start. With the wiring above, the signals are nearly simultaneous, too fast to be sure that the drive is ready to start. This causes the switch to either be unreliable or not work at all. This can be remedied by adding a time delay to the start signal. By changing Digital Input 1 from DI Start to DI Hand-Off-Auto Start, the drive

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Drive Configuration Chapter 1

+24V

XOO

OOX

DI 0: Stop

DI 1: HOA Start

+24V

+10V

XOO

OOX

XOO

DI 0: Stop

DI 1: HOA Start and Manual Control

Analog IN 0: DI Manual Speed Reference

Speed Potentiometer

automatically adds this time delay and makes sure that the system is ready to start before it receives the command.

Using Hand-Off-Auto with Auto/Manual

To take control of the drive speed when switching from Auto to Hand on the HO-A switch, the Auto/Manual feature can be used. See Auto/Manual for more on Auto/Manual Control.

on page 27

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Chapter 1 Drive Configuration

+24V

XOO

OOX

DI 0: Stop

DI 1: HOA Start

Start Relay

+24V

XOO

OOX

DI 0: Stop and HOA Start

Start Relay

For this circuit, set the following parameters (P301 [Access Level] must be set to 1 “Advanced” to see P563 [DI ManRef Sel]).

Parameter No. Parameter Name Value

158 DI Stop Digital Input 0

172 DI Manual Control Digital Input 1

176 DI HOA Start Digital Input 1

324 Logic Mask xxxxxxxxxxxxxxx1 (Digital In)

326 Manual Cmd Mask xxxxxxxxxxxxxxx1 (Digital In)

327 Manual Ref Mask xxxxxxxxxxxxxxx1 (Digital In)

563 DI Manual Reference Select Anlg In0 Value

The drive requests Manual mode, starts and tracks the reference speed coming from the Analog Input when the H-O-A switches to Hand. (The HIM still reads Auto. This display changes only when the HIM has control of Manual mode).

Using Hand-Off-Auto with a Start Relay

The Hand-Off-Auto switch can also be wired to ability to start the drive through a separate start relay.

In the circuit below, the run relay closes the circuit to both the stop and start inputs when the H-O-A switch is in Auto. Using this option, the drive can be started only if the H-O-A switch is in Hand or in Auto and the Run Relay is energized. No network or HIM control of the drive is possible.

The above circuit can also be accomplished with a single digital input. Unlike P161 [DI Start], P176 [DI HOA Start] can share the same physical input with P158 [DI Stop]. The circuit can thus become the following.

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Drive Configuration Chapter 1

+24V

XOO

OOX

XOO

OOX

DI 0: Stop

Start Relay

DI 1: HOA Start

To use the H-O-A switch, the run relay and allow for network or HIM control, the circuit can be wired as in the figure below.

Here, the stop input is high when the H-O-A switch is in the Hand or Auto position. This eliminates the asserted stop caused when the stop input is low, allowing for the drive to be started from several sources when the H-O-A switch is in the Auto position.

Masks

A mask is a parameter that contains one bit for each of the possible ports for the respective PowerFlex 750-Series drive. Each bit acts like a valve for issued commands. Closing the valve (setting a bit value to 0) stops the command from reaching the drive. Opening the valve (setting a bit value to 1) lets the command pass through the mask into the drive.

Table 6 -

Mask Parameters and Functions

Parameter No. Parameter Name Description

222 Dig In Filt Mask

324 Logic Mask Enables/disables ports to control the logic command (such as start

325 Auto Mask Enables/disables ports to control the logic command (s uch as start

326 Manual Cmd Mask Enables/disables ports to control the logic command (such as start

327 Manual Ref Mask Enables/disables ports to control the speed reference while in

885 Port Mask Act

886 Logic Mask Act

(1)

(2)

Digital Input Filter Mask. Filters the selected digital input.

and direction). Does not mask Stop commands.

and direction), while in Auto mode. Does not mask Stop commands.

and direction), while in Manual mode. Does not mask Stop commands.

Manual mode. When a port is commanding Manual mode, the reference is forced to the commanding port if the respective bit in this parameter is set. If an alternate speed reference source is desired, use P328 [Alt Man Ref Sel] to select the source.

Active status for port communication. Bit 15 “Security” determines if network security is controlling the logic mask instead of this parameter.

Active status of the logic mask for ports. Bit 15 “Security” determines if network security is controlling the logic mask instead of this parameter.

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Parameter No. Parameter Name Description

887 Write Mask Act

(2)

Active status of write access for ports. Bit 15 “Security” determines if network security is controlling the write mask instead of this parameter.

888 Write Mask Cfg Enables/disables write access (parameters, links, and so forth.) for

DPI ports. Changes to this parameter become effective only when power is cycled, the drive is reset or Bit 15 of P887 [Write Mask Actv], transitions from “1” to “0.”

2 Dig In Filt Mask

(1) Used only by the PowerFlex 753 main control board. (2) Read only parameter. (3) Used only by I/O Module models 20-750-2263C-1R2T and 20-750-2262C-2 R. (Modules with 24V DC inputs.)

(3)

Digital Input Filter Mask. Filters the selected digital input.

The individual bits for each parameter are as follows.

Table 7 - Mask Parameters with Bit Designations

P222 [Dig In Filt Mask]

Bit 0 Reserved Digital In Digital In Digital In Digital In Digital In Digital In Reserved Reserved Input 0

Bit 1 Input 1 Port 1 Port 1 Port 1 Port 1 Port 1 Port 1 Port 1 Port 1 Input 1

Bit 2 Input 2 Port 2 Port 2 Port 2 Port 2 Port 2 Port 2 Port 2 Port 2 Input 2

Bit 3 Reserved Port 3 Port 3 Port 3 Port 3 Port 3 Port 3 Port 3 Port 3 Input 3

Bit 4 Reserved Port 4 Port 4 Port 4 Port 4 Port 4 Port 4 Port 4 Port 4 Input 4

Bit 5 Reserved Port 5 Port 5 Port 5 Port 5 Port 5 Port 5 Port 5 Port 5 Input 5

Bit 6 Reserved Port 6 Port 6 Port 6 Port 6 Port 6 Port 6 Port 6 Port 6 Reserved

Bit 7 Reserved Port 7 Reserved Reserved Reser ved Port 7 Reserved Port 7 Port 7 Reser ved

Bit 8 Reserved Port 8 Reserved Reserved Reser ved Port 8 Reserved Port 8 Port 8 Reser ved

Bit 9 Reserved Port 9 Reserved Reserved Reser ved Port 9 Reserved Port 9 Port 9 Reser ved

Bit 10 Reserved Port 10

Bit 11 Reserved Port 11

Bit 12 Reserved Reserved Reser ved Reserved Reser ved Reserved Reserved Reser ved Reserved Reserved

Bit 13 Reserved Port 13

Bit 14 Res erved Por t 14 Port 1 4 Port 14 Por t 14 Po rt 14 Por t 14 Po rt 14 Por t 14 Reser ved

Bit 15 Reserved Reserved Reser ved Reser ved Reserved Security Security Security Security Reser ved

(1) Used only by the PowerFlex 753 main control board. (2) PowerFlex 755 Frame 8 drives and larger only. (3) PowerFlex 755 drives only. (4) Used only by I/O Module models 20-750-2263C-1R2T and 20-750-2262C-2 R. (Modules with 24V DC inputs.)

(1)

P324 [Logic Mask]

(2)

(3)

P325 [Auto Mask]

P326 [Manual Cmd Mask]

P327 [Manual Ref Mask]

P885 [Port Mask Act]

Reserved Reserved Reser ved Port 10

Reserved Reserved Reser ved Port 11

Port 13

(3)

Port 13

(3)

Port 13

(3)

Port 13

P886 [Logic Mask Act]

(2)

Reserved Port 10

(2)

Reserved Port 11

(3)

Port 13

(3)

P887 [Write Mask Act]

(2)

(3)

Port 13

P888 [Write Mask Cfg]

(2)

Port 10

(2)

Port 11

(3)

Port 13

P2 [Dig In Filt Mask]

Reserved

(4)

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Drive Configuration Chapter 1

Example

A PowerFlex 755 drive is controlled via the embedded ethernet (Port 13) remotely by a PLC. Normal operation prevents any type of control from being issued from the remote HIM (Port 2). However, the ability to manually control the drive via the HIM is needed in some cases. To assure these two modes of control, masks are set as follows.

This masks out (disables) the remote HIM (Port 2) to control the logic command word (such as start, jog and direction) when the drive is in Auto mode and lets (enables) the HIM to control the logic command word when the drive is in Manual mode.

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Chapter 1 Drive Configuration

Owners

An owner is a parameter that contains one bit for each of the possible port adapters. The bits are set high (value of 1) when its adapter is currently issuing that command, and set low (Value of 0) when its adapter is not issuing that command.

Parameters and Functions

• P919 [Stop Owner] indicates which port is issuing a valid stop command.

• P920 [Start Owner] indicates which port is issuing a valid start command.

• P921 [Jog Owner] indicates which port is issuing a valid jog command.

• P922 [Dir Owner] indicates which port has exclusive control of direction

command.

• P923 [Clear Flt Owner] indicates which port is currently clearing a fault.

• P924 [Manual Owner] indicates which port has requested manual control

of all drive logic and reference functions.

• P925 [Ref Select Owner] indicates which port is issuing a valid reference select.

The bits for each parameter can be broken down as follows.

Options

(1)

Reserved

Port 14

Port 13

Reserved

Port 6

Port 5

Port 4

Port 3

Port 2

Port 1

Default0000000000000000

Bit 1514131211109876543210

(1) 755 drives only.

Digital In

Ownership falls into two categories.

Exclusive: Only one adapter at a time can issue the command and only one bit in the parameter is high.

Non Exclusive: Multiple adapters can simultaneously issue the same command and multiple bits can be high.

Some ownership must be exclusive; that is, only one adapter at a time can issue certain commands and claim ownership of that function. For example, it is not allowable to have one adapter command the drive to run in the forward direction while another adapter is issuing a command to make the drive run in reverse. Direction control ownership is exclusive.

Conversely, any number of adapters can simultaneously issue stop commands. Stop control ownership is not exclusive.

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Drive Configuration Chapter 1

Stop Asserted

0.00 Hz

AUTO

Port 00 Dev Param

Start Owner

x00x xxxx x000 0010 Bit 01 Port 1

ESC

920

PAR#

Stop Asserted

0.00 Hz

AUTO

Port 00 Dev Param

Stop Owner

x00x xxxx x000 0001 Bit 00 Digital In

ESC

919

PAR#

Ownership Example

The operator presses the HIM Stop button 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. The operator first views the Start Owner to see if the HIM is issuing a valid Start. When the start button on the HIM is pressed, a valid start is being issued as shown below.

Because the start command is not maintained causing the drive to run, the operator views the Stop Owner. Note that the status bar on the HIM indicates that a stop has been asserted, but it does not indicate from which port the stop command is originating. 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 closed, a permanent Start Inhibit condition exists and the drive will not restart.

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Chapter 1 Drive Configuration

Power Loss

The drive contains a sophisticated algorithm to manage initial application of power as well as recovery from a partial power loss event. The drive also has programmable features that can minimize the problems associated with a loss of power in certain applications.

Terms and Definitions

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 se t equa l to bus voltage . Therea fter it is upda ted by r amping at a ver y slow rate towa rd Vbus. The fil tered value ramps at 2.4V DC per minute (for a 480VAC drive). An increase in Vmem is blocked during deceleration to prevent a false high value due to the bus being pumped up by regeneration. Any change to Vmem is blocked during inertia ride through.

Vslew The rate of change of Vmem in volts per minute.

Vrecover The threshold for recovery from power loss.

Vtrigger The threshold to detect power loss.

The level is adjustable. The default is the value in the PowerFlex 750-Series Bus Level table. If “Pwr Loss Lvl” is selected as an input functio n AND energ ized, Vtrigg er is set to Vmem minus [Pwr Loss Le vel]. Vopen is normally 60V DC below Vtrigger (in a 480VAC drive). Both Vopen and Vtrigger are limited to a minimum of Vmin. This is a factor only if [Pwr Loss Level] is set to a large value.

Important: When using a value of P451/P454 [Pwr Loss A/B Level] that is larger than default, you must provide a minimum line impedance to limit inrush current when the power line recovers. Provide an input impedance that is equal to or greater than the equivalent of a 5% transformer with a VA rating 5 times the drive’s input VA rating.

Vinerti a The softwa re regulation re ference for Vbus during inertia ride through.

Vclose The threshold to close the pre-charge contactor.

Vopen The threshold to open the pre-charge contactor.

Vmin The minimum value of Vopen.

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

Table 8 - PowerFlex 750-Series Bus Levels

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

Vslew 1.2V DC 2.4V DC 3.0V DC

Vrecover Vmem – 30V Vmem – 60V Vmem – 75V

Vclose Vm em – 6 0V Vme m – 120V Vmem – 150V

Vtrigger1,2 Vmem – 60V Vmem – 120V Vmem – 150V

Vtrigger1,3 Vmem – P451/P454 [Power

Loss A/B Level]

Vopen Vmem – P451/P454 [Power

Loss A/B Level]

Vopen4 153V DC 305V DC 382V DC

Vmin 153V DC 305V DC 382V DC

Voff – 200V DC –

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Vmem – P451/P454 [Power Loss A/B Level]

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Drive Configuration Chapter 1

Recover Closer Tri gg er Open

Recover Closer Trigger Open

Recover Closer Tri gg er Open

AC Input Volts AC Input Volts AC Input Volts

Line Loss Mode = Coast Line Loss Mode = Decel Line Loss Mode = Continue

DC Bus Volts

In the following diagram, the x-axis across the bottom indicates what the input voltage is into the drive and the y-axis indicates the corresponding DC Bus Voltage. Then the levels of each event are indicated in the graph. For example if I measure at the input of my drive, 450 volts - phase to phase, I find that voltage across the bottom. Now the various voltage levels can be derived according to that voltage level.

Restart after Power Recovery

If a power loss causes the drive to coast, and power recovers, the drive returns to powering the motor if it is in a Run Permit state. The drive is in a Run Permit state if the following is true:

•3 Wire mode - it is not faulted and if all Enable and Not Stop inputs are energized.

•2 Wire mode - it is not faulted and if all Enable, Not Stop, and Run inputs are energized.

Power Loss Modes

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. (default)

• “Decel” - Decelerate the motor at a rate that regulates 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, P959 [Alarm Status A] Bit 0 turns on if the P449 [Power Loss Actn] is set to 1 “Alarm.”

If the P449 [Power Loss Actn] is set to 3 “FltCoastStop,” an F3 “Power Loss” fault occurs when the power loss event exceeds P452/455 [Pwr Loss A/B Time].

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Chapter 1 Drive Configuration

Bus Voltage

Motor Speed

Power Loss

Output Enable

Pre-Charge

Drive Fault

680V 620V 560V 500V

407V 305V

The drive faults with a F4 “UnderVoltage” fault if the bus voltage falls below Vmin and the P460 [UnderVltg Action] is set to 3 “FltCoastStop.”

The pre-charge relay opens if the bus voltage drops below Vopen and closes if the bus voltage rises above Vclose.

If the bus voltage rises above Vrecover for 20 ms, the drive determines the power loss is over. The power loss alarm is cleared.

If the drive is in a Run Permit state, the reconnect algorithm is run to match the speed of the motor. The drive then accelerates at the programmed rate to the set speed.

Coast

This is the default mode of operation. The drive determines a power loss has occurred if the bus voltage drops below Vtrigger. If the drive is running, the inverter output is disabled and the motor coasts.

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 Vtrigger.

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 Vinertia.

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Drive Configuration Chapter 1

Bus Voltage

Motor Speed

Power Loss

Output Enable

Pre-Charge

Drive Fault

680V 620V 560V 500V

407V 305V

Bus Voltage

Motor Speed

Power Loss

Output Enable

Pre-Charge

Drive Fault

680V 620V 560V

365V 305V

The inverter output is disabled and the motor coasts if the output frequency drops to zero or if the bus voltage drops below Vopen or if any of the Run Permit inputs are de-energized.

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.

Continue

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.

ATT EN TI ON : To guard against drive damage, a minimum line impedance must be provided to limit inrush current when the power line recovers. Provide an input impedance that is equal to or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive’s input VA rating.

Drive damage can occur if proper input impedance is not provided as explained below. If the value for [Power Loss Level] is greater than 18% of [DC Bus Memory], you must provide a minimum line impedance to limit inrush current when the power line recovers. Provide input impedance that is equal to or greater than the equivalent of a 5% transformer with a VA rating 5 times the drives input VA rating.

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Chapter 1 Drive Configuration

0 Volts

Dancer Pot P1072 [PID Fdbk Sel]

Master Speed Reference

Equilibrium Point

P1067 [PID Ref Sel]

10 Volts

Process PID Loop

The internal PID function provides closed loop process control with proportional and integral control action. The function is designed to be used in applications that 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 then adjusts 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 P1079 [PID Output Sel].

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.

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Drive Configuration Chapter 1

Slip Adder

Spd Ref

PID Ref

PID Fbk

Process PID

Controller

PID Disabled Speed Control

Linear Ramp

and S Curve

Spd Cmd

Slip

Comp

Open

Loop

Process

PID

Slip Adder

Spd Ref

PID Ref

PID Fbk

Process PID

Controller

PID Enabled Speed Control

Linear Ramp

and S Curve

Spd Cmd

Slip

Comp

Open

Loop

Process

PID

When the PID is disabled the commanded speed is the ramped speed reference.

When the PID is enabled the output of the PID Controller is added to the ramped speed reference.

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

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Chapter 1 Drive Configuration

Pressure

Tra ns du ce r

PID Feedback

Motor

Pump

Desired Pressure P1067 [PID Ref Sel]

Slip Adder

Spd Ref

PID Ref

PID Fbk

Process PID

Controller

PID Disabled Speed Control

Linear Ramp

and S Curve

Spd Cmd

Slip

Comp

Open

Loop

Process

PID

Slip Adder

Spd Ref

PID Ref

PID Fbk

Process PID

Controller

PID Enabled Speed Control

Linear Ramp

and S Curve

Spd Cmd

Slip

Comp

Open

Loop

Process

PID

the drive turning the pump at the required speed, the pressure is maintained in the system.

However, when additional valves in the system are opened and the pressure in the system drops, the PID error alters its output frequency to bring the process back into control. When the PID is disabled the commanded speed is the ramped speed reference.

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.

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Drive Configuration Chapter 1

Options

Reserved

Perce nt Ref

Anti Windup

Stop Mode

Fdbk Sqrt

Zero Clamp

Ramp Ref

Preload Int

Default0000000000000000

Bit 1514131211109876543210

0 = Disabled 1 = Enabled

PID Output Select

Parameter 1079 [PID Output Sel]

• “Not Used” (0) - PID output is not applied to any speed reference.

• “Speed Excl” (1) - PID output is the only reference applied to the speed

reference.

• “Speed Trim” (2) - PID output is applied to speed reference as a trim value. (Default)

• “Torque Excl” (3) - PID output is only reference applied to torque reference.

• “Torque Trim” (4) - PID output is applied to torque reference as a trim value.

• “Volt Excl” (5) - PID output is only reference applied to voltage reference.

• “Volt Trim” (6) - PID output is applied to voltage reference as a trim value.

PID Configuration

No. Display Name

File

Group

1065 PID Cfg

Process PID

APPLICATIONS

Parameter 1065[PI Cfg] 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.

Full Na me Description

PID Configuration

Main configuration of the Process PID controller.

PID Preload

This feature steps the PID Output 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 can be initialized to the PID Preload Value or the current value of the commanded speed. The operation of Preload is selected in the PID Configuration parameter. By default, Preload 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 starts from zero and regulates 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 can result in the PID reaching steady state

Values

Read-Write

Data Type

RW 16-bit

Integer

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Chapter 1 Drive Configuration

Diagram A Diagram B

PID Enabled

PID Output

Speed Command

PID Preload Value = 0 PID Preload Value > 0

PID Preload Value

PID Enabled

PID Output

Speed Command

Preload to Command Speed

Start at Speed Command

sooner, however if the step is too large the drive can go into current limit and extend the acceleration.

Preload command can 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.

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

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control). When PID Ramp Reference is selected in the PID Configuration parameter, and PID is disabled, the value used for the PID reference is the PID feedback. This causes the PID error to be zero. Then when the PID is enabled the value used for the PID reference ramps 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. Scurve is not available as part of the PID linear ramp.

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Drive Configuration Chapter 1

Normalized Feedback

Normalized SQRT (Feedback)

Zero Clamp

This feature limits the possible drive action to one direction only. Output from the drive is 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 always has 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 limits 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 limits 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, because 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.

100.0

75.0

50.0

25.0

0.0

-25.0

-50.0

-75.0

-100.0

-100.0 -75.0 -50.0 -25.0 0.0 25.0 50.0 75.0 100.0

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Chapter 1 Drive Configuration

Stop Mode

When P370/371 [Stop Mode A/B] is set to 1 “Ramp” and a Stop command is issued to the drive, the PID loop continues to operate during the decel ramp until the PID output becomes more than the master reference. When set to 0 “Coast,” the drive disables PID and performs a normal stop. This bit is active in Trim mode only.

Anti-Wind Up

When P1065 [PID Cfg] Bit 5 “Anti Windup” is set to 1 “Enabled” the PID loop automatically prevents the integrator from creating an excessive error that could cause loop instability. The integrator is automatically controlled without the need for PID Reset or PID Hold inputs.

Percent 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

Percent Ref selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum Frequency = 130 Hz. 4.3 Hz is added to the final speed reference.

Percent Ref not selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum Frequency = 130 Hz. 13.0 Hz is added to the final speed reference.

PID Control

P1066 [PID 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.

PID 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.

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Drive Configuration Chapter 1

Running Running

DigInCfg

.PI_Enable

DigInCfg

.PI_Enable

DigIn

.PI_Enable

PI_Control

.PI_Enable

PI_Status

.Enable

Signal Loss

DigInCfg

.PI_Enable

PI_Control .PI_Enable

DigInCfg

.PI_Hold

PI_Status .PI_Hold

DigIn

.PI_Hold

DigInCfg .PI_Hold

PI_Control

.PI_Hold

Current Lmt or Volt Lmt

The drive must be in Run before the PID Enabled status can turn on. The PID remains 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 P1065 [PID Cfg] is enabled.

When a digital input is configured as “PI Enable,” the PID Enable bit of P1066 [PID 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 [PID Control] is turned On, then the PID loop can become enabled. If the PID Enable bit of [PID Control] is left continuously, then the PID can become enabled as soon as the drive goes into Run. If analog input signal loss is detected, the PID loop is disabled.

PID 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 maintains 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 turns on.

• If a digital input is configured to provide PID Hold and that digital input is turned on then the PID integrator stops 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 the PID integrator stops changing.

• If the current limit or voltage limit is active then the PID is put into Hold.

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Chapter 1 Drive Configuration

PI Reset

This feature holds the output of the integral function at zero. The term “anti windup” is often applied to similar features. It can 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 increases 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 is commanded. When the drive reaches programmed Maximum Frequency, it is possible that a significant amount of integral value has been “built up” (windup). This can cause undesirable and sudden operation if the system were switched to manual operation and back. Resetting the integrator eliminates this windup.

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 is 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 needs to cause an increase in output. The option to invert the sign of PID Error is selected in the PID Configuration parameter.

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No. Display Name

Options

Reserved

PID In Limit

PID Reset

PID Hold

PID Enabled

Default0000000000000000

Bit 1514131211109876543210

0 = Condition False 1 = Condition True

File

Group

1089 PID Status

Process PID

APPLICATIONS

PID Status

P1089 [PID Status] parameter is a set of bits that indicate the status of the process PID controller.

Full Na me Description

PID Status

Status of the Process PI regulator.

Bit 0 “PID Enable” – PID controller is enabled. Bit 1 “PID Hold” – Hold PID integrator. Bit 2 “PID Reset” – Reset PID integrator. Bit 3 “PID In Limit” – PID in limit.

Values

Drive Configuration Chapter 1

Read-Write

Data Type

RO 16-bit

Integer

PID Reference and Feedback

The selection of the source for the reference signal is entered in P1067 [PID Ref Sel]. The selection of the source for the feedback signal is selected in P1072 [PID Fdbk Sel]. 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 P1090 [PID Ref Meter] as a read only parameter. The value used for feedback is displayed in P1091 [PID Fdbk Meter] 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 analog PID reference can be limited by using P1068 [PID Ref AnlgHi] and P1069 [PID Ref AnlgLo]. [PID Ref AnlgHi] determines the high value, in percent, for the analog PID reference. [PID Ref AnlgLo] determines the low value, in percent, for the PID reference.

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The analog PID feedback can be limited by using P1068 [PID Ref AnlgHi] and P1069 [PID Ref AnlgLo]. [PID Ref AnlgHi] determines the high value, in percent, for the PID feedback. [PID Ref AnlgLo] determines the low value, in percent, for the PID feedback.

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Chapter 1 Drive Configuration

Example

Display P1090 [PID Ref Meter] and P1091 [PID Fdbk Meter] as positive and negative values. Feedback from our dancer comes into Analog Input 2 as a 0-10V DC signal.

• P1067 [PID Ref Sel] = 0 “PI Setpoint”

• P1070 [PID Setpoint] = 50%

• P1072 [PID Fdbk Sel] = 2 “Analog In 2"

• P1068 [PID Ref AnlgHi] = 100%

• P1069 [PID Ref AnlgLo] = –100%

• P1073 [PID Fdbk AnlgHi] = 100%

• P1074 [PID Fdbk AnlgLo] = 0%

• P61 [Anlg In1 Hi] = 10V

• P62 [Anlg In2 Lo] = 0V

PI Feedback Scaling

• P675 [Trq Ref A Sel] = “Analog In 1”

• P61 [Anlg In1 Hi] = 10V

• P62 [Anlg In2 Lo] = 0V

• P1073 [PID Fdbk AnlgHi] = 100%

• P1074 [PID Fdbk AnlgLo] = 0%

Now 5V corresponds to 50% on the PID Feedback, and we try to maintain a PID setpoint of 50% (5V).

PID Setpoint

This parameter can be used as an internal value for the setpoint or reference for the process. If P1067 [PID Ref Sel] points to this parameter, the value entered here becomes 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 P1084 [PID LP Filter BW] 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.

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Drive Configuration Chapter 1

PID Gains

Parameters P1086 [PID Prop Gain], P1087 [PID Int Time], and P1088 [PID Deriv Time] 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 is cut in half. With only proportional control there is always an error, so the feedback and the reference are never equal. [PID Prop Gain] is unit less and defaults to 1.00 for unit gain. With [PID Prop Gain] set to 1.00 and PID Error at 1.00% the PID output is 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 continues 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). [PID Int Time] is entered in seconds. If [PID Int Time] is set to 2.0 seconds and PI Error is 100.00% the PI output integrates 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, P1084 [PID LP Filter BW] is useful in filtering out unwanted signal response in the PID loop. The filter is a Radians/Second low pass filter.

PID Lower and Upper Limits/Output Scaling

The output value produced by the PID is displayed as ±100% in P1093 [PID Output Meter].

P1082 [PID Lower Limit] and P1081 [PID Upper Limit] are set as a percentage. In exclusive or speed trim mode, they scale the PID Output to a percentage of P37 [Maximum Freq]. In torque trim mode, they scale the PID Output as a percentage of rated motor torque.

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Chapter 1 Drive Configuration

Stopped

0.00 Hz

AUTO

Host Drive 240V 4.2A 20G...D014

ESC REF TEXT

PAR#

Example

Set the PID lower and Upper limits to ±10% with Maximum Frequency set to 100 Hz. This lets the PID loop adjust the output of the drive ±10 Hz.

P1081 [PID Upper Limit] must always be greater than P1082 [PID 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 Mult

P1080 [PID Output Mult] enables 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.

Reset Parameters to Factory Defaults

PID Deadband

P1083 [PID Deadband] conditions the PID reference. If the PID reference has undesired rapid changes, the deadband can help smooth out these transitions.

1. Access the Status Screen on the 20-HIM-A6 or 20-HIM-CS6 Human Interface Module.

2. Use the left-right arrow keys to scroll to the port of the device whose parameters you want to set to factory defaults (for example, Port 00 for the Host Drive or the respective port number for the drive’s connected peripherals).

3. Press the Folder key next to the green Start key to display its last-viewed folder.

4. Use the left-right arrow keys to scroll to the Memory folder.

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5. Use the up-down arrow keys to select Set Defaults.

ESC

MEMORY

HIM CopyCat

Set Defaults

Stopped

0.00 Hz

AUTO

Stopped

0.00 Hz

AUTO

ESC

Port 00 Set Defaults

Host and Ports (Preferred)

This Port Only

INFO

Stopped

0.00 Hz

AUTO

ESC

Port xx Set Defaults

This Port Only

INFO

For Host Drive

For Connecte d Peripheral

Stopped

0.00 Hz

AUTO

WARNING

Sets most parameters in the Host device and all ports to factory defaults. Continue?

ESC

ENTER

Stopped

0.00 Hz

AUTO

MOSTALL

WARNING

Use MOST to reset typical ▲ settings on this port (preferred). Use ALL to reset all settings. ▼

ESC

Drive Configuration Chapter 1

6. Press the Enter (5) key to display the Set Defaults screen.

7. Use the up-down arrow keys select the appropriate action.

• Host and Ports (Preferred): Selects the Host device and all ports for a

factory default action.

• This Port Only: Selects only this port for a factory default action. (For a description of a selected menu item, press the INFO soft key)

8. Press the Enter (5) key to display the warning pop-up box to reset defaults.

Host and Ports (preferred) Pop-up Box

This Port Only Pop-up Box

Press the ENTER soft key to affirm and set most parameters for the Host Drive and port devices to factory defaults. In this case, refer to the Host Drive and port device user manuals for the settings that will NOT be restored—or press the ESC soft key to cancel.

Press the MOST soft key to set MOST settings for the selected port device to factory defaults. In this case, refer to the Host Drive User Manual for the settings that will NOT be restored. Press the ALL soft key to set ALL settings for the selected port device to factory defaults—or press the ESC soft key to cancel.

A pop-up Fault warning display follows the parameter changes. This can be reset by pressing the clear soft key. And the following confirm pop-up box can be cleared by pressing the enter soft key. Pressing the escape key twice returns the display to the Status screen.

Refer to the PowerFlex 20-HIM-A6/-C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001 HIM and the resetting of parameters.

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 89

, for further information on using the

Page 90

Chapter 1 Drive Configuration

Drive

Run

Sleep/Wake

Functio n

Start

Stop

Sleep Timer

Satisfied

Sleep Level

Satisfied

Wake Timer

Satisfied

Wake Level

Satisfied

Wake Level

Sleep Level

Analog Signal

Example Conditions Wake T ime = 3 Secon ds Sleep Time = 3 Seconds

Wake

Time

Sleep

Time

Wake Time

Sleep Time

Sleep/Wake Mode

The purpose of the sleep/wake function is to Start (wake) the drive when an

SleepWake RefSel signal is greater than or equal to the value in P354 [Wake

Level], and Stop (sleep) the drive when an analog signal is less than or equal to the

value in P352 [Sleep Level]. Setting P350 [Sleep Wake Mode] to 1 “Direct”

enables the sleep/wake function to work as described.

An Invert mode also exists that changes the logic so that an analog value less than

or equal to P354 [Wake Level] starts the drive and an SleepWake RefSel signal

greater than or equal to P352 [Sleep Level] stops the drive.

Related Sleep/Wake parameters noted below.

Parameter No. Parameter Name Description

350 Sleep Wake Mode Enables/disables the Sleep/Wake function.

351 SleepWake RefSel Selects the source of the input controlling the sleep/wake function.

352 Sleep Level Defines the SleepWake RefSel signal level that stops the drive.

353 Sleep Time Defines the amount of time at or below 352 [Sleep Level] before a Stop is

issued.

354 Wake Level Defines the SleepWake RefSel signal level that starts the drive.

355 Wake Time Defines the amount of time at or above 354 [Wake Level] before a Start is

issued.

Sleep/Wake Operation

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Drive Configuration Chapter 1

Requirements

In addition to enabling the sleep function with P350 [Sleep Wake Mode], the

following conditions must be met:

• A proper value must be programmed for P352 [Sleep Level] and P354 [Wake Level].

• A sleep/wake reference must be selected in P351 [SleepWake RefSel].

• At least one of the following must be programme d (and input closed ) in

P155 [DI Enable], P158 [DI Stop], P163 [DI Run], P164 [DI Run Forward], or P165 [DI Run Reverse].

Conditions to Start/Restart

ATT EN TI ON : 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 Ta bl e 9 national and international codes, standards, regulations or industry guidelines.

below and applicable local,

Table 9 - Conditions Required to Start Drive

Input After Powerup After a Drive Fault After a Stop Command

(4)

Stop

Enable Enable Closed

Run Run Forward Run Reverse

(1) When power is cycled, if all conditions are present after power is restored, restart occurs. (2) If all conditions are present when [Sleep-Wake Mode] is “enabled,” the drive star ts. (3) The active speed reference. The Sleep/Wake function and the speed reference can be assigned to the same input. (4) Cannot use P159 [DI Cur Lmt Stop] or P160 [DI Coast Stop] as the only Stop Input. This causes the drive to go into a Sleep Cfg Alarm - Event No. 161. (5) Command must be issued from HIM, TB or network. (6) Run Command must be cycled. (7) SleepWake Ref Sel signal does not need to be greater than the wake level. (8) SleepWake Ref Sel signal does not need to be less than the wake level.

Stop Closed Wake Sig nal New Start or Run Command

Wake Sig nal

Run Closed Wake Sig nal

(1) (2) (3)

Reset by HIM or Software “Stop” Reset by HIM, Network/Software, or

Stop Closed Wake Sign al

(5)

New Start or Run Command

Enable Closed Wake Sign al New Start or Run Command

New Run Command Wake Sign al

(5)

(6)

Digital Input “Clear Faults”

Stop Closed Wake Sign al

Enable Closed Wake Sign al

Run Closed Wake Sign al

HIM, Network/Software or Digital Input “Stop”

Stop Closed Direct mode SleepWake RefSel Signal > Sleep Level Invert mode: SleepWake RefSel Signal < Sleep Level New Start or Run Command

Enable Closed Direct mode SleepWake RefSel Signal > Sleep Level Invert mode: SleepWake RefSel Signal < Sleep Level New Start or Run Command

New Run Command Direct mode: SleepWake RefSel Signal > Sleep Level Invert mode: SleepWake RefSel Signal < Sleep Level

(7)

(8)

(5)

(7)

(8)

(5)

(7)

(8)

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Page 92

Chapter 1 Drive Configuration

For Invert function, refer to the [Anlg Inn LssActn] parameter.

Normal operation requires that P354 [Wake Level] be set greater than P352 [Sleep Level]. However, there are no limits that prevent the parameter settings from crossing, but the drive will not start until such settings are corrected. These levels are programmable while the drive is running. If P352 [Sleep Level] is made greater than P354 [Wake Level] while the drive is running, the drive continues to run as long as the P351 [SleepWake RefSel] signal remains at a level that doesn’t trigger the sleep condition. P353 [Sleep Time] is also factored into this as well. Once the drive goes to sleep in this situation, it is not allowed to restart until the level settings are corrected (increase P354 [Wake Level], or decrease P352 [Sleep Level]). If however, the levels are corrected prior to the drive going to sleep, normal Sleep/Wake operation continues.

Timers

P353 [Sleep Time] P355 [Wake Time]

Timers determine the length of time required for Sleep/Wake levels to produce true functions. These timers start counting when the Sleep/Wake levels are met and count in the opposite direction whenever respective level is not met. If the timer counts all the way to the user specified time, it creates an edge to toggle the Sleep/Wake function to the respective condition (sleep or wake). On powerup, timers are initialized to the state that does not permit a start condition. When the analog signal satisfies the level requirement, the timers start counting.

Interactive Functions

Separate start commands are also honored (including a digital input start), but only when the sleep timer is not satisfied. Once the sleep timer times out, the sleep function acts as a continuous stop. There are two exceptions that ignore the Sleep/Wake function.

1. When a device is commanding local control, that is HIM in Manual mode or a digital input programmed to P172 [DI Manual Ctrl].

2. When a jog command is being issued.

When a device is commanding local control, the port that is commanding it has exclusive start control (in addition to ref select), essentially overriding the Sleep/ Wake function, and allowing the drive to run in the presence of a sleep situation. This holds true even for the case if digital input is programmed to P172 [DI Manual Ctrl], a digital input start or run is able to override a sleep situation.

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Drive Configuration Chapter 1

Sleep/Wake Sources

The P351 [SleepWake RefSel] signal source for the sleep/wake function can be any analog input, whether it is being used for another function or not, a DeviceLogix software source (P90 [DLX Real OutSP1] thru P97 [DLX Real OutSP8]), or a valid numeric edit configuration. Configuring the sleep/wake source is done through P351 [SleepWake RefSel].

Also, [Anlg Inn Hi] and [Anlg Inn Lo] parameters have no effect on the function, however, the factory calibrated result, [Anlg Inn Value] parameter, is used. In addition, the absolute value of the calibrated result is used, thus making the function useful for bipolar direction applications.

The analog in loss function, configured by the [Anlg Inn LssActn] parameter, is unaffected and therefore operational with the sleep/wake function, but not tied to the sleep or wake levels and is triggered off the [Anlg Inn Raw Value] parameter.

Refer to the PowerFlex 750-Series Programming Manual, publication 750-

PM001, for more details.

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Chapter 1 Drive Configuration

Start Permissives

Start permissives are conditions required to permit the drive to start in any mode, such as run, jog, or auto-tune. When all permissive conditions are met, the drive is considered ready to start. The ready condition is confirmed through the ready status in P935 [Drive Status 1].

Permissive Conditions

• No faults can be active.

• No Type 2 alarms can be active.

• The DI Enable input, if configured, must be closed.

• The DC bus precharge logic must indicate it is a start permissive.

• All Stop inputs must be negated nor any drive functions are issuing a stop.

• No configuration changes (parameters being modified) can be in-progress.

• The drive’s safety option module logic must be satisfied.

If a CIP Motion connection is active and if alignment is set to “Not Aligned” then the “CommutNotCfg” bit is high (on). To clear this start inhibit, from the Axis Properties within the Logix Designer application, run a Commutation Test, enter the proper value into the Offset and then set the Alignment to “Controller Offset.”

94 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 95

No. Display Name

Options

Reserved

CommutNotCfg

Profiler

(1)

(1) PowerFlex 755 drives only.

Sleep

Safety

Startup

Database

Stop

Precharge

Enable

Alarm

Faul ted

Default00000000000000000000000000000000

Bit 313029282726252423222120191817161514131211109876543210

0 = False, 1 = True

Options

Reserved

CommutNotCfg

Profilier

Sleep

Safety

Startup

Database

Stop

Precharge

Enable

Alarm

Fau lted

Default00000000000000000000000000000000

Bit 313029282726252423222120191817161514131211109876543210

0 = False, 1 = True

File

Group

933 Start Inhibits

Status

DIAGNOSTICS

934 Last StrtInhibit

Drive Configuration Chapter 1

If all permissive conditions are met, a valid start, run or jog command starts the drive. The status of all current inhibit conditions are reflected in P933 [Start Inhibits] and the last inhibit conditions are reflected in P934 [Last StrtInhibit] details are shown below.

Values

Full Na me Description

Start Inhibits

Indicates which condition is preventing the drive from starting or running.

Bit 0 “Faulted” – Drive is in a faulted state. See P951 [Last Fault Code]. Bit 1 “Alarm” – A Type 2 alarm exists. See P961 [Type 2 Alarms]. Bit 2 “Enable” – An Enable input is open. Bit 3 “Precharge” – Drive is in precharge. See P321 [Prchrg Control], P11 [DC Bus Volts]. Bit 4 “Stop” – Drive is receiving a stop signal. See P919 [Stop Owner]. Bit 5 “Database” – Database is performing a download operation. Bit 6 “Startup” – Startup is active and preventing a start. Go to Start-Up Routine and abort. Bit 7 “Safety” – Safety option module is preventing a start. Bit 8 “Sleep” – Sleep function is issuing a stop. See P 350 [Sleep Wake Mode], P351 [SleepWake RefSel]. Bit 9 “Profiler” – Profiler function is issuing a stop. See P1210 [Profile Status]. Bit 10 “CommutNotCfg” – The associated PM motor commutation function has not been configured for use.

Last Start Inhibit

Displays the Inhibit that prevented the last Start signal from starting the drive. Bits are cleared after the next successful start sequence. See parameter 933

[Start Inhibits] for bit descriptions.

Read-Write

Data Type

RO 32-bit

Integer

RO 32-bit

Integer

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 95

Page 96

Chapter 1 Drive Configuration

Stop Modes

Stop Mode A/B can be configured as a method of stopping the drive when a stop command is given. A normal stop command and the run input changing from true to false results in a normal stop command. However, when using TorqueProve, P1100 [Trq Prove Cfg] with Bit 0 enabled, [Stop Mode A/B] must be set to 1 “Ramp.”

P392 [Stop Dwell Time] can also be used with a stop command. This can be used to set an adjustable time between detecting zero speed and turning off the drive output.

The PowerFlex 750 series offers several methods for stopping a load. The stop method or mode is defined by parameters 370/371 [Stop Mode A/B] These modes include the following:

• Coast

• Ramp

• Ramp to Hold

• DC Brake

• DC Brake Auto Off

• Current Limit

• Fast Brake

Additionally, P388 [Flux Braking In] can be selected separately (not part of the Stop mode selection) to provide additional braking during a Stop command or when reducing the speed command. For Stop commands, this provides additiona l braking power during “Ramp” or “Ramp to Hold” selections only. If “Fast Brake” or “DC Brake” is used, “Flux Braking” is active only during speed changes (if enabled).

A “Ramp” selection always provides the fastest stopping time if a method to dissipate the required energy from the DC bus is provided (that is Dynamic Braking resistor, regenerative brake, and so forth.). The PowerFlex Dynamic Braking Selection Guide presented in Appendix A of the Reference Manual, explains Dynamic Braking in detail.

The alternative braking methods to external hardware brake requirements, can be enabled if the stopping time is not as restrictive. Each of these methods dissipates energy in the motor (use care to avoid motor overheating).

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Page 97

Drive Configuration Chapter 1

Bus Voltage

Output Voltage

Output Current

Motor Speed

Command Speed

Time

Coast Time is load dependent

Stop Command

Braking Methods

Method Use when application Requires Braking Power

Coast Power is removed from the motor and it coasts to zero speed None

Ramp The fastest stopping time or fastest ramp time for speed changes (external

brake resistor or regenerative capability required for ramp times faster than the methods below). High duty cycles, frequent stops or speed changes. (The other methods can result in excessive motor heating).

Ramp to Hold Same as ramp above only when zero speed is reach the drive outputs a DC

brake current to be sure the motor shaft doesn't move after it has stopped. This continues until the drive is started again.

DC Brake DC braking is immediately applied (does not follow programmed decel ramp).

May have to adjust P397 [DC Brake Kp].

DCBrkAutoOff Applies DC braking until zero speed is reached or DC brake time is reached,

whichever is shorter.

Current Lmt Max torque / current applied until zero speed Big Stuff

Fast Brake High slip braking for maximum braking performance above base speed. More than DC

The most

Same as “Ramp”

Less than Ramp or Fast Brake

Brake / DC Brake Auto Off

Coast

Coast is selected by setting P370/371 [Stop Mode A/B] to 0 “Coast.” When in Coast to Stop, the drive acknowledges the Stop command by shutting off the output and releasing control of the motor. The load/motor will coast or free spin until the kinetic energy is dissipated.

• On Stop, the drive output goes immediately to zero (off ).

• No further power is supplied to the motor. The drive has released control.

• The motor coasts for a time that is dependent on the mechanics of the

system (Inertia, friction, and so forth).

Rockwell Automation Publication 750-RM002B-EN-P - September 2013 97

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Chapter 1 Drive Configuration

Bus Voltage

Output Voltage

Output Current

Motor Speed

Command Speed

Time

DC Hold Time

Stop Command

(B) (C) (A)

DC Brake

This method uses DC injection of the motor to Stop and/or hold the load. DC Brake is selected by setting P370/371 [Stop Mode A/B] to 3 “DC Brake.” You can also choose the amount of time the braking is applied and the magnitude of the current used for braking with P395 [DC Brake Time] and P394 [DC Brake Level]. This mode of braking generates up to 40% of rated motor torque for braking and is typically used for low inertia loads with infrequent Stop cycles:

• On Stop, 3 phase drive output goes to zero (off ).

• Drive outputs DC voltage on the last used phase to provide the current

level programmed in P394 [DC Brake Level]. This voltage causes a stopping brake torque. If the voltage is applied for a time that is longer than the actual possible stopping time, the remaining time is used to attempt to hold the motor at zero speed (decel profile “B” on the diagram above).

• DC voltage to the motor continues for the amount of time programmed in P395 [DC BrakeTime]. Braking ceases after this time expires.

• After the DC Braking ceases, no further power is supplied to the motor. The motor/load may or may not be stopped. The drive has released control of the motor/load (decel profile “A” on the diagram above).

• The motor, if rotating, coasts from its present speed for a time that is dependent on the remaining kinetic energy and the mechanics of the system (inertia, friction, and so forth).

• Excess motor current and/or applied duration, could cause motor damage. Motor voltage can exist long after the Stop command is issued. The right combination of Brake Level and Brake Time must be determined to provide the safest, most efficient stop (decel profile “C” on the diagram above).

98 Rockwell Automation Publication 750-RM002B-EN-P - September 2013

Page 99

Ramp

Bus Voltage

Output Voltage

Output Current

Motor Speed

Command Speed

Time

DC Hold Time

Stop Command Zero Command Speed

Output Voltage

Output Current

DC Hold Level

This method uses drive output reduction to stop the load.

Drive Configuration Chapter 1

Ramp To Stop is selected by setting parameters 370/371[Stop Mode A/B] to 1 “Ramp.” The drive ramps the frequency to zero based on the deceleration time programmed into parameters 537/538 [Decel Time 1/2]. The normal mode of machine operation can utilize [Decel Time 1]. If the machine Stop requires a faster deceleration than desired for normal deceleration, [Decel Time 2] can be activated with a faster rate selected. When in Ramp mode, the drive acknowledges the Stop command by decreasing or ramping the output voltage and frequency to zero in a programmed period (Decel Time), maintaining control of the motor until the drive output reaches zero. The drive output is then shut off. The load/motor follows the decel ramp. Other factors such as bus regulation and current limit can alter the actual decel rate.

Ramp mode can also include a timed hold brake. Once the drive has reached zero output hertz on a Ramp-to-Stop and both parameters 395 [DC Brake Time] and P394 [DC Brake Level] are not zero, the drive applies DC to the motor producing current at the DC Brake Level for the DC Brake Time:

• On Stop, drive output decreases according to the programmed pattern from its present value to zero. The pattern can be linear or squared. The output decreases to zero at the rate determined by the programmed P520 [Max Fwd Speed] or P521 [Max Rev Speed] and the programmed active (Decel Time n).

• The reduction in output can be limited by other drive factors such as bus or current regulation.

• When the output reaches zero the output is shut off.

• The motor, if rotating, coasts from its present speed for a time that is

dependent on the mechanics of the system (inertia, friction, and so forth).

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Chapter 1 Drive Configuration

Bus Voltage

Output Voltage

Output Current

Motor Speed

Command Spe ed

Time

DC Hold for

indeterminate

amount of time.

Stop Command Zero Command Speed

Output Voltage

Output Current

DC Hold Level

Bus Voltage

Output Voltage

Output Current

Motor Speed

Command Speed

Start Command

Ramp to Hold

This method combines two of the methods above. It uses drive output reduction to stop the Load and DC injection to hold the load at zero speed once it has stopped:

• On Stop, drive output decreases according to the programmed pattern from its present value to zero. The pattern can be linear or squared. The output decreases to zero at the rate determined by the programmed P37 [Maximum Freq] and the programmed active P537/538 [Decel Time 1/2]

• The reduction in output can be limited by other drive factors such as bus or current regulation.

• When the output reaches zero 3 phase drive output goes to zero (off ) and the drive outputs DC voltage on the last used phase to provide the current level programmed in P394 [DC Brake Level]. This voltage causes a holding brake torque.

• DC voltage to the motor continues until a Start command is reissued or the drive is disabled.

• If a Start command is reissued, DC Braking ceases and the drive returns to normal AC operation. If an Enable command is removed, the drive enters a Not Ready state until the enable is restored.

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Rockwell Automation 20G-750 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Summary of Changes

New and Updated Information

Table of Contents

Overview

Preface

Who Should Use This Manual

What Is Not in This Manual

Additional Resources

Allen-Bradley Drives Technical Support

Product Certification

Manual Conventions

General Precautions

Qualified Personnel

Personal Safety

Product Safety

Class 1 LED Product

Studio 5000 Environment

Drive Configuration

Accel/Decel Time

Acceleration Time

Deceleration Time

Adjustable Voltage

Overview

Adjustable Voltage Control Setup

Additional Parameter Changes

Application Considerations

Auto Restart

Configuration

Operation

Beginning an Auto-Reset/Run Cycle

Aborting an Auto-Reset/Run Cycle

Auto/Manual

Auto/Manual Masks

Alternate Manual Reference Select

HIM Control

Digital Input Control

Hand-Off-Auto

Safe Limited Speed

Automatic Device Configuration

Autotune

Tes ts

Test Dependencies

Individual Tests

Autotune Parameters

Permanent Magnet Motors

Interior Permanent Magnet Motors

Auxiliary Power Supply

Bus Regulation

Operation

Bus Regulation Modes

Internal Resistor

External Resistor

Flux Vector (FV) Control

Sensorless Vector (SV) Control

Level/Gains

Configurable Human Interface Module Removal

Droop Feature

Duty Rating

Feedback Devices

Flying Start

Configuration

Scope Plots

Hand-Off-Auto

Hand-Off-Auto Start

Using Hand-Off-Auto with Auto/Manual

Using Hand-Off-Auto with a Start Relay

Masks

Owners

Parameters and Functions

Ownership Example

Power Loss

Terms and Definitions

Restart after Power Recovery

Power Loss Modes

Coast