Allen-Bradley PowerFlex 70 Enhanced Control Reference Manual
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Allen-Bradley PowerFlex 70 Enhanced Control Reference Manual

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Summary of Contents for Allen-Bradley PowerFlex 70 Enhanced Control

  • Page 1 70 Enhanced Control 700 Vector Control Reference Manual www.abpowerflex.com...
  • Page 2 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices.

  • Page 3: Table Of Contents

    Table of Contents Overview Preface Manual Conventions ............. . .1 Reference Materials .
  • Page 4 Table of Contents Speed Reference ..............98 Speed Regulation .

  • Page 5: Preface

    The following symbols will be used throughout to identify specific drive information. Symbol Information pertains to … PowerFlex 70 Enhanced Control (EC) drive ✔ PowerFlex 700 Vector Control (VC) drive ✔ Reference Materials...

  • Page 6: General Precautions

    • Wiring AC line to drive output or control terminals. • Improper bypass or output circuits not approved by Allen-Bradley. • Output circuits which do not connect directly to the motor. • Contact Allen-Bradley for assistance with application or wiring.

  • Page 7: Detailed Drive Operation

    Reference Information Detailed Drive Operation This chapter explains PowerFlex drive functions in detail. Explanations are organized alphabetically by topic. Refer to the Table of Contents for a listing of topics. Accel/Decel Time [Accel Time 1, 2] [Decel Time 1, 2] ✔...

  • Page 8: Analog Inputs

    Analog Inputs Configuration Type 2 Alarms are always enabled (not configurable). Type 1 Alarms will always be displayed in [Drive Alarm 1], but can be configured to either mask or allow specific alarms from a) turning on the “Alarm” bit within the [Drive Status 1] parameter and b) turning on a digital output when [Digital Outx Sel] is set to “Alarm.”...
  • Page 9 Analog Inputs Example 1 − [Anlg In Config], bit 0 = “0” (Voltage) − [Speed Ref A Sel] = “Analog In 1” − [Speed Ref A Hi] = 60 Hz − [Speed Ref A Lo] = 0 Hz − [Analog In 1 Hi] = 10V −...
  • Page 10 Analog Inputs Example 3 − [Anlg In Config], bit 0 = “0” (Voltage) − [Speed Ref A Sel] = “Analog In 1” − [Speed Ref A Hi] = 30 Hz − [Speed Ref A Lo] = 0 Hz − [Analog In 1 Hi] = 10V −...
  • Page 11 Analog Inputs Example 6 − [Anlg In Config], bit 0 = “0” (Voltage) − [Speed Ref A Sel] = “Analog In 1” − [Speed Ref A Hi] = 60 Hz − [Speed Ref A Lo] = 0 Hz − [Analog In 1 Hi] = 5V −...
  • Page 12 Analog Inputs Square Root The square root function can be applied to each analog input through the use of [Analog In Sq Root]. The function should be enabled if the input signal varies with the square of the quantity (e.g. drive speed) being controlled. If the mode of the input is bipolar voltage (–10v to 10v), then the square root function will return 0 for all negative voltages.
  • Page 13 Analog Inputs Operation with Analog Selected as Operation with Analog Selected as [Analog In x Loss] Normal Operation Process PID Fdbk Exclusive Mode Process PID Fdbk Trim Mode 0, “Disabled” (default) Disabled Disabled Disabled 1, “Fault” Faults Faults Faults 2, “Hold Input” Holds speed at last valid analog Disables PID and follows selected Disables PID and follows selected...

  • Page 14: Analog Outputs

    Analog Outputs Analog Outputs Each drive has one or more analog outputs that can be used to annunciate a wide variety of drive operating conditions and values. The user selects the analog output ✔ ✔ source by setting [Analog Out Sel]. Configuration The analog outputs have 10 bits of resolution yielding 1024 steps.
  • Page 15 Analog Outputs Example 2: Unsigned Output Quantity, Negative Slope − [Analog Out1 Sel] = “Output Current” − [Analog Out1 Lo] = 9 volts − [Analog Out1 Hi] = 1 volts [Analog Out1 Lo] Analog Output Voltage [Analog Out1 Hi] 200% Output Current This example shows that [Analog Out1 Lo] can be greater than [Analog Out1 Hi].
  • Page 16 Analog Outputs Filtering Software filtering is performed on quantities that can be monitored as described in the following table. The purpose of this filtering is to provide a signal and display that is less sensitive to noise and ripple. Software Filters Quantity Filter Output Frequency...

  • Page 17: Auto/Manual

    Auto/Manual Auto/Manual The purpose of the Auto/Manual function is to permit temporary override of speed control, or both speed control and start (run)/stop control. Each connected HIM or the control terminal block is capable of performing this function. However, only ✔...
  • Page 18 Auto/Manual General Rules The following rules apply to the granting and releasing of Manual control: 1. Manual control is requested through a one-time request (Auto/Man toggle, not continuously asserted). Once granted, the terminal holds Manual control until the Auto/Man button is pressed again, which releases Manual control (e.g. back to Auto mode).

  • Page 19: Auto Restart

    Auto Restart Auto Restart 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. ✔ ✔ This allows remote or “unattended” operation. Only certain faults are allowed to be reset.

  • Page 20: Autotune

    Autotune Aborting an Auto-Reset/Run Cycle During an auto reset/run cycle the following actions/conditions will abort the reset/ run attempt process. • Issuing a stop command from any source. (Note: Removal of a 2-wire run-fwd or run-rev command is considered a stop assertion). •...
  • Page 21 Autotune Autotune Procedure for Sensorless Vector and Economizer The purpose of Autotune is to identify the motor flux current and stator resistance for use in Sensorless Vector Control and Economizer modes. The user must enter motor nameplate data into the following parameters for the Autotune procedure to obtain accurate results: •...

  • Page 22: Bus Regulation

    Bus Regulation Refer to the "Autotune Procedure for Sensorless Vector and Economizer" on page 17 for a description of these tests. After the Static or Dynamic Autotune, the Inertia test should be performed. The motor shaft will rotate during the inertia test. During the inertia test the motor should be coupled to the load to find an accurate value.
  • Page 23 Bus Regulation 0V Fault @V Single Seq 500 S/s Drive Output Shut Off 100mV Ch2 100mV M 1.00s Ch3 1.47 V 500mV 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.
  • Page 24 Bus Regulation Figure 1 Bus Voltage Regulator, Current Limit and Frequency Ramp. Current Limit U Phase Motor Current Derivative Gain Magnitude W Phase Motor Current Block Calculator SW 3 Current Limit Level PI Gain Block I Limit, No Bus Reg Limit SW 1 No Limit...
  • Page 25 Bus Regulation The derivative term senses a rapid rise in the bus voltage and activates the bus regulator prior to actually reaching the bus voltage regulation set point Vreg. The derivative term is important since it minimizes overshoot in the bus voltage when bus regulation begins thereby attempting to avoid an over-voltage fault.
  • Page 26 Bus Regulation The bus voltage regulation setpoint is determined from bus memory (a means to average DC bus over a period of time). The following tables and figure describe the operation. Voltage Class DC Bus Memory DB On Setpoint DB Off Setpoint <...

  • Page 27: Copy Cat

    Copy Cat If [Bus Reg Mode x] is set to “Both-DB 1st” Both regulators are enabled, and the operating point of the Dynamic Brake Regulator is lower than that of the Bus Voltage Regulator. The Bus Voltage Regulator setpoint follows the “DB Turn On” curve. The Dynamic Brake Regulator follows the “DB Turn On”...

  • Page 28: Current Limit

    Current Limit Current Limit There are 5 ways that the drive can protect itself from overcurrent or overload situations: ✔ ✔ • Hardware Overcurrent - This is a feature that instantly faults the drive if the output current exceeds this value. The value is fixed by hardware and is typically 250% of drive rated amps.
  • Page 29 Datalinks Programmable Remote I/O Adjustable Frequency Controller Communication AC Drive I/O Image Table Module Output Image Block Transfer Logic Command Parameter/Number Analog Reference Datalink A WORD 3 Data In A1 WORD 4 Data In A2 WORD 5 Datalink A WORD 6 Data Out A1 WORD 7 Data Out A2...

  • Page 30: Dc Bus Voltage / Memory

    DC Bus Voltage / Memory Datalink Most/Least Significant Word Parameter Data (decimal) -Not Used- Even if non-consecutive Datalinks are used (in the next example, Datalinks A1 and B2 would not be used), data is still returned in the same way. Datalink Most/Least Significant Word Parameter Data (decimal)
  • Page 31 Digital Inputs • Run Forward, Run Reverse These settings cause the drive to run and with a specific direction, as long as the configured input is held closed. Also, these “2-wire” settings prevent any other connected device from starting the drive. To use a “2-wire” digital input setting that is compatible with start commands from a communication adapter, see "Run w/Comm"...
  • Page 32 Digital Inputs Example 2 A drive is faulted and the “Run Level” input is held closed the entire time. Next, the network issues a “Stop/Clear Faults” command, or another digital input programmed for “Stop/Clear Faults” is activated, or the “Stop button is pressed on the HIM. The drive will not restart until the “Run Level” input is opened and then re-closed, because the fault clearing method used was combined with a stop command.
  • Page 33 Digital Inputs The drive will not jog while the drive is running or while the “Stop-Clear Faults” input is open. Start has precedence ATTENTION: If a normal drive start command is received while the drive is jogging, the drive will switch from jog mode to run mode. The drive will not stop, but may change speed and/or change direction.
  • Page 34 Digital Inputs • MOP Increment, MOP Decrement These functions are used to increment and decrement the Motor Operated Potentiometer (MOP) value inside the drive. The MOP is a reference value that can be incremented and decremented by external devices. The MOP value will be retained through a power cycle.
  • Page 35 Digital Inputs • Local Control This input function allows exclusive control of all drive logic functions from the terminal block. If it is closed, the terminal block has exclusive control (disabling all the DPI devices) of drive logic, including start, reference selection, acceleration rate selection, etc.
  • Page 36 Digital Inputs • Precharge Enable This function is used to manage disconnection from a common DC bus. If the input is closed, this indicates that the drive is connected to common DC bus and normal precharge handling can occur, and that the drive can run (start permissive).

  • Page 37: Digital Outputs

    Digital Outputs • User Set Select 1 and 2 These settings are used in the “dynamic mode” of user sets, which provides switching between entire parameter sets from digital input combinations. See "User Sets" on page 114 for a complete description of these modes and the digital input combinations that activate each mode.
  • Page 38 Digital Outputs Condition Description Economize The drive is currently reducing the output voltage to the motor to attempt to reduce energy costs during a lightly loaded situation. Motor Overld The drive output current has exceeded the programmed [Motor NP FLA] and the electronic motor overload function is accumulating towards an eventual trip.
  • Page 39 Digital Outputs Level] is degrees C. No units will be displayed on HIMs, offline tools, devices communicating over a network, PLC’s, etc. The minimum and maximum value for [Dig Outx Level] is independent of the selection for [Dig Outx Sel]. The following values can be annunciated Value Description...

  • Page 40: Direction Control

    Direction Control Controlled by the Network This configuration is used when it is desired to control the digital outputs over network communications instead of a drive related function. In this case, [Digital Out x Sel] is set to “Param Cntl,” in which case the bit value of [DigOut Setpt], parameter 379 energizes the respective digital output.

  • Page 41: Dpi

    Drive Peripheral Interface (DPI) is a CAN based, Master-Slave protocol, created to provide a standard way of connecting motor control products and optional ✔ ✔ peripheral devices together. It allows multiple (up to 6) devices to communicate with a motor control product without requiring configuration of the peripheral. DPI provides two basic message types called Client/Server (C/S) and Producer/ Consumer (P/C).
  • Page 42 Peer-to-Peer operation Peer-to-Peer messaging allows two devices to communicate directly rather than through the master or host (e.g. drive). They are the same priority as C/S messages and will occur in the background. If an LCD HIM is attached, it will be able to directly access peripheral parameters (e.g.

  • Page 43: Driveguard

    DriveGuard DriveGuard Refer to “DriveGuard Safe-Off User Manual” publication PFLEX-UM001. ✔ Drive Overload The drive overload function has two separate protection schemes, an inverse time protection based on current, and thermal manager based on measured power ✔ ✔ module temperature and operating conditions. The drive may fold back current limit when either of these methods detects a problem.
  • Page 44 Drive Overload Figure 2 Normal Duty Boundary of Operation 1.80 1.70 1.60 1.50 1.40 1.30 1.20 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 1.00 10.00 100.00 1,000.00 Time (Seconds) Heavy Duty operation follows the same algorithm as Normal Duty, but allows a larger percentage of rated current (one size smaller motor).
  • Page 45 Drive Overload Figure 4 Thermal Manager Inputs/Outputs DTO Select DTO Fault (Off,PWM,ILmt,Both) (On,Off) PWM Frequency Active PWM Frequency (2 - 12 kHz) (2 - 12 kHz) Current Limit Active Current Limit (0 - 200%) (0 - 200%) Drive Temperature Analog Input Drive Temperature Thermal (Volts)

  • Page 46: Droop

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

  • Page 47: Faults

    Faults Faults Faults are conditions occurring within and/or outside of the drive. These conditions are (by default) considered to be important enough that drive operation is ✔ ✔ discontinued. Faults are annunciated via the HIM, communications and/or digital outputs. Once a fault occurs, it is latched, requiring a fault reset action. If the condition that caused fault still exists when the fault is reset, the drive will fault again and the fault will be latched again.
  • Page 48 Faults Fault Code/Text [Fault Code x] The fault code for each entry can be read in its respective read-only parameter. When viewed with a HIM, only the fault code (not text) is displayed. If viewed via a DPI peripheral (communications network), the queue is not accessed through parameters, and a text string of up to 16 characters is also available.

  • Page 49: Flux Braking

    Flux Braking Following is a brief list of each configurable fault. Some of these faults are explained in more detail in their own section of this document. Fault Description Power Loss Undervoltage Reserved Motor Overload Shear Pin Auto Restart Tries Decel Inhibit Motor Thermistor Input Phase Loss...

  • Page 50: Flux Up

    Flux Up Flux Up AC induction motors require flux to be established before controlled torque can be developed. To build flux, voltage is applied. There are two methods to flux the ✔ ✔ motor. The first method is during a normal start. Flux is established as the output voltage and frequency are applied to the motor.

  • Page 51: Flying Start

    Flying Start Flying Start 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.

  • Page 52: High Resolution Speed Reference

    High Resolution Speed Reference High Resolution The high resolution speed reference provides a 32 bit (as opposed to a 16 bit) speed Speed Reference reference from a communication network. The high resolution 32 bit reference is scaled so that a value of 2147483647 corresponds to [Maximum Freq], parameter ✔...

  • Page 53: Language

    Language Language Seven languages are supported; English, Spanish, German, Italian, French, Portuguese and Dutch. All drive functions and information displayed on an LCD ✔ ✔ HIM are shown in the selected language. The desired language can be selected by any of the following methods. •...

  • Page 54: Mop

    The Motor Operated Pot (MOP) function uses either digital inputs or network commands to increment or decrement the speed reference at a programmed rate. ✔ ✔ The MOP has three components: • [MOP Rate] parameter • [Save MOP Ref] parameter •...

  • Page 55: Motor Control Modes

    Motor Control Modes Motor Control Modes [Motor Cntl Sel] selects the output mode of the drive. The choices are: • Custom Volts/Hertz ✔ ✔ Used in multi-motor or synchronous motor applications. • Fan/Pump Volts/Hertz Used for centrifugal fan/pump (variable torque) applications to achieve maximum energy savings.
  • Page 56 Motor Control Modes 2. Custom Custom Volts/Hertz allows a wide variety of patterns. The default configuration is a straight line from zero to rated voltage and frequency. As seen in the diagram below, the volts/hertz ratio can be changed to provide increased torque performance when required by programming 5 distinct points on the curve: –...
  • Page 57 Motor Control Modes In sensorless vector control, the drive commands a specific amount of voltage to develop flux. Maximum Voltage Base Voltage (Nameplate) Ir Voltage Base Frequency Maximum (Nameplate) Frequency Sensorless Vector w/Economizer Economizer mode consists of the sensorless vector control with an additional energy savings function.

  • Page 58: Motor Nameplate Data

    Motor Nameplate Data Figure 8 Flux Vector High Bandwidth Current Regulator CURRENT FEEDBACK Flux V mag Reg. Current Speed Voltage SPEED REF. Inverter Motor Reg. Reg. Control TORQUE REF. V ang Encoder SLIP Adaptive Controller AUTOTUNE PARAMETERS SPEED FEEDBACK Motor Nameplate These parameters provide motor information to the drive, so the drive can both Data protect the motor and also make internal adjustments to provide the best...

  • Page 59: Motor Overload

    Motor Overload Motor Overload The motor overload protection feature uses an IT (inverse time) algorithm to model the temperature of the motor and follows the same curve as a physical class 10 ✔ ✔ overload device. Motor Overload Curve 100000 10000 Cold 1000...
  • Page 60 Motor Overload 3. [Motor OL Hertz] is used to further protect motors with limited speed ranges. Since many motors do not have sufficient cooling ability at lower speeds, the overload feature can be programmed to increase protection in the lower speed areas.

  • Page 61: Notch Filter

    Notch Filter Important: If the application requires high overload current for long durations (e.g. 150% for 60 seconds), heavy duty sizing (between drive and motor) will be required. See "Normal Duty and Heavy Duty Operation" on page Notch Filter A notch filter exists in the torque reference loop to reduce mechanical resonance created by a gear train.
  • Page 62 Notch Filter Figure 11 Resonance Figure 12 represents the same mechanical gear train but with [Notch Filter Freq] set to 10. Figure 12 10 Hz Notch...

  • Page 63: Owners

    Owners Owners Owners are status parameters that show which peripheral devices (HIMs, comm ports, etc.) are commanding or have exclusive control of specific control functions. ✔ ✔ The list of devices also includes the drive’s control terminal block. Exclusive Only one device at a time can control the drive and only one owner bit will be high. The following owners are Exclusive: •...

  • Page 64: Password

    Password Password By default the password is set to 00000 (password protection disabled). ✔ ✔ Logging in to the Drive Step Key(s) Example Displays 1. Press the Up or Down Arrow to enter your password. Press Sel to move Login: Enter from digit to digit.

  • Page 65: Position Indexer/Speed Profiler

    Position Indexer/Speed Profiler Position Indexer/ Overview Speed Profiler The profile/indexer may be configured as a velocity regulator or a position ✔ regulator. If position control is desired, encoder feedback is required. Parameter 088, [Speed/Torque Mod] is used to select the “Pos/Spd Prof” mode. Sixteen steps are available with this feature.
  • Page 66 Position Indexer/Speed Profiler Profile Command Control Word The profile/indexer is controlled with [Profile Command], parameter 705. The bit definitions are as follows: Name Description Start Step 0 The binary value of these bits determines which step will be the starting step for the profile when a start command is issued.
  • Page 67 Position Indexer/Speed Profiler Position Regulated Step Parameters Each of the Position Regulated steps has the following associated parameters or functions: Step Type Encoder Absolute Encoder Incremental End Hold Position Value Position & Direction Position & Direction Velocity Speed Speed Accel Time Accel Rate Accel Rate Decel Time...
  • Page 68 Position Indexer/Speed Profiler Homing to Limit Switch with Encoder Feedback - When “Find Home” is commanded, the homing routine is run when a start command is issued. The Homing bit (11) in [Profile Status], parameter 700 will be set while the homing routine is running.
  • Page 69 Position Indexer/Speed Profiler Disable Homing Requirement – If a home position is not required, the routine can be disabled by clearing [Alarm Config 1] bit 17 “Prof SetHome” to “0.” This will disable the alarm from being set when “Pos/Spd Prof” mode is configured in [Speed/Torque Mod] and will set the present position as home.
  • Page 70 Position Indexer/Speed Profiler Time Blend - When started the drive will ramp to the desired velocity and hold speed for the programmed time at which point it will transition to the next step and ramp to the programmed velocity without going to zero speed. The example below shows a five step profile.
  • Page 71 Position Indexer/Speed Profiler Digital Inputs Digital Input #6 Digital Input #5 -150 Dwell Digital Input #4 Step 6 -250 Step 5 Step 4 Digital Input #3 Step 3 Step 2 Step 1 -350 Time Note: Step 5 is a Parameter Level Step. [Encoder Speed], 415 [Profile Status], 700 [Units Traveled], 701...
  • Page 72 Position Indexer/Speed Profiler Step X Step X Step X Step X Step X Step X Step X Step # Step X Type Velocity AccelTime DecelTime Value Dwell Batch Next EncInc Blend 100 10.00 0.00 EncInc Blend 200 10.00 0.00 EncInc Blend 300 10.00 0.00 Encoder Abs 400...
  • Page 73 Position Indexer/Speed Profiler Encoder Incremental Blend w/Velocity Override Complete Velocity Override -150 -250 Step 5 Step 4 Step 3 -350 Step 2 Step 1 -450 Time [Encoder Speed], 415 [Profile Status], 700 [Units Traveled], 701 Current Step Step X Step X Step X Step X Step X...
  • Page 74 Position Indexer/Speed Profiler Parameter Level Step 3 Dwell Level, 745 Step 2 Dwell Level, 735 -150 Step 1 Dwell Level, 725 -250 Step 5 Step 4 -350 Step 2 Step 1 Step 3 -450 Time [Encoder Speed], 415 [Profile Status], 700 [Units Traveled], 701 Current Step Step X...
  • Page 75 Position Indexer/Speed Profiler Encoder Incremental w/Dwell Complete At Position -150 -250 Step 5 Step 4 -350 Step 2 Step 1 Step 3 -450 Time [Encoder Speed], 415 [Profile Status], 700 [Units Traveled], 701 Current Step Step X Step X Step X Step X Step X Step X...
  • Page 76 Position Indexer/Speed Profiler Encoder Incremental with Velocity Override - This profile is the same as Encoder Incr, but contains the “Velocity Override” function. During step 3 the “Vel Override” bit was set. While active the [Step 3 Velocity] is multiplied by [Vel Override].

  • Page 77: Power Loss

    Power Loss 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.
  • Page 78 Power Loss Line Loss Mode = Decel Line Loss Mode = Coast Recover Recover Close Close Trigger Trigger Open Open AC Input Volts AC Input Volts Table F PF700VC Bus Levels Class 200/240V AC 400/480V AC 600/690V AC 1.2V DC 2.4V DC 3.0V DC slew...
  • Page 79 Power Loss Power Loss Actions The drive is designed to operate at a nominal input voltage. When voltage falls below this nominal value by a significant amount, action can be taken to preserve the bus energy and keep the drive logic alive as long as possible. The drive has three methods of dealing with low bus voltages: •...
  • Page 80 Power Loss 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.

  • Page 81: Process Pid Loop

    Process PID Loop 680V Bus Voltage 620V 560V 365V 305V Motor Speed Power Loss Output Enable Pre-Charge Drive Fault 480V example shown, see Table F for further information. Coast Input and Decel Input 700VC ONLY These modes operate similarly to their “non-input” versions, but provide additional ride through time.
  • Page 82 Process PID Loop 0 Volts Equilibrium Point Dancer Pot [PI Reference Sel] [PI Feedback Sel] 10 Volts Master Speed Reference When the PID is disabled the commanded speed is the ramped speed reference. Slip Comp Slip Adder Open Loop Linear Ramp Spd Ref Spd Cmd &...
  • Page 83 Process PID Loop Pump Pressure Transducer Motor PI Feedback Desired Pressure [PI Reference Sel] However, when additional valves in the system are opened and the pressure in the system drops, the PID error will alter its output frequency to bring the process back into control.
  • Page 84 Process PID Loop PID Configuration [PI Configuration] is a set of bits that select various modes of operation. The value of this parameter can only be changed while the drive is stopped. • Exclusive Mode - see page • 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.
  • Page 85 Process PID Loop PI Enabled Start at Spd Cmd PI Output Spd Cmd Pre-load to Command Speed When the PID is configured to have exclusive control of the commanded speed and the drive is in current limit or voltage limit the integrator is preset to the commanded speed so that it knows where to resume when no longer in limit.
  • Page 86 Process PID Loop • Stop Mode - When Stop Mode is set to “1” and a Stop command is issued to the drive, the PID loop will continue to operate during the decel ramp until the PID output becomes more than the master reference. When set to “0,” the drive will disable PID and perform a normal stop.
  • Page 87 Process PID Loop When a digital input is configured as “PI Enable,” the PID Enable bit of [PI Control] must be turned On for the PID loop to become enabled. If a digital input is not configured as “PI Enable” and the PID Enable bit in [PI Control] is turned On, then the PID loop may become enabled.
  • Page 88 Process PID Loop PID Status [PI Status] parameter is a set of bits that indicate the status of the process PID controller • Enabled - The loop is active and controlling the drive output. • Hold - A signal has been issued and the integrator is being held at its current value.
  • Page 89 Process PID Loop Using Scale Blocks with PID Reference and Feedback Scale Blocks are included in the Reference and Feedback selections of the Process PID controller. This selects the output of the scale block for use as Reference or Feedback to the Process PID. PID Setpoint This parameter can be used as an internal value for the setpoint or reference for the process.

  • Page 90: Ptc Motor Thermistor Input

    PTC Motor Thermistor Input PID Lower and Upper Limits/ Output Scaling The output value produced by the PID is displayed as ±100% in [PI Output Meter]. [PI Lower Limit] and [PI Upper Limit] are set as a percentage. In exclusive or speed trim mode, they scale the PID Output to a percentage of [Maximum Freq].

  • Page 91: Pwm Frequency

    PWM Frequency Fault Operation A fault will occur when the PTC resistance increases above 3230 ohms (5V DC), and must be cleared (reset) by a fault clear command (see "Faults" on page 43) after the resistance has decreased below 3230 ohms (5V DC). The drive will also fault if the PTC voltage drops below 0.2V DC, indicating a shorted PTC.

  • Page 92: Regen Power Limit

    Regen Power Limit Regen Power Limit The [Regen Power Lim] is programmed as a percentage of the rated power. The mechanical energy that is transformed into electrical power during a deceleration or overhauling load condition is clamped at this level. Without the proper limit, a bus ✔...

  • Page 93: S Curve

    S Curve S Curve The S Curve function provides control of the rate of change of acceleration and deceleration (also known as “jerk”). S Curve helps control the transition from ✔ ✔ steady state speed to a change in speed. By adjusting the percentage of S Curve applied, the ramp takes the shape of an “S.”...
  • Page 94 S Curve Time to Accelerate When accelerating from 0 to maximum speed, with maximum speed set to 60 Hz, Ta = 2.0 sec, and S Curve = 25%, acceleration time is extended by 0.5 seconds (2.0 x 25%). When accelerating to only 30 Hz the amount of jerk control (S Curve) is the same, but the extended amount of acceleration time is different.

  • Page 95: Safe-Off

    Safe-Off Safe-Off Refer to “DriveGuard Safe-Off User Manual” publication PFLEX-UM001. ✔ Scale Blocks See also "Analog Scaling" on page 4 page Scale blocks are used to scale a parameter value. [ScaleX In Value] is linked to the ✔ parameter that you wish to scale. [ScaleX In Hi] and [ScaleX In Lo] determine the high and low values for the input to the scale block.

  • Page 96: Security

    Security Parameter Settings Parameter Value Description [Scale 1 In Hi] 2.5 V 2.5 V = 200% torque from other drive [Scale 1 In Lo] –2.5V –2.5 V = –200% torque from other drive [PI Reference Sel] 25, Scale The PI Reference becomes the output of the scale block Block1 Out [PI Reference Hi] 100 % 100% PI Reference corresponds to 200% torque from other drive...
  • Page 97 Security Any changes to [Write Mask Cfg] will not take effect until one of the following three events occur: • Power is removed and reapplied. • A drive reset (not reset to defaults) is performed. • [Write Mask Act], parameter 597, bit 15 transitions from “1” to “0.” The status of a port’s write access may be verified at [Write Mask Act].

  • Page 98: Shear Pin

    Shear Pin Shear Pin As a default, the drive will fold back when the output current exceeds the current limit level. However, the shear pin feature can be used to instantly fault the drive ✔ ✔ when output current exceeds a programmed amount. Additionally, the drive can be programmed to ignore this condition during acceleration and deceleration which often requires current that would otherwise cause a shear pin fault.
  • Page 99 Skip Frequency Some machines may have a resonant operating frequency (vibration speed) that is undesirable or could cause equipment damage. To guard against continuous operation at one or more resonant points, parameters 084-086, ([Skip Frequency 1-3]) can be programmed. The value programmed into a skip frequency parameter, sets the center point for an entire “skip band”...

  • Page 100: Sleep Mode

    Sleep Mode Sleep Mode The purpose of the Sleep-Wake function is to Start (wake) the drive when an analog signal is greater than or equal to the specified [Wake Level], and Stop ✔ ✔ (sleep) the drive when an analog signal is less than or equal to the specified [Sleep Level].
  • Page 101 Sleep Mode (1)(2)(3) Table G Conditions Required to Start Drive Input After Power-Up After a Drive Fault After a Stop Command Reset by Stop-CF, Reset by Clear HIM or TB HIM or TB Faults (TB) Stop Stop Closed Stop Closed Stop Closed Stop Closed Wake Signal...

  • Page 102: Speed Reference

    Speed Reference 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 of Port 0, where a digital input start or run will be able to override a sleep situation.
  • Page 103 Speed Reference Network Reference When a network (communication adapter) is selected as the speed reference, a 16 bit word is used as the speed reference. If [Direction Mode], parameter 190 is set to “Bipolar”, the most significant bit (MSB) is used for direction control. Otherwise, the MSB is ignored.
  • Page 104 Speed Reference Figure 17 Trim Trim Enable Select Trim Both None Reference A Trimmed Reference A Reference B Trimmed Reference B The source of the trim signal is selected through [Trim In Sel], parameter 117. All selections for [Speed Ref A] and [Speed Ref B] are also valid choices for a trim source.

  • Page 105: Speed Regulation

    Speed Regulation Min/Max Speed Maximum and minimum speed limits are applied to the reference. These limits apply to the positive and negative references. The minimum speed limits will create a band that the drive will not run continuously within, but will ramp through. This is due to the positive and negative minimum speeds.
  • Page 106 Speed Regulation Figure 18 Rotor Speed with/without Slip Compensation Open Loop Slip Compensation Slip Compensation Mode Active Active 1.5 p.u. Load Load Load 1.0 p.u. Load Applied Applied 0.5 p.u. Load No Load 0.5 p.u. Load Load 1.0 p.u. Load Removed 1.5 p.u.
  • Page 107 Speed Regulation Application Example - Baking Line The diagram below shows a typical application for the Slip Compensation feature. The PLC controls the frequency reference for all four of the drives. Drive #1 and Drive #3 control the speed of the belt conveyor. Slip compensation will be used to maintain the RPM independent of load changes caused by the cutter or dough feed.
  • Page 108 Speed Regulation Integral Gain The integral gain block outputs a torque command relative to the error integrated over a period of time. [Ki Speed Loop] sets the integral gain of the speed regulator. Its value is automatically calculated based on the bandwidth setting in [Speed Desired BW]. Integral gain may be manually adjusted by setting [Speed Desired BW] to a value of zero.

  • Page 109: Speed/Torque Mode

    Speed/Torque Mode Speed Feedback Filter 700VC ONLY [Fdbk Filter Select] determines the type of filter to use for the speed feedback. The filter is used to filter out high frequency signals (noise) by reducing the gain at high frequencies. The selections for the filter are: Select this Description To select this type of filter .
  • Page 110 Speed/Torque Mode The Min mode is typically used with positive torque and forward speed operation, the minimum of the two being closest to zero. The Max mode is opposite, typically used with reverse speed and negative torque, the maximum being the least negative (closest to zero).
  • Page 111 Speed/Torque Mode When the Process PID loop is setup for torque trim ([Process PI Config], bit 8 “Torque Trim” is set to 1), the output of the Process PI Loop also becomes a torque reference. The final torque reference, in the Torque Mode, is the sum of scaled Torque Ref A, scaled Torque Ref B (700VC only) and the output of the Process PID loop when it is set to trim torque.

  • Page 112: Start Permissives

    Start Permissives Absolute Min Mode 700VC ONLY This mode regulates to the smallest absolute value of torque or speed, when the torque reference and torque generated from the speed regulator are compared. Position/Speed Profile Mode 700VC ONLY The drive operates as a speed or position regulator as determined by the Profile Step parameters (720-877) and Setup parameters (705-719).

  • Page 113: Stop Modes

    Stop Modes Stop Modes Several methods are available for braking or stopping a load as described in the table below. ✔ ✔ Method Use When Application Requires . . . Braking Power • Ramp The fastest stopping time or fastest ramp time for speed changes Most, if an (external brake resistor or regenerative capability required for ramp external resistor...
  • Page 114 Stop Modes Detailed operation Mode Description Coast to Stop Bus Voltage Output Voltage Output Current Motor Speed Command Speed Time Coast Time is load dependent Stop Command Coast is selected by setting [Stop Mode A/B] to a value of “0.” When in Coast to Stop, the drive acknowledges the Stop command by shutting off the drive output and releasing control of the motor.
  • Page 115 Stop Modes Mode Description Ramp Bus Voltage Output Voltage Output Current Motor Speed Output Current Command Speed Output Voltage Brake Level Time DC Brake Time Stop Zero Command Command Speed This method uses drive output reduction to stop the load. Ramp is selected by setting [Stop Mode A/B] to a value of “1”. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2].
  • Page 116 Stop Modes Mode Description Fast Brake Bus Voltage Output Voltage Output Current Motor Speed Command Speed Time Stop Command This method takes advantage of the characteristic of the induction motor whereby frequencies greater than zero (DC braking) can be applied to a spinning motor that will provide more braking torque without causing the drive to regenerate. 1.

  • Page 117: User Display

    User Display Implementation Block Diagram for Fast Braking Current Regulator IqCmd − T (θ) IdCmd Brake Level − IqFdbk θe IdFdbk Bus Voltage Gain Reference − Frequency Bus Voltage User Display The User Display is shown when module keys have been inactive for a predetermined amount of time.

  • Page 118: User Sets

    User Sets User Sets Normal Mode The drive has additional parameter storage memory beyond what is being used for ✔ ✔ operation at any given time. This additional memory is divided up into 3 areas called User Sets. When the drive is stopped, a HIM command or parameter command (similar to Reset to Defaults) can be used to load any of these user sets.

  • Page 119: Voltage Class

    Voltage Class These parameter bits are normally written to over a network (using Datalinks) and control the user sets as follows: [Dyn UserSet Sel] [Dyn UserSet Sel] Parameter 205, bit 1 Parameter 205, bit 0 User Set • [Dyn UserSet Actv], parameter 206 reports the status of Dynamic Mode and which User Set is active.

  • Page 120: Voltage Tolerance

    Voltage Tolerance Voltage Tolerance Drive Rating Nominal Line Nominal Motor Drive Full Power Drive Operating ✔ ✔ Voltage Voltage Range Range 200-240 200* 200-264 180-264 208-264 230-264 380-480 380* 380-528 342-528 400-528 460-528 500-600 575* 575-660 432-660 575* 575-660 475-759 690-759 475-759 Drive Full Power Range =...

  • Page 121: Appendix

    Appendix Supplemental Information Engineering Parameters ATTENTION: To guard against unstable or unpredictable operation, ✔ ✔ the following parameters must only be changed by qualified service personnel. The following parameters can only be viewed when “2, Reserved” is selected in parameter 196, [Param Access Lvl]. Parameter Name &...
  • Page 122 Engineering Parameters Parameter Name & Description Values ✔ ✔ 508 [Stability Filter] Default: 3250 The Stability Filter coefficient is used to adjust the Min/Max: 0/32767 bandwidth of a low pass filter. The smaller the value Units: of this coefficient, the lower the bandwidth of the filter. ✔...
  • Page 123 Engineering Parameters Parameter Name & Description Values ✔ ✔ 532 [Ki Slip Reg] Default: Integral gain for the slip frequency regulator. Min/Max: 0/32767 Units: ✔ ✔ 533 [Flux Reg Enable] Default: Enables or disables the flux regulator. Min/Max: Units: ✔ ✔ 534 [Kp Flux Reg] Default: Proportional gain for the flux regulator.

  • Page 124: Derating Guidelines

    Derating Guidelines Parameter Name & Description Values ✔ ✔ 549 Flux Braking % (% of normal output voltage) Default: Gain adjustment for Flux Braking mode. Min/Max: 100/250 Units: ✔ 550 Ki Flying Start Default: Integral gaing for Flying Start mode. Min/Max: 20/5000 Units:...
  • Page 125 Derating Guidelines PowerFlex 70 Ambient Temperature/Load 240V AC PowerFlex 70 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 240 Volt 0.5 - 3.0 0.33 - 2.0 None % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 126 Derating Guidelines 400V AC PowerFlex 70 Power Rating Derating ND kW HD kW 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 400 Volt 0.37 - 5.5 0.25 - 4.0 None % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current 18.5 % of Rated Continuous Current...
  • Page 127 Derating Guidelines PowerFlex 70 Power Rating Derating ND kW HD kW 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 400 Volt % of Rated Continuous Current 480V AC PowerFlex 70 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz...
  • Page 128 Derating Guidelines PowerFlex 70 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 480 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current 600V AC PowerFlex 70 Power Rating Derating ND HP...
  • Page 129 Derating Guidelines PowerFlex 70 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 600 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 130 Derating Guidelines PowerFlex 700 Ambient Temperature/Load 240V AC PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 240 Volt 0.5 - 5.0 0.33 - 3.0 None % of Rated Continuous Current 10 - 15 7.5 - 10 None...
  • Page 131 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 240 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current 400V AC PowerFlex 700 Power Rating Derating ND kW...
  • Page 132 Derating Guidelines PowerFlex 700 Power Rating Derating ND kW HD kW 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 400 Volt 18.5 % of Rated Continuous Current 18.5 None % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 133 Derating Guidelines PowerFlex 700 Power Rating Derating ND kW HD kW 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 400 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current 480V AC PowerFlex 700 Power Rating Derating ND HP...
  • Page 134 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 480 Volt % of Rated Continuous Current None % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 135 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 480 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current 600V AC PowerFlex 700 Power Rating Derating ND HP...
  • Page 136 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 600 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 137 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 600 Volt % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current % of Rated Continuous Current...
  • Page 138 Derating Guidelines PowerFlex 700 Power Rating Derating ND HP HD HP 2 kHz 4 kHz 6 kHz 8 kHz 10 kHz 600 Volt % of Rated Continuous Current 690V AC PowerFlex 700 Power Rating Derating ND kW HD kW 2 kHz 4 kHz 6 kHz 8 kHz...

  • Page 139: Powerflex 70Ec Block Diagrams

    PowerFlex 70EC Block Diagrams PowerFlex 70EC 102 - Preset Speed 2 271 - Drive Logic Rslt Block Diagrams Changeable Parameter Bit Parameter - Not Set (0) 10.0 Bit 13 - Spd Ref ID ✔ 271 - Drive Logic Rslt 11 - MOP Frequency Read Only Parameter Bit Parameter - Set (1) ✔...
  • Page 140 PowerFlex 70EC Block Diagrams...
  • Page 141 PowerFlex 70EC Block Diagrams...
  • Page 142 PowerFlex 70EC Block Diagrams...
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  • Page 156 PowerFlex 70EC Block Diagrams...

  • Page 157: Powerflex 700Vc Block Diagrams

    PowerFlex 700VC Block Diagrams PowerFlex 700VC 102 - Preset Speed 2 271 - Drive Logic Rslt Block Diagrams Changeable Parameter Bit Parameter - Not Set (0) 10.0 Bit 13 - Spd Ref ID ✔ 271 - Drive Logic Rslt 11 - MOP Frequency Read Only Parameter Bit Parameter - Set (1) ✔...
  • Page 158 PowerFlex 700VC Block Diagrams...
  • Page 159 PowerFlex 700VC Block Diagrams...
  • Page 160 PowerFlex 700VC Block Diagrams...
  • Page 161 PowerFlex 700VC Block Diagrams...
  • Page 162 PowerFlex 700VC Block Diagrams...
  • Page 163 PowerFlex 700VC Block Diagrams...
  • Page 164 PowerFlex 700VC Block Diagrams...
  • Page 165 PowerFlex 700VC Block Diagrams...
  • Page 166 PowerFlex 700VC Block Diagrams...

  • Page 167: Index

    Index Exclusive Link, 31 Exclusive Mode, 78 Absolute, Analog Output, 10 Accel/Decel Time, 3 Alarms, 3 Fast Stop, 32 Type 1, 3 Fault Configuration, 44 Type 2, 3 Fault Queue, 43 Analog I/O, 4 Fault, clearing, 44 Analog Input Faults, 43 Square Root, 8 Flux Up, 46 Analog Inputs, 4...
  • Page 168 Index-2 Digital, 33 Speed Profile, 61 Overload Speed Reference, 98 Drive, 39 High Resolution, 48 Owners, 59 Speed Reference Trim, 99 Speed Regulation, 101 Speed Regulation Mode, 106 Password, 60 Speed Select, 29 PI Enable, 30 Speed Trim Mode, 77 PI Hold, 30 Speed Units, 108 PI Invert, 30...
  • Page 170 U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444...

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Powerflex 700 vector control

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