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Rockwell Automation Allen-Bradley PowerFlex 755T Flux Vector Tuning Original Instructions Manual

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Application Technique
Original Instructions
PowerFlex 755T Flux Vector Tuning
Bulletins 20G, 20J

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 755T Flux Vector Tuning

  • Page 1 Application Technique Original Instructions PowerFlex 755T Flux Vector Tuning Bulletins 20G, 20J...

  • Page 2: Summary Of Changes

    Added parameters to configure for current/torque loop performance tuning New chapter on Active Front End (AFE) Tuning Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the movement toward inclusive language in technology.

  • Page 3: Table Of Contents

    Other Considerations ..........58 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 4 Reactive Power Control ........... . 97 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 5 ............... . 115 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 6: About This Publication

    Recommended Default Settings on page Download Firmware, AOP, EDS, and Other Files Download firmware, associated files (such as AOP, EDS, and DTM), and access product release notes from the Product Compatibility and Download Center at rok.auto/pcdc. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 7: Background

    Adverse effects of non-rigid components (compliance and back lash) are amplified, making it more difficult to tune. A motor with a connected load is shown in Figure 1 as a simple two mass system. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 8 Total Inertia is the sum of load inertia and motor inertia. It is the total inertia of the moving mechanical system that is driven by the drive. Total inertia determines the maximum acceleration and deceleration of the mechanical system. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 9: Compliance

    Furthermore, another resonance is present at the end of the load or end effector. This load side resonance has a resonant frequency equal to the motor side anti-resonant frequency. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 10 When k = ∞, the load is rigid When 0 < k < ∞, everything else is compliant and/or has backlash. This condition constitutes most industrial applications over a wide range of dynamic behaviors. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 11: Backlash

    This method cancels the effect of backlash distance and confirms that the final load side position is consistent, regardless of where the starting load side position was. This nonlinearity creates tuning problems in the form of resonances. A dynamic model is given. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 12: Resonances

    There are two main types of resonances: motor side resonances and load side resonances. Motor side resonances are further broken down into three subtypes based on their frequency range: Low Frequency (LF) resonances, Mid Frequency (MF) resonances, and High Frequency (HF) resonances. Figure 9 shows the types of resonances. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 13 Otherwise, it is left to the user to manually reduce notch filter widths, decrease control loop gains, and decrease load observer gains. Similarly, torque loop low pass filters impact stability when they are applied at frequencies as low as 3…5 times the closed loop bandwidth Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 14: Performance

    The following sections describe the metrics that are used to adjust performance during tuning: • Bandwidth • Damping Factor on page 16 • System Bandwidth on page 16 • System C/U Select on page 18 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 15: Bandwidth

    Feedback resolution (higher is better) • Drive loop update rate (higher is better) • Drive Model Time Constant (smaller is better) System Bandwidth on page 16 for more information on drive model time constant. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 16: Damping Factor

    High-Resolution Example: Resolution = 1024 pulses per revolution * 1024 edge counts per pulse = 1,048,576 EPR (20-bit). For high- resolution devices, the overall resolution choices are 20-bit default or an optional 24-bit when the corresponding configuration bit is selected. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 17 “BW Calc” 1010 1010 Alt Fb GnScale Alt Fb GnScale “JMtr BW Calc” “JMtr BW Calc” Alt Encoder EPR Alt Encoder EPR “JTotalBWCalc” “JTotalBWCalc” 1006 1006 Alt Vel Fb Sel Alt Vel Fb Sel Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 18: System C/U Select

    Figure 16 on page 19 shows how various parameters impact the System C/U Selection. Autotune updates the parameters in red, which then triggers the automatic calculations upon any change of their input parameters. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 19: Control Structure Overview

    Figure 17 - Flux Vector Control Structure Position Feed Command Forwards Adaptive Tuning Kvff Kaff Torque Loop Filters System Under Control Load Torque Torque Estimate Velocity Load Feedback Position Observer Filter Velocity Feedback Estimate Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 20: Position Loop

    ) – The position regulator consists of a proportional-integral (PI) controller. In legacy PowerFlex 755 drives, K is in parallel with K . Here, legacy K 10:839 [Psn Reg Kp] is the position loop bandwidth in units of [rad/sec] and legacy K 10:838 [Psn Reg Ki] Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 21: Velocity Loop

    Estimate In Velocity mode, the velocity and torque loops are enabled and the position loop is replaced by a velocity reference command. Here, the velocity loop consists of the highlighted elements in Figure Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 22 The primary feedback channel is used when the Automatic Tach Switchover feature is disabled or before a switchover has occurred. Feedback is then switched from the primary to the alternate feedback channel when the Automatic Tach Switchover feature is enabled and a switchover has occurred. Relevant parameters are given in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 23 Flux Vector motor control modes. – This value is applied when parameter 10:905 • Entering a value of 1 turns off the filter. [System C/U Sel] is set to 'User Entered' (1). Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 24 These signals have acceleration units of [rev/sec ]. They are applied before the Torque Scaler conversion to percent [% motor torque]. Table 6 lists the parameters for Acceleration Feed Forward. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 25: Torque Loop

    In torque mode, the torque loop is enabled and the position and velocity loops are replaced by a torque reference command. Here, the torque loop consists of the highlighted elements that are shown in Figure Figure 24 - Torque Reference Adaptive Tuning Torque Loop Filters System Under Control Load Torque Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 26 Lead Lag Filters on page 52 for more information. Adaptive Tuning – The adaptive tuning feature can be configured to automatically adjust torque notch and low pass filters. See Adaptive Tuning on page 34 for more information. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 27: Product Features

    Figure 25 on page 28 shows a rigid mechanical load with a load inertia that does not change over time. K is the motor rated torque constant, which is compensated for by block Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 28 Calculation for Both Rigid and Non-rigid Loads It has been shown that K for rigid loads and K is for non-rigid loads. In the drive, torque scaler is calculated as *(R+1)/T to allow for all cases. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 29: Load Observer

    Automatically compensate for disturbances and changing inertia • Force consistent dynamic behavior, which makes the drive easy to tune This section includes: • Benefits • How It Works on page 30 • Configuration on page 31 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 30: Benefits

    Velocity Feedback signal that comes from the velocity feedback FIR and low pass filters. It also helps to reduce high frequency output noise that is caused by the load observer aggressively acting on the Acceleration Reference signal. Together, load observer with velocity estimate provides the best overall performance for position control applications. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 31: Configuration

    The torque scaler K is also set internally. See Torque Scaler on page 27 for more information on which parameters affect K Recommended settings are shown in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 32 This mode applies the Torque Estimate signal to the control loops but not the Velocity Estimate signal. The velocity regulator uses the default filtered Velocity Feedback instead of the Velocity Estimate signal. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 33 Torque Estimate signal. It replaces the default filtered Velocity Feedback signal with the Velocity Estimate signal. Figure 33 - Velocity Estimate Only Configuration System Under Control Control Loops Power Converter Unloaded Motor Torque Load Torque Acceleration Estimate Reference Velocity Load Feedback Observer Velocity Position Filter Estimate Feedback Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 34: Adaptive Tuning

    • Minimizes tracking error, machine vibration, and power consumption • Allows bandwidth and line speeds to be increased • Provides tighter control of moving parts, which reduces wear and saves on material costs Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 35: How It Works

    Gain Stabiliza on de-tunes and Tracking Notch sets Gain Stabiliza on Gain Op miza on up-tunes torque notch filters sets torque LPF Configuration Figure 36 shows parameters that are relevant to adaptive tuning. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 36 Adaptive Tuning Tracking Enter the number of torque notch filters that are automatically tuned by Adaptive Tuning when 10:2110 10:2118 [AdptTune NF Num] Notches [AdptTune Config] = TrackingNF or TrkNFGainStb. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 37 Stability Magnitude Gain Optimization 10:2138 [GnOpt Error Max] Displays the maximum velocity or position error used in gain optimization, in error units. Error Maximum Output parameters and their descriptions are summarized in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 38 • Adaptive tuning sets this value between the minimum and maximum widths proportional to the frequency estimate in relation to the high and low frequency limits when the adaptive tuning Tracking Notch function is active. See 10:2110 [AdptTune Config] for adaptive tuning modes. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 39 Adaptive tuning status bits let you create custom logic, trap errors, debug, or manually react to changes. This custom logic is useful for condition monitoring, diagnostics, and preventative maintenance purposes. Table 15 describes when output parameters get reset to their default values. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 40: Adaptive Tuning Modes

    10:2112 [Trq NF Freq LLim] and 10:2113 [Trq NF Freq HLim]. See Figure 35 on page Figure 38 shows the frequency response of an example resonance to illustrate how it is identified. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 41 The default value of the low limit is small which produces a narrow notch with little phase lag to interfere with stability. 4. It repeats step 1 through step 3 to set torque notch filters 2…4, depending on the value set by 10:2118 [AdptTune NF Num] and if more resonances are identified. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 42 Figure 41 - Gain Stabilization Configuration Feed Position Forwards Command Adaptive Tuning Kvff Kaff Torque Loop Filters System Under Control Load Torque Torque Estimate Velocity Load Feedback Position Observer Filter Velocity Feedback Estimate Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 43 Next, the adaptive tuning Gain Stabilization function sets the actual torque low pass filter parameters to suppress additional HF resonances if they exist. This is useful for suppressing more HF resonances than there are notch filters. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 44 When an LF resonance is detected with a magnitude less than the 10:2135 [GnOpt TorqueLim] threshold line, see Figure 35 on page 35, Gain Optimization increases 10:2121 [AdptTune GnScale] to greater than 1.0 in additive increments until the LF resonance magnitude increases Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 45 However, repeated gain stabilization can cause degradation because it reacts to momentary instability. This timer feature is disabled when 10:2142 [GnOpt Time] is set to zero, which is typical for constant speed or non-cyclic applications. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 46: Notch Filters

    See Resonances on page 12 for more information on the various types of resonances and how to suppress them. Corresponding reference notch filter parameters are given in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 47: Configuration

    – 0.5z – ------- - Notch filter depth can be calculated in units of [dB] at the center frequency of the filter.     ------- Depth dB     Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 48 When K = 0, the notch filter is configured to operate as a second order low-pass filter with bandwidth F and damping Z . Bode plots with differing low-pass filter settings for K = 0 are shown in Figure Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 49 (lead) at F = F/K with damping Z . Bode plots with differing lag-lead filter settings for 0 < K < 1 are shown in Figure Figure 50 - Lag-Lead Filter Configurations Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 50 Figure 51 - Lead-Lag Filter Configurations Initial recommended settings for damping are Z = 1 and Z = 1. Lead-lag filters have been used to boost velocity or acceleration loop bandwidth in order to improve performance. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 51: Low Pass Filters

    • This filter determines the amount of filtering applied to the primary parameter 10:905 [System C/U Sel] is set to 'Calculated' velocity feedback channel and is only active in Flux Vector motor control (0). The ' c alculated' filter gain is always zero. modes. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 52: Lead Lag Filters

    The filter is disabled when F = 0 Hz, regardless of the other settings. The filter has a DC gain of 1, a user-configurable pole (lag) at F, and a user-configurable zero (lead) at F/K. Bode plots with differing gain settings are shown in Figure Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 53: Finite Impulse Response Filters

    Finite Impulse Response (FIR) filters are digital filters where the output is a weighted sum of the recent inputs. They are inherently stable and represented by the following equation.    – y t   k i x t where: x (t) is the filter input signal Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 54 10:1001 [Vel Fb Taps] - This parameter sets the number of taps in the FIR filter applied to the primary feedback channel. 10:1007 [Alt Vel Fb Taps] - This parameter sets the number of taps in the FIR filter applied to the alternate feedback channel. Typical values are given in Table 5 on page Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 55: Out-Of-Box Tuning

    Electrical Mechanics Velocity Loop Motor Position ( + 1) Torque Load Scalar ( Torque Integrator Damping Variables that are relevant to increasing damping when K is artificially lowered include those listed in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 56: Load Observer Disabled

    10 because the load observer accounts for the unknown load to maintain that K is not artificially lowered. Also, K is disabled because the load observer operates as a good velocity integrator. Load Observer Only mode is recommended for velocity control applications. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 57: Velocity Estimate Only

    Estimate automatically accounts for the arbitrary load disconnect created by the load, which forces it to function like a mechanically disconnected motor. As a result, standard 4Z spacing sufficient for controlling a mechanically disconnected motor is applied. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 58: Other Considerations

    [kg•m • Multiply [kW] by 1.341 to convert to [Hp]. 10:1000 [Pri Vel Fb Sel] Enter the 2-digit port location followed by the 4-digit parameter number of the primary feedback device. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 59 Run 10:910 [Autotune] = Rotate MtrID (3) to measure the motor electrical parameters. It initiates motion and rotates the load. To obtain the most accurate measure of motor flux current, disconnect the load for this test. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 60 Temporarily set 10:1019 [Fb Loss Action] = Alt Only (1) and adjust 10:1010 [Alt Fb GnScale] to the desired performance. After the performance with the alternate feedback is adjusted, set 10:1019 [Fb Loss Action] back to Auto Tach SW (2). Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 61: Single Knob Tuning

    Quality mechanical components help to achieve this. If the load requires additional tuning to optimize performance, continue on to Auto Tuning on page 63. See Figure 60 for guidance on progressing through the tuning process. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 62 Chapter 5 on page 76 Set 10:905 [System C/U Sel] = “User Entered” “User Entered” Manually adjust User-entered tuning parameters Is problem Is problem resolved? resolved? Check Other Check Other Good Good Parameters Parameters Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 63: General Modes

    10:510 [MtrParam C/U Sel] allows either calculated or user-entered parameters to be applied to motor electrical gains. It also allows you to transfer calculated parameter values to user-entered parameter values so that you can use them as a starting point for manual tuning, if desired. Parameters are given in Table Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 64 Autotune to overwrite them when 10:910 [Autotune] = Static MtrID (2) for IM or when 10:910 [Autotune] = Rotate MtrID (3). Figure 61 shows how the Motor Parameter C/U Selection impacts various parameters. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 65: Current Regulator Gain Calculation

    Open loop current regulator gains for IPM and SPM motors are calculated as functions of bandwidth and damping: VCL CReg IdKp = 2*B *Ld100 VCL CReg IqKp = 2*B *Lq75 VCL CReg IdKi = VCL CReg IqKi = 2*B *Rs/Damping Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 66 PM Lq at 100 u PM Lq at 125 u PM Lq at 150 u PM Lq at 175 u PM Lq at 200 VCL CReg BW User Entered VCL CReg Damping Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 67: Modes

    10:524 [IM StatResComp] 10:910 [Autotune] = Rotate MtrID (3) – Enables the Autotune function to perform the Rotating Motor ID Test. After selecting this value, you must issue a start command to begin the test. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 68 Finally, a rotate test is performed to calculate the counter-emf voltage: 10:614 [u PM CEMF Vltg] In order for these parameters to be applied, set 10:510 [MtrParam C/U Sel] = User Entered (1). Figure 65 shows how Autotune Electrical modes impact various parameters. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 69 Vector mode, either a coupled or uncoupled load produces valid results. Caution must be used when the load is connected to the motor shaft and an Autotune is performed. Rotation during the tuning process can exceed machine limits. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 70: Inertia Tests

    IMPORTANT This test is only an option if the load can be disconnected to run the test. It must be performed with the load disconnected from the motor to generate accurate results. Otherwise, the motor inertia is calculated as the total inertia of the motor and load together. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 71: Gain Calculation

    71. This test works well for high-performance rigid loads. After an Autotune bandwidth calculation, adjust 10:2112 [Trq NF Freq LLim] to a value that is at least 2…3 times the value of 10:906 [System BW]. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 72: Configuration

    10:2020 [LdObs Mode] = Disabled (0) for torque mode applications • 10:2020 [LdObs Mode] = LdObs Only (1) for Velocity mode applications • 10:2020 [LdObs Mode] = LdObs VelEst (2) for Position mode applications Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 73 When 10:901 [Load Ratio] > 0 and 10:2020 [LdObs Mode] = LdObs Only (1) or 10:2020 [LdObs Mode] = LdObs VelEst (2) or 10:2020 [LdObs Mode] = Accel Fdbk (4), K is disabled because load observer operates as a good velocity integrator. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 74 Vel Fb LPF Gn u Vel Fb LPF Gn 1009 1009 u AltVelFbLPF BW u AltVelFbLPF BW 1022 1022 u AltVelFbLPF Gn u AltVelFbLPF Gn 1929 1929 u Vel Comp Gain u Vel Comp Gain Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 75: Is Further Tuning Required

    - Misalignments between load and gearbox - Damaged mechanical components - Poor lubrication - Belt misalignments - Improper tensioning If the load requires additional tuning, continue to Manual Tuning on page Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 76: Manual Tuning

    1. Configure drive parameters by following the Recommended Default Settings on page 2. Run the drive and adjust 10:906 [System BW] with 10:905 [System C/U Select] = Calculate (0) to achieve the performance you want. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 77: Tune The Current Loop (Optional)

    10:2155 [u Trq LPF BW] 10:1974 [u Accel FF Gain] b. Temporarily set these parameters to zero. c. Set all torque notch filter bandwidths to zero. d. Set 10:1760 [Vel FF Gain] = 100%. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 78 If all four notch filters are configured and audible resonances are still present, adjust 10:2155 [u Trq LPF BW] and/or reduce 10:1956 [u Vreg Kp] and 10:2022 [u LdObs Kp] until the resonances vanish. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 79: Tune The Velocity Loop In Encoderless Mode

    Velocity Loop on page 77 again to tune the velocity loop, but adjust only 10:1010 [Alt Fb Gn Scale] instead of control loop gains (10:1956 [u VReg Kp] and 10:2022 [u LdObs Kp]). Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 80: Tune The Position Loop (Optional)

    Typical ranges for integrator and feed forward gains are given: 0 ≤ K ≤ 100 0 ≤ K ≤ K IMPORTANT Make sure the drive stays set with 10:905 [System C/U Select] = User Entered (1) after finishing this manual tuning procedure. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 81: Active Front End Tuning

    These power converters are commonly connected to the grid through an LCL filter that is responsible for filtering out higher-order harmonics associated with the switching action of the power converter. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 82: Configuration

    – This mode is enabled by checking 13:40 [Conv Options Cfg] Bit 2 ActvCurLoop Converter Options 13:40 [Conv Options Cfg] Bit 2 ActvCurLoop configures the line-side converter to function in Active Current mode. Configuration Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 83: Regulators

    In most applications, the power converter is supplied by a source transformer or a generator. The inductance of the transformer/generator is automatically calculated based on the kVA and the percentage impedance of the transformer/generator based on the corresponding Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 84 Setting the B and damping of the current control loop is more straightforward and it is recommended for most of applications. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 85: Disturbance Rejection

    This is achieved by using two main functions, the feed forward power and the DC bus observer, which are configured using 13:300 [PwrFeedFwdConfig] and 13:320 [BusObsConfig]. Table 29 explains the parameters for these functions. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 86: Feed Forward Power

    Because this feature relies on fast communication between the inverter to converter signal, it cannot be used in 755TM bus supply applications and it cannot compensate for external loads connected to the DC terminals of an integrated drive. In these applications, use the DC Bus Observer function instead. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 87: Dc Bus Observer

    Figure 73 - Simplified Functional Block Diagram for DC Bus Observer Iq_Load Power converter VbusReg V DC V DC CurrentLoop Plant-Bus Capacitance — VbusObsReg • s POBS Vdc_Est Iq_Load_Est Ini al Bus Capacitance — IOBS Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 88 Bus Observer Enter the Bus Observer proportional gain in units of Hz. 13:322 [u BusObs Kp] Proportional Gain - • Used when 13:305 [BusObs C/U Sel] is set to User Entered (1). User Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 89: Resonance Mitigation And Feed Forward Components Of Grid Voltages

    13:81 [Actv Damping Gn] to 0. Table 32 summarizes the parameters that are discussed in this section Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 90: Phase Locked Loop

    PowerFlex 755T AFE converter can provide perfect rejection for the unbalance in the grid line voltages while maintaining a B of 100 Hz (628 rad/sec). Figure 75 - Function Block Diagram of the PLL with Adaptive Tracking Filter abc/dq Integrator transforma on Regulator Output Angle Output Frequency Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 91: Pll Configuration

    DC offset can be controlled using 13:90 [DC Offst Filt Bw] and 13:91 [DC Offst LPF Bw], where higher values result in a slower overdamped response and lower values result in a faster underdamped response. Figure 76 shows a functional block diagram that indicates the configuration parameters for the PLL. Table 33 summarizes the PLL parameters. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 92: Loss Of Synchronization Detection

    The steady-state error limit is set by 13:192 [BasicPLL Err Limit]. The corresponding transient error limit can be calculated as follows: PLL Transient Error= 3.5 x PLL Steady-state Error Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 93: Power Disturbance Module

    If the voltage sag condition is still active after the Ride Through time expires, the converter performs as configured in 13:174 [VltgSagRTExpActn]. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 94: High-Frequency Variation

    PowerFlex 755TL and TR drives are integrated. This means they have a line-side converter and a motor-side inverter. These drives utilize Rockwell Automation’s Adaptive Bus Reference Ride Through technology. The line-side converter is disabled when the abnormal condition is detected. If the Ride Through option is selected, an additional signal passes from the line-side converter to the motor-side inverter. When the signal is high, the motor-side inverter takes control of the DC bus.
  • Page 95 50V, and 10:273 [Pwr Loss A Time] to 60 s in the motor-side inverter. The duration of the power loss in this test was approximately 10 s. Figure 78 - Ride Through for PowerFlex 755TR Drives Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 96: Power Disturbance Module Configuration

    Thru Expired Action – Type 2 Alarms prevent the line-side converter from starting its modulation. • Major Fault (2) – A Major Fault occurs immediately. – Major Faults stop the line-side converter from modulating. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 97: Reactive Power Control

    The inherent uncertainty in the actual value of the source inductance is compensated for by an internal regulator that is designed to trim the commanded DC bus voltage of the power converter, this Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 98 Displays available Reactive Power based on the rating and the load of the line-side converter. Available Displays the limited and conditioned Reactive Power reference. Reactive Power 13:72 [kVAR Command] Command • The Reactive Power regulator consumes this signal as its command. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 99 Port 0, DC Bus Volts Metering [D5] VoltRefGen [C5] Metering [D1] SourceImpedance LscData [C5] BusRefAutoAdjCalcula on Ac ve Cur Cmd CurrPwrLmt [F5] Reference Reac ve Current Calcula on kVAR Ref Rate Limit kVAR Rate Limit Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 100: Friction Compensation

    Viscous friction is defined as the component of friction that increases linearly with the speed of the mechanical system. The method of compensating for viscous friction is to multiply the configured viscous friction compensation value by the speed of the motor and apply the result to the torque reference signal. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 101: Configuration

    The load observer is often used to compensate for friction instead because the user is not required to know or measure various friction parameters. Figure 83 shows how the friction compensation parameters relate to the torque and speed. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 102: Torque Sharing

    However, tightly coupled loads typically do not require the use of droop. Instead, the master is configured with an integral gain K > 0 and the slaves are set with K = 0. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 103: Vertical Loads

    6. Set 10:2077 [Torque Step] to 1% while monitoring the position error. 7. Increase 10:2077 [Torque Step] until the position error is zero and the drive is performing well. 8. Disable the drive. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 104: Process Pid Controller

    PID feedback to control the tension in the system. An equilibrium point is programmed as the 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. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 105 In the pumping application example shown in Figure 87, the setpoint is the required pressure in the system. The pressure transducer output is the PID feedback and it Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 106 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. Figure 89 - Pump When PID Is Enabled Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 107: Features

    PID reference ramps to the selected value for the PID reference at the selected acceleration or deceleration rate. After the PID reference reaches the selected value, the ramp is bypassed until the PID is disabled and enabled again. S-curve is not available as part of the PID linear ramp. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 108 PID Enable – The PID controller can be enabled or disabled. The enabled status of the PID controller determines when the PID controller output is part or all of the commanded speed. The logic that is evaluated for the PID enabled status is shown in Figure Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 109 PID Reference and Feedback – The selection of the source for the reference signal is entered in 9:25 [PID Ref Sel]. The selection of the source for the feedback signal is selected in 9:35 [PID Fdbk Sel]. The reference and feedback have the same limit of possible options. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 110 PID Error – The PID error is then sent to the proportional and integral functions, which are summed together. 9:10 [PID LPF BW] sets the bandwidth of a first order low pass filter that is applied to the PID error. This is useful in filtering out unwanted signal response, such as noise in the PID feedback signal. Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 111: Diagrams

    Figure 95 on page 112 Figure 96 on page 113 comprise one extended diagram. The output of the diagram in Figure 95, PID Output Limited, is the input for the diagram in Figure Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 112 Chapter 7 Applications Figure 95 - Process PID Diagram Part 1 Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 113 Trq Ref Sel [G4] Trq Ref Sel [G4] PID Cfg PID Cfg (Zero Clamp) (Zero Clamp) Motor Side Sts 2 Motor Side Sts 2 (PID FB Loss) (PID FB Loss) Proc 1 [C4] Proc 1 [C4] Rockwell Automation Publication 750-AT006D-EN-P - January 2022...
  • Page 114 Chapter 7 Applications Notes: Rockwell Automation Publication 750-AT006D-EN-P - January 2022...

  • Page 115: Additional Resources

    PowerFlex 755T Flux Vector Tuning Application Technique Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex Drives with TotalFORCE Control Programming Manual, Provides detailed information on I/O, control, and feedback options; Parameters and...
  • Page 116 Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the form at rok.auto/docfeedback. Allen-Bradley, Connected Components Workbench, expanding human possibility, Kinetix, PowerFlex, Rockwell Automation, and TotalFORCE are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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