PowerFlex Drive 750 Rm002 - en P
PowerFlex Drive 750 Rm002 - en P
PowerFlex Drive 750 Rm002 - en P
Original Instructions
Important User Information
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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, Connected Components Workbench, DriveExecutive, DriveExplorer, PowerFlex, RSLogix, SCANport, Studio 5000, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
New and Updated This table contains the changes made to this revision.
Information Topic Page
Added information about 270 kW, 400 HP drives to the table of minimum 214
resistances.
Notes:
Preface
Overview 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
Chapter 2
Feedback and I/O Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
PTC Motor Thermistor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Chapter 3
Diagnostics and Protection 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
Motor Control 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 Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Energy Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
High Speed Trending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Position Homing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Chapter 6
Integrated Motion on the EtherNet/ Additional Resources for Integrated Motion on the
IP Network Applications for EtherNet/IP Network Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
Coarse Update Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
PowerFlex 755 AC Drives
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
Notes:
Overview
Who Should Use This Manual 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.
What Is Not in This Manual The purpose of this manual is to provide detailed drive information including
operation, parameter descriptions and programming.
Additional Resources The following table lists publications that provide information about PowerFlex
750-Series drives.
Resource Description
PowerFlex 750-Series Drive Installation Instruction, 750- Provides the basic steps required to install a PowerFlex®
IN001 750-Series AC drive.
PowerFlex 750-Series AC Drives Programming Manual, Provides detailed information on:
publication 750-PM001 • I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series AC Drives Technical Data, Provides detailed information on:
publication 750-TD001 • Drive specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Provides detailed information on HIM components,
Module) User Manual, publication 20HIM-UM001 operation, features.
PowerFlex 750-Series AC Drives Hardware Service Manual Provides detailed information on:
- Frame 8 and Larger, publication 750-TG001 • Preventive maintenance
• Component testing
• Hardware replacement procedures
PowerFlex 755 Drive Embedded EtherNet/IP Adapter User These publications provide detailed information on
Manual, publication 750COM-UM001 configuring, using, and troubleshooting PowerFlex
750-Series communication option modules and adapters.
PowerFlex 750-Series Drive DeviceNet Option Module User
Manual, publication 750COM-UM002
PowerFlex 7-Class Network Communication Adapter User
Manuals, publications 750COM-UMxxx
Resource Description
PowerFlex 750-Series Safe Torque Off User Manual, These publications provide detailed information on
publication 750-UM002 installation, set up, and operation of the 750-Series safety
option modules.
Safe Speed Monitor Option Module for PowerFlex
750-Series AC Drives Safety Reference Manual, publication
750-RM001
Wiring and Grounding Guidelines for Pulse Width Provides basic information needed to properly wire and
Modulated (PWM) AC Drives, publication DRIVES-IN001 ground PWM AC drives.
PowerFlex AC Drives in Common Bus Configurations, Provides basic information needed to properly wire and
publication DRIVES-AT002 ground common bus PWM AC drives.
Safety Guidelines for the Application, Installation and Provides general guidelines for the application,
Maintenance of Solid State Control, publication SGI-1.1 installation, and maintenance of solid-state control.
A Global Reference Guide for Reading Schematic Provides a simple cross-reference of common schematic/
Diagrams, publication 100-2.10 wiring diagram symbols used throughout various parts of
the world.
Guarding Against Electrostatic Damage, publication 8000- Provides practices for guarding against Electrostatic
4.5.2 damage (ESD)
Product Certifications website, http://ab.com Provides declarations of conformity, certificates, and other
certification details.
Resource Description
Logix5000 Controllers Common Procedures, publication This publication links to a collection of programming
1756-PM001 manuals that describe how you can use procedures that
are common to all Logix5000 controller projects.
Logix5000 Controllers General Instructions, publication Provides a programmer with details about each available
1756-RM003 instruction for a Logix-based controller.
Logix5000 Controllers Process Control and Drives Provides a programmer with details about each available
Instructions, publication 1756-RM006 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 Provides procedures and specifications for the installation
1786-5.7 of ControlNet coaxial taps.
ContolNet Fiber Media Planning and Installation Guide, Provides basic information for fiber cable planning and
publication CNET-IN001 installation.
Allen-Bradley Drives Use one of the following methods to contact Automation and Control Technical
Support.
Technical Support
Online Email Telephone
www.ab.com/support/abdrives support@drives.ra.rockwell.com 262-512-8176
Title Online
Rockwell Automation Technical http://support.rockwellautomation.com/knowledgebase
Support
Product Certification Product Certifications and Declarations of Conformity are available on the
internet at www.rockwellautomation.com/products/certification.
Personal Safety
ATTENTION: 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.
Product Safety
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.
Drive Configuration
Topic Page
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
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 750-
Series Programming Manual, publication 750-PM001) or by Logic Command
(sent over a communication network or DeviceLogix™ software).
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) or by Logic
Command (sent over a communication network or DeviceLogix software).
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 non-
standard 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.
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.
Rated Voltage
Voltage
0
0
Frequency Max Frequency
Overview
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 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.
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.
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.
Modulation mode is default at space vector only because 2-phase modulation will
degrade the filter’s performance.
IMPORTANT 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.
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.
Single Phase - PWM into Resistor - No Reactor
Voltage
DC Bus
Current
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.
Single Phase - PWM into Resistor - No Reactor
Voltage
Current
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.
Single Phase - PWM into Resistor - No Reactor
Voltage
DC Bus
Current
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.”
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. . XL = 2 pi f H
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.
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.
DC Voltage Resistor Current
Resistor Current
DC Voltage
Times
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
where the drive outputs a frequency not equal to the commanded frequency. The
cause of this anomaly is the introduction of the jerk function. This bit needs to be
off during this condition.
40 Mtr Options Cfg RW 32-bit
Motor Options Configuration Integer
Configuration of motor control-related functions. For motors above 200 Hz, a carrier frequency of 8 kHz or higher is recommended. Consider drive derate and motor
lead distance restrictions.
MOTOR CONTROL
Mtr Ctrl Options
AsyncPWMLock
Common Mode
EnclsTrqProv (1)
Options
PWM FreqLock
Trq ModeStop
DB WhileStop
Trq ModeJog
Zero TrqStop
RS Adaption
Xsistor Diag
Jerk Select
Elect Stab
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Not Used
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 1 1 1 0 0 1 1 1
Bit 32 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
(1) 755 drives only.
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 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 Non-
Resettable 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.
P349 [Auto Rstrt Delay] sets the time, in seconds, between each reset/run
attempt.
Operation
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.
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.)
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.”
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.
Auto/Manual Masks
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].
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
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.
Stopped MAN
0.00 Hz F
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.
Stopped AUTO
0.00 Hz F
Host Drive
240V 4.2A
20G...D014
00
ESC REF PAR# TEXT
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.
Control Screen Key Function Map
corresponds to Navigation/Number Keys
Stopped AUTO
0.00 Hz F
REMOVE REF
HIM MANUAL
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.
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.
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.
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
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.
O
H A
XOO
+24V DI 0: Stop
OOX
XOO
DI 1: HOA Start and
Manual Control
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 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.
See the Safe Speed Monitor Option Module for PowerFlex 750-Series AC Drives
Safety Reference Manual, publication 750-RM001, for more information.
Automatic Device Automatic Device Configuration (ADC) supports the automatic download of
configuration data to a Logix controller that has an EtherNet/IP connection to a
Configuration 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 Supervisor
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.
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.
Tests
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 ].
Calculate
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.
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 Table 3.
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.
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.
Individual Tests
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
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) that is
connected to a motor shaft.
WK 2 N
Using the following formula, Tacc = -------------------------
308 t
Tacc 308 t
and rearranging it to WK 2 = --------------------------------------
N
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.
T Speed
My motor is 10hp, 1785RPM, HP = -------------------------
5252
HP 5252
and rearranging it to T = -----------------------
Speed
10 5252
So let’s plug in the numbers. T = -------------------- T = lb•ft
1785
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
Tacc 308 t
plugging these into the formula, WK 2 = -------------------------------------- WK2 = 10.76
N
After these calculations, one can conclude that the connected inertia is equal to
10.76 lb•ft. Multiplying by 0.04214011 you get 0.453 kg•m.
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.
CEMF Test
Autotune Parameters
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.
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.
Auxiliary Power Supply 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.
The auxiliary power supply module is designed to power all peripherals, I/O, and
connected feedback devices.
Bus Regulation 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.
Motoring Regenerating
With bus regulation disabled, the bus voltage can exceed the operating limit and
the drive faults to protect itself from excess voltage.
0V Fault @ Vbus Max
With bus regulation enabled, the drive can respond to the increasing voltage by
advancing the output frequency until the regeneration is counteracted. This
keeps the bus voltage at a regulated level below the trip point.
DB Bus
Motor Speed
Output Frequency
Operation
Bus voltage regulation begins when the bus voltage exceeds the bus voltage
regulation setpoint Vreg and the switches shown in Figure 1 move to the positions
shown.
SW 1 SW 2 SW 3 SW 4 SW 5
Bus Regulation Limit Bus Reg Open Closed Don’t Care
SW 3
Current Limit Level PI Gain Block
I Limit,
Proportional Channel
No Bus Reg
Integral Channel
Limit
0
SW 1
No Limit I Limit,
No Bus Reg
Frequency
Acc/Dec Rate Jerk Jerk No Limit Frequency Reference Frequency Output Frequency
Ramp Clamp Ramp Limits
SW 2 (Integrator)
Bus Reg
Speed
SW 5 Control
Frequency Setpoint Mode
Proportional Channel
SW 4
Bus Voltage Regulation Point, Vreg
PI Gain Block
Bus Reg On
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 Vreg . 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.
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.
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
<685V DC 750V DC
480 On - 8V DC
>685V DC Memory + 65V DC
880
815
DB Turn On
750
DB Turn Off
DC Volts 685
1 2
650 ve # urve #
g Cur g C
Re Re
Bus Bus ry
emo
B us M
509
453
320 360 460 484 528 576
AC Volts
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.
600 8
Stop Pressed Motor Coasts
DC Bus Volts
500
6
400
300 4
200
2
100
0 0
-0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Seconds
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 (Table 5). For example, with a DC Bus Memory at 684V
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.
500
6
400
300 4
Motor stops in just under 7 seconds instead
of the programmed 1 second decel.
200
2
100
0 0
-1 0 1 2 3 4 5 6 7 8 9
Seconds
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.
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.
500
6
400
300 4
200
Brake Current 2
100
0 0
-0.1 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Seconds
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.
10
760
10 Volts = Base Speed
Motor Speed
8
740
DC Bus Volts
6
Brake Current
720
4
700
2
680 0
660 -2
-0.2 0 0.2 0.4 0.6 0.8 1 1.2
Seconds
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.
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.
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 (Table 4). The Dynamic Brake
Regulator follows the “DB Turn On” and turn off curves. For example, with a
DC Bus Memory at 684V DC, the Bus Voltage Regulator setpoint is 742V DC
and the Dynamic Brake Regulator 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).
Motor Speed
760 8
DC Bus Volts
720 4
700 2
Brake Current
680 0
660 -2
-0.2 0 0.2 0.4 0.6 0.8 1 1.2
Seconds
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.
700
10
600
10 Volts = Base Speed
8
500
DC Bus Volts
Motor Speed 6
400
Brake
Current 4
300
2
200
100 0
0 -2
-0.2 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8
Seconds
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.
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.
PowerFlex 750-Series Bus Regulation – Both DB First SV
DC Bus Voltage DC Current Speed Fdbk
900 14
DC Bus
800
12
700
10
600
400 6
Motor Speed
300
4
200
2
100
0 0
-0.15 0.05 0.25 0.45 0.65 0.85 1.05 1.25 1.45
Seconds
Level/Gains
The following parameters are Level/Gains related to bus regulation.
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.
Configurable Human With the PowerFlex 750-Series the drives response to a HIM communication
loss (removal) is configurable. This feature is available in drives with firmware
Interface Module Removal revision 3.0 or later.
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.
Droop Feature 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.
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].
Feedback Devices There are three different feedback option modules available for PowerFlex 750-
Series 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.
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.
The Sweep function is currently not in the PowerFlex 750-Series drives frame 8
and larger.
Configuration
Disabled
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].
Scope Plots
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.
PowerFlex 753 Flying Start - Sweep Mode - Decelerating Load
Current Speed Frequency Frequency Sweep
Coasting Motor
Start Pressed
Slope determined by P359
Detection
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.
PowerFlex 753 Flying Start - Sweep Slope A
Current Speed Frequency
This plot shows the result of increasing P359 [FS Speed Reg Ki]. The slope is
extended.
PowerFlex 753 Flying Start - Sweep Slope B
Current Speed Frequency
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.
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.
PowerFlex 753 Flying Start - Rotating Load - P360 = 1, Default = 75
Current Speed Frequency
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
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
the rotating motor. See the previous plot when this parameter set to its lowest
setting.
PowerFlex 753 Flying Start - Rotating Load - P360 = 9000, Default = 75
Current Speed Frequency
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.
PowerFlex 753 Flying Start - Rotating Reverse - Sweep Mode
Current Speed Frequency
Acceleration to
Sweep Forward Commanded Speed
Controlled Decel
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.
PowerFlex 753 Flying Start - Enhanced Mode
TP 138 Current Speed Frequency Output Current
Motor “caught,” Normal Accel
Attempt to measure
counter EMF Current pulses, motor excitation
Enhanced mode - It’s the Kp in the current regulator used in the detection
process. Used along with P358.
Enhanced mode - It’s the Ki in the current regulator used in the detection
process. Used along with P357.
Enhanced mode - It’s the Ki in the speed regulator used in the detection process.
Used along with P358.
Enhanced mode - It’s the Kp in the speed regulator used in the detection process.
Used along with P357.
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.
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.
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.
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.
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
XOO
DI 1: Start
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
automatically adds this time delay and makes sure that the system is ready to start
before it receives the command.
O
H A
+24V XOO DI 0: Stop
OOX
XOO
DI 1: HOA Start
To take control of the drive speed when switching from Auto to Hand on the H-
O-A switch, the Auto/Manual feature can be used. See Auto/Manual on page 27
for more on Auto/Manual Control.
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.
O
H A
XOO
+24V DI 0: Stop
OOX
XOO
DI 1: HOA Start and
Manual Control
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).
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.
O
H A
+24V XOO DI 0: Stop
OOX
Start Relay
DI 1: HOA Start
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.
O
H A
+24V XOO DI 0: Stop and
HOA Start
OOX
Start Relay
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.
O
H A
+24V XOO DI 0: Stop
OOX
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.
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.
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.
Options
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Digital In
Port 14
Port 6
Port 5
Port 4
Port 3
Port 2
Port 1
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
(1) 755 drives only.
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.
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.
ESC PAR#
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.
ESC PAR#
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.
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.
Line Loss Mode = Coast Line Loss Mode = Decel Line Loss Mode = Continue
Recover Recover Recover
Closer Closer Closer
Trigger Trigger Trigger
Open Open Open
DC Bus Volts
DC Bus Volts
DC Bus Volts
AC Input Volts AC Input Volts AC Input Volts
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.
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].
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.
Bus Voltage 680V
620V
560V
500V
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
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.
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.
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.
Bus Voltage 680V
620V
560V
500V
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
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.
Bus Voltage 680V
620V
560V
365V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
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].
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.
0 Volts
10 Volts
When the PID is disabled the commanded speed is the ramped speed reference.
Slip
+
Comp
Slip Adder
+ Open
Linear Ramp Loop
Spd Ref and S Curve Spd Cmd
Process
+ PID
+
PID Ref
Process PID
Controller
PID Fbk PID Disabled Speed Control
When the PID is enabled the output of the PID Controller is added to the
ramped speed reference.
Slip
+ Comp
Slip Adder
+ Open
Linear Ramp Loop
Spd Ref and S Curve Spd Cmd
Process
+ PID
+
PID Ref
Process PID
Controller
PID Fbk PID Enabled Speed Control
Exclusive Mode
In this mode, the output of PID regulator is the speed reference, and does not
“trim” a master speed reference. This mode is appropriate when speed is
unimportant and the only thing that matters is satisfying the control loop. In the
pumping application example below, the reference or setpoint is the required
pressure in the system. The input from the transducer is the PID feedback and
changes as the pressure changes. The drive output frequency is then increased or
decreased as needed to maintain system pressure regardless of flow changes. With
the drive turning the pump at the required speed, the pressure is maintained in
the system.
Pump
Pressure
Motor Transducer
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.
Slip
+
Comp
Slip Adder
+ Open
Linear Ramp Loop
Spd Ref and S Curve Spd Cmd
Process
PID
PID Ref
Process PID
Controller
PID Fbk PID Disabled Speed Control
When the PID is enabled, the speed reference is disconnected and PID Output
has exclusive control of the commanded speed, passing through the linear ramp
and S curve.
Slip
+
Comp
Slip Adder
+ Open
Linear Ramp Loop
Spd Ref and S Curve Spd Cmd
Process
PID
PID Ref
Process PID
Controller
PID Fbk PID Enabled Speed Control
PID Configuration
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.
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Anti Windup
Options
Percent Ref
Zero Clamp
Preload Int
Stop Mode
Ramp Ref
Fdbk Sqrt
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 = Disabled
1 = Enabled
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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
sooner, however if the step is too large the drive can go into current limit and
extend the acceleration.
Diagram A Diagram B
PID Enabled
Speed Command
PID Preload Value = 0 PID Preload Value > 0
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.
PID Enabled
Speed Command
When the PID is configured to have exclusive control of the commanded speed
and the drive is in current limit or voltage limit the integrator is preset to the
commanded speed so that it knows where to resume when no longer in limit.
Ramp Ref
The PID Ramp Reference feature is used to provide a smooth transition when
the PID is enabled and the PID output is used as a speed trim (not exclusive
control). When PID Ramp Reference is selected in the PID Configuration
parameter, and PID is disabled, the value used for the PID reference 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. S-
curve is not available as part of the PID linear ramp.
Zero Clamp
This feature limits the possible drive action to one direction only. Output from
the drive 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.
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
Normalized SQRT (Feedback)
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
Normalized Feedback
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.
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.
DigInCfg DigIn PI_Control PI_Status
Running Running .PI_Enable .PI_Enable .PI_Enable Signal Loss .Enable
DigInCfg PI_Control
.PI_Enable .PI_Enable
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.
DigInCfg DigIn PI_Status
.PI_Hold .PI_Hold .PI_Hold
DigInCfg PI_Control
.PI_Hold .PI_Hold
Current Lmt
or Volt Lmt
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.
PID Status
P1089 [PID Status] parameter is a set of bits that indicate the status of the
process PID controller.
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
PID Enabled
PID In Limit
Options
PID Reset
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
PID Hold
APPLICATIONS
Process PID
0 = Condition False
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 = Condition True
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
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%.
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.
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.
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.
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.
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.
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.
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.
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.
Reset Parameters to Factory 1. Access the Status Screen on the 20-HIM-A6 or 20-HIM-CS6 Human
Interface Module.
Defaults
Stopped AUTO
0.00 Hz F
Host Drive
240V 4.2A
20G...D014
00
ESC REF PAR# TEXT
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.
Stopped AUTO
0.00 Hz F
MEMORY
HIM CopyCat
Set Defaults
00
ESC
6. Press the Enter (5) key to display the Set Defaults screen.
Host and Ports (preferred) Pop-up Box This Port Only Pop-up Box
Press the ENTER soft key to affirm and set most parameters Press the MOST soft key to set MOST settings for the selected
for the Host Drive and port devices to factory defaults. In this port device to factory defaults. In this case, refer to the Host
case, refer to the Host Drive and port device user manuals for Drive User Manual for the settings that will NOT be restored.
the settings that will NOT be restored—or press the ESC soft Press the ALL soft key to set ALL settings for the selected port
key to cancel. 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.
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.
Sleep/Wake Operation
Drive
Run
Sleep/Wake
Function
Start
Stop
Sleep Timer
Satisfied
Sleep Level
Satisfied
Wake Timer
Satisfied
Wake Level Wake Sleep Wake Sleep
Time Time Time Time
Satisfied
Wake Level
Sleep Level Example Conditions
Wake Time = 3 Seconds
Analog Signal Sleep Time = 3 Seconds
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 programmed (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
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
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.
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.
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.
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 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.
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
CommutNotCfg
Options
Profiler (1)
Precharge
Database
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Startup
Faulted
Enable
Safety
Alarm
Sleep
Stop
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Bit 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
(1) PowerFlex 755 drives only. 0 = False, 1 = True
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].
DIAGNOSTICS
Status
Options
Precharge
Database
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Profilier
Startup
Faulted
Enable
Safety
Alarm
Sleep
Stop
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Bit 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
0 = False, 1 = True
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 additional
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).
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 The most
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 Same as “Ramp”
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). Less than Ramp or
May have to adjust P397 [DC Brake Kp]. Fast Brake
DCBrkAutoOff Applies DC braking until zero speed is reached or DC brake time is reached, Less than Ramp or
whichever is shorter. Fast Brake
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
Brake / DC Brake
Auto Off
Coast
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
Time
Stop Command Coast Time is load dependent
DC Brake
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
Time
(B) (C) (A)
Stop Command
DC Hold Time
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).
Ramp
Bus Voltage
Output Voltage
Output Current
Motor Speed
Output Current
Command Speed
Output Voltage
DC
Hold
Level
Time
Stop Command Zero Command Speed DC Hold Time
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).
Ramp to Hold
Time
DC Hold for
Stop Command Zero Command Speed indeterminate Start Command
amount of time.
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.
Fast Brake
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
Time
Stop Command
IMPORTANT For this feature to function properly the active [Bus Reg Mode A/B] must be
set to 1 “Adjust Freq” and not be 0 “Disabled.”
Example
Block Diagram
Current Regulator
Brake
Level
Bus Voltage
Gain
Reference
Frequency
Bus Voltage
Output Voltage
Current Limit
Output Current
Motor Speed
Time
Stop Command Zero Speed
Current Limit stop is not typically set up as the normal Stop mode. Usually the
normal stop is programmed at some ramp rate. For the current limit stop a digital
input is used for the function. However, you certainly could set the normal stop
as CurrentLimit Stop
Current limit stop ramp rate is 0.1 second and is not programmable
Example
Current Limit Stop
DC Bus Voltage Motor Current P685 Motor Speed
DC Bus Voltage
In this example the current limit was set high enough to allow the full rating of
the drive to be used in the stop sequence.
Example
Current Limit - Lowered Limit
DC Bus Voltage Motor Current P685 Motor Speed
DC Bus Voltage
In this example the current limit was set at some value such that when the stop
was issued the output current was clamped at that setting. Note the decel time is
extended.
Voltage Class PowerFlex drives are sometimes referred to by voltage class, which identifies the
general input voltage to the drive. P305 [Voltage Class] includes a range of
voltages. For example, a 400V class drive has an input voltage range of 380…480V
AC. While the hardware remains the same for each class, other variables, such as
factory defaults, catalog number, and power unit ratings change. In most cases the
voltage of a drive can be reprogrammed to another value within the class by
resetting the defaults to something other than factory settings.
P305 [Voltage Class], is required by the drive when parameter downloads occur
and is generally not programmed individually. This parameter provides a “Low
Voltage” and “High Voltage” setting. The default value is dependent upon the
voltage that matches the catalog number (for example 400V or 480V). For
example, a drive shipped as 400V (catalog code “C”) has a default of “Low
Voltage” for P305 [Voltage Class]. A drive shipped as 480V (catalog code “D”)
has a default of “High Voltage.”
When a change is made to P305 [Voltage Class], the continuous current rating of
the drive changes by an amount equal to the published difference between catalog
numbers. With a change to the current rating, review P422 [Current Limit 1]
and P423 [Current Limit 2].
Also note that a Reset to Defaults “All” resets the voltage to the original factory
setting.
Topic Page
Analog Inputs 105
Analog Outputs 113
Digital Inputs 119
Digital Outputs 130
PTC Motor Thermistor Input 152
Analog Inputs There are two analog inputs per I/O module. Up to four I/O modules can be
mounted in the drive ports. See the PowerFlex 750-Series Installation
Instructions, publication 750-IN001, for valid ports. Accessing the analog input
parameters is done by selecting the port that the module is mounted in, then
accessing the Analog Input group of parameters.
Analog Scaling
Example 1
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P547 [Spd Ref A AnlgHi] = 60 Hz
• P548 [Spd Ref A AnlgLo] = 0 Hz
• P61 [Anlg In1 Hi] = 10V
• P62 [Anlg In1 Lo] = 0V
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hertz
Example 2
Consider the following setup:
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P61 [Anlg In1 Hi] = 10V
• P62 [Anlg In1 Lo] = 0V
• P547 [Spd Ref A AnlgHi] = 60 Hz
• P548 [Spd Ref A AnlgLo] = 0 Hz
• P520 [Max Fwd Speed] = 45 Hz
• P522 [Min Fwd Speed] = 15 Hz
This configuration is used when non-default settings are desired for minimum
and maximum speeds, but full range (0…10V) scaling from 0…60 Hz is still
desired.
P522 [Min Fwd Speed] P520 [Max Fwd Speed]
P61 [Anlg In1 Hi]
10V
Command Frequency
Example 3
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P547 [Spd Ref A AnlgHi] = 30 Hz
• P548 [Spd Ref A AnlgLo] = 0 Hz
• P61 [Anlg In1 Hi] = 10V
• P62 [Anlg In1 Lo] = 0V
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hertz
Example 4
• P255 [Anlg In Type], Bit 0 = “1” (Current)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P547 [Spd Ref A AnlgHi] = 60 Hz
• P548 [Spd Ref A AnlgLo] = 0 Hz
• P61 [Anlg In1 Hi] = 20 mA
• P62 [Anlg In1 Lo] = 4 mA
10
8
6
4
2
0
0 10 20 30 40 50 60
Output Hertz
Example 5
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P547 [Spd Ref A AnlgHi] = 0 Hz
• P548 [Spd Ref A AnlgLo] = 60 Hz
• P61 [Anlg In1 Hi] = 10V
• P62 [Anlg In1 Lo] = 0V
This configuration is used to invert the operation of the input signal. Here,
maximum input (10V) represents 0 Hz and minimum input (0V) represents
60 Hz.
10
9
8
7
6
Input Volts
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hertz
Example 6
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P545 [Spd Ref A Sel] = “Analog In 1”
• P547 [Spd Ref A AnlgHi] = 60 Hz
• P548 [Spd Ref A AnlgLo] = 0 Hz
• P61 [Anlg In1 Hi] = 5V
• P62 [Anlg In1 Lo] = 0V
This configuration is used when the input signal is 0…5V. Here, minimum input
(0V) represents 0 Hz and maximum input (5V) represents 60 Hz. This provides
full scale operation from a 0…5V source.
5
4.5
4
3.5
3
Input Volts
2.5
2
1.5
1
0.5
0
0 10 20 30 40 50 60
Output Hertz
Example 7
• P255 [Anlg In Type], Bit 0 = “0” (Voltage)
• P675 [Trq Ref A Sel] = “Analog In 1”
• P677 [Trq Ref A AnlgHi] = 200%
• P678 [Trq Ref A AnlgLo] = 0%
This configuration is used when the input signal is 0…10V. The minimum input
of 0V represents a torque reference of 0% and maximum input of 10V represents
a torque reference of 200%.
10
9
8
7
6
Input Volts
5
4
3
2
1
0
0 20 40 60 80 100 120 140 160 180 200
Torque Ref %
Square Root
The square root function can be applied to each analog input through the use of
P256 [Anlg In Sqrt]. Enable the function if the input signal varies with the square
of the quantity (for example drive speed) being controlled.
If the mode of the input is bipolar voltage (-10…10V), then the square root
function returns 0 for all negative voltages.
The function uses the square root of the analog value as compared to its full scale
(for example 5V = 0.5 or 50% and 0.5 = 0.707 ) and multiplies it times the full scale of
what it controls (for example 60 Hz).
Setting high and low values to 0V, 10V, 0 Hz, and 60 Hz, the expression reduces
to the following:
Analog Value- 60 Hz
-----------------------
10V
10
9
8
7
6
5
4
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10
Signal loss detection can be detected for each analog input. P47 [Anlg In Loss
Sts] bits 0, 1, 2 indicate if the signal is lost. Bit 0 indicates that one or both signals
are lost. P53 [Anlg In0 LssActn] and P63 [Anlg In1 LssActn] defines what action
the drive takes when loss of any analog input signal occurs.
Selects drive action when an analog signal loss is detected. Signal loss is defined as
an analog signal less than 1V or 2 mA. The signal loss event ends and normal
operation resumes when the input signal level is greater than or equal to 1.5V or
3 mA.
• “Ignore” (0) – No action is taken.
• “Alarm” (1) – Type 1 alarm indicated.
• “Flt Minor” (2) – Minor fault indicated. If running, drive continues to
run. Enable with P950 [Minor Flt Cfg]. If not enabled, acts like a major
fault.
• “FltCoastStop” (3) – Major fault indicated. Coast to Stop.
• “Flt RampStop” (4) – Major fault indicated. Ramp to Stop.
• “Flt CL Stop” (5) – Major fault indicated. Current Limit Stop.
• “Hold Input” (6) – Holds input at last value.
• “Set Input Lo” (7) – Sets input to P52 [Anlg In0 Lo] or P62 [Anlg In1
Lo].
• “Set Input Hi” (8) – Sets input to P51 [Anlg In0 Hi] or P61 [Anlg In1
Hi].
If the input is in Current mode, 4 mA is the normal minimum usable input value.
Any value below 3.2 mA is interpreted by the drive as a signal loss, and a value of
3.8 mA is required on the input for the signal loss condition to end.
If the input is in Unipolar Voltage mode, 2V is the normal minimum usable input
value. Any value below 1.6V is interpreted by the drive as a signal loss, and a value
of 1.9V is required on the input for the signal loss condition to end. No signal loss
detection is possible while an input is in Bipolar Voltage mode. The signal loss
condition never occurs even if signal loss detection is enabled.
Analog Outputs There are two analog outputs per I/O module. Up to five I/O modules can be
mounted in the drive ports. See 750-IN001 for valid ports. Accessing the analog
output parameters is done by selecting the port that the module is mounted in
then accessing the Analog Output group of parameters.
Parameters 75 and 85 [Anlg Outn Select] are use to specify the signal used on
Analog Outputs 1 and 2, respectively. These parameters can be programmed to
the following selections.
Parameter No. Parameter Name
1 Output Frequency
2 Commanded SpdRef
3 Mtr Vel Fdbk
4 Commanded Trq
5 Torque Cur Fdbk
6 Flux Cur Fdbk
7 Output Current
8 Output Voltage
9 Output Power
11 DC Bus Volts
Scaling
The scaling for the analog output is defined by entering analog output voltages
into two parameters, P91 [Anlg Out1 Lo] and P90 [Anlg Out1 Hi]. These two
output voltages correspond to the bottom and top of the possible range covered
by the quantity being output. Scaling of the analog outputs is accomplished with
low and high analog parameter settings that are associated with fixed ranges (see
the PowerFlex 750-Series Programming Manual, publication 750-PM001,) for
each target function. Additionally, the PowerFlex 755 contains an adjustable scale
factor to override the fixed target range. P77 [Anlg Out0 Data] and 82 [Anlg
Out0 Val] are described in the following charts.
Case 1
P77 [Anlg Out0 Data] P78 [Anlg Out0 DataHi] P79 [Anlg Out0 DataLo] P82 [Anlg Out0 Val] P80 [Anlg Out0 Hi] P81 [Anlg Out0 Lo] P76 [Anlg Out0 Stpt]
Case 1: This shows P77 [Anlg Out0 Data] the units are consistent with the
selection of P75 [Anlg Out0 Sel]. In this case, the analog out select is set to P3
[Mtr Vel Fdbk] and the units are in rpm. P80 [Anlg Out0 Hi], P81 [Anlg Out0
Lo], P78 [Anlg Out0 DataHi], and P79 [Anlg Out0 DataLo] are all at default.
The motor was started and ramped to 1800 rpm. Note that P82 [Anlg Out0 Val]
remained zero.
Case 2: Here the P80 [Anlg Out0 Hi] is changed to 9 and P81 [Anlg Out0 Lo] is
changed to 1. As the motor ramps up and down, there is no change in the value or
scaling of P77 [Anlg Out0 Data]. Note that P82 [Anlg Out0 Val] is still zero.
Case 3: Now P78 [Anlg Out0 DataHi] is changed to 1800 and P79 [Anlg Out0
DataLo] is left at zero. When started P82 [Anlg Out0 Val] starts at 1 and reaches
9 when the motor speed is at maximum.
Case 4: In this section the P80 [Anlg Out0 Hi] and P81 [Anlg Out0 Lo] were
reversed in value. Now when the motor ramps up and down P82 [Anlg Out0 Val]
is just the opposite. It starts out at 9 and is at 1 at full speed.
Case 2
P77 [Anlg Out0 Data] P78 [Anlg Out0 DataHi] P79 [Anlg Out0 DataLo] P82 [Anlg Out0 Val]
When the motor speed reaches 500 rpm, [Anlg Outn Val] begins to increase from 0.
When the motor speed reaches 1500 rpm, [Anlg Outn Val] is at maximum of 10.
Case 3
P77 [Anlg Out0 Data] P78 [Anlg Out0 DataHi] P79 [Anlg Out0 DataLo] P82 [Anlg Out0 Val] P80 [Anlg Out0 Hi] P81 [Anlg Out0 Lo]
Absolute (Default)
Certain quantities used to drive the analog output are signed, for example the
quantity can be both positive and negative. You have the option of having the
absolute value (value without sign) of these quantities taken before the scaling
occurs. Absolute value is enabled separately for each analog output via the bit
enumerated P71 [Analog Out Abs].
Setpoint
Digital Inputs Physical inputs are programmed to desired digital input functions. These
parameters cannot be changed while the drive is running.
Technical Information
The PowerFlex 753 drive has three digital inputs on its main control board:
• Di 0 – Configured for 115V AC or 24V DC
– Shared common (Di C) between Di 0ac and Di 0dc terminals
– TB3 - bottom of the main control board
• Di 1 and Di 2 – Configured for 24V DC
– Shared common (Di C) for Di 1 and Di 2
– TB1 - lower front of the main control board
PowerFlex 753 Main Control Board I/O TB1 wiring examples are included in
the PowerFlex 750-Series AC Drives Installation Instructions, publication 750-
IN001.
The PowerFlex 755 drive has one digital input on its main control board:
• Di0 – configured for 115V AC or 24V DC
– Shared common (Di C) between Di 0ac and Di 0dc terminals
– TB1 - bottom of the main control board
There are also PowerFlex 750-Series option modules that expand the amount of
digital inputs that can be used in both the PowerFlex 753 and 755 drives.
20-750-2262C-2R / 20-750-2263C-1R2T
• Six 24V DC input terminals:
– Labeled as Di 0, Di 1, Di 2, Di 3, Di 4 and Di 5
– Shared common (Di C)
– TB1 - front of the option module
20-750-2262D-2R
• Six 115V AC input terminals:
– Labeled as Di 0, Di 1, Di 2, Di 3, Di 4 and Di 5
– Shared common terminal (Di C)
– TB1 - front of the option module
PowerFlex 750-Series Option Modules I/O TB1 wiring examples are included in
the PowerFlex 750-Series AC Drives Installation Instructions, publication 750-
IN001.
Configuration
Operation for DI Run type parameters can be defined by P150 [Digital In Cfg]:
• “Run Edge” (0) – Control function requires a rising edge (open to close
transition) for the drive to run.
• “Run Level” (1) – As long as a separate “Stop” command is not issued, the
level alone (no rising edge required) determines whether the drive runs.
When set to 1 “Run Level” the absence of a run command is indicated as a
stop asserted and P935 [Drive Status 1] Bit 0 is low.
ATTENTION: 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.
Functional Descriptions
DI Enable
Closing this input lets the drive run when a Start command is issued. If the drive
is already running when this input is opened, the drive will coast stop and
indicate “not enabled” on the HIM (if present). This is not considered a fault
condition, and no fault is generated. If this function is not configured, the drive is
considered enabled.
IMPORTANT If the ENABLE (J1) jumper is removed, the Di 0 becomes a hardware enable.
For the PowerFlex 753, Di 0 is found on TB3 and for the PowerFlex 755, Di 0 is
found on TB1.
DI Clear Fault
The “Clear Fault” digital input function lets an external device reset drive faults
through the terminal block. An open to closed transition on this input causes an
active fault (if any) to be reset.
DI Aux Fault
This input function is normally closed and lets external equipment fault the
drive. When this input opens, the drive faults on a F2 “Auxiliary Input” fault
code. If this input function is not configured, the fault will not occur.
DI Stop
An open input causes the drive to stop and become “Not Ready.” A closed input
lets the drive run when given a Start or Run command. If “Start” is configured,
then “Stop” must also be configured, otherwise, a digital input configuration
alarm occurs.
P370 [Stop Mode A] and P371 [Stop Mode B] dictate the drive’s stop action.
Refer to Stop Modes on page 96 for more details.
DI Coast Stop
With this digital input function, an open input causes the drive to Coast-to-Stop.
The drive acknowledges the stop command by shutting off the output transistors
and releasing control of the motor. The load/motor will coast or free spin until
the mechanical energy is dissipated.
DI Start
An open to closed transition while the drive is stopped causes the drive to run in
the current direction, unless the “Stop” input function is open. If “Start” is
configured, then a “Stop” must also be configured.
DI Fwd Reverse
This digital input function is one of the ways to provide direction control when
the “Start” or “Run” functions (not combined with direction) are used. An open
input sets direction to forward. A closed input sets direction to reverse. If state of
input changes and drive is running or jogging, the drive changes direction.
The table below describes the basic action taken by the drive in response to
particular states of these input functions.
Run Forward Run Reverse Action
Open Open Drive stops, terminal block relinquishes direction ownership.
Open Closed Drive runs in reverse direction, terminal block takes direction ownership.
Closed Open Drive runs in forward direction, terminal block takes direction ownership.
Closed Closed Drive continues to run in current direction, but terminal block maintains
direction ownership.
It is not necessary to program both “Run Forward” and “Run Reverse.” These
two functions operate with or without each other.
IMPORTANT Direction control is an “Exclusive Ownership” function (see Owners). This means that
only one control device (terminal block, DPI device, HIM, and so forth) at a time is
allowed to control direction at a time. The terminal block must become direction
“owner” before it can be used to control direction. If another device is currently the
direction owner (as indicated by P922 [Dir Owner]), it is not possible to start the drive
or change direction by using the terminal block digital inputs programmed for both
Run and Direction control (for example Run/Fwd).
DI Run
This digital input function is similar to “Run Forward” and “Run Reverse”
settings. The only difference being that direction is determined by another input
or another device’s command (HIM or communication adapter).
An open to closed transition on one input or both inputs while the drive is
stopped causes the drive to jog unless the “Stop” input function is configured and
open. The table below describes the actions taken by the drive in response to
various states of these input functions.
Jog Forward Jog Reverse Action
Open Open Drive stops if already jogging, but can be started by other means. Terminal block
relinquishes direction ownership.
Open Closed Drive jogs in reverse direction. Terminal block takes direction ownership.
Closed Open Drive jogs in forward direction. Terminal block takes direction ownership.
Closed Closed Drive continues to jog in current direction, but terminal block maintains
direction ownership.
The drive will not jog while the drive is running or while the “Stop” input is open.
Start has precedence.
DI Jog 1, DI Jog 2
These digital input functions are similar to “Jog Forward” and “Jog Reverse” with
the only difference being that direction is determined by another input or
another device’s command (HIM or communication adapter). In addition, these
settings use either P556 [ Jog Speed 1] or P557 [ Jog Speed 2], respectively. In
Unipolar mode, the absolute value is used along with a separate direction
command. In Bipolar mode, the polarity of P556 [ Jog Speed 1] or P557 [ Jog
Speed 2] determines the direction of jog.
DI Manual Ctrl
The digital input function works in conjunction with the overall Auto/Manual
function. When this input is closed, it overrides other speed references, but only
if another device (HIM) did not have ownership of the Manual state. If the
digital input is successful in gaining manual control, the speed reference comes
from P563 [DI ManRef Sel], which can be set to any of the Analog Inputs, Preset
Speeds, MOP Reference, or an applicable Port Reference.
Associated with this digital input function, there is the ability to configure the
drive to switch smoothly from an automatic (communicated) speed reference to
manual speed reference produced by the Human Interface Module (HIM).
When the drive is commanded to switch from the automatic (communicated)
speed reference to the manual reference via a digital input, it preloads the last
value from the speed feedback into the HIM. Then the operator can modify the
manual reference on the HIM. This avoids a step change in speed that otherwise
occurs from the switch. Use this feature by configuring P328 [Alt Man Ref Sel],
P331 [Manual Preload], P172 [DI Manual Ctrl], and P563 [DI ManRef Sel].
This feature requires revision 2.001 of 20-HIM-A6 firmware or later.
DI Speed Sel 2 DI Speed Sel 1 DI Speed Sel 0 Auto Reference Source (Parameter)
0 0 0 Reference A (P545 [Spd Ref A Sel])
0 0 1 Reference A (P545 [Spd Ref A Sel])
0 1 0 Reference B (P550 [Spd Ref B Sel])
0 1 1 Preset Speed 3 (P573 [Preset Speed 3])
1 0 0 Preset Speed 4 (P574 [Preset Speed 4])
1 0 1 Preset Speed 5 (P575 [Preset Speed 5])
1 1 0 Preset Speed 6 (P576 [Preset Speed 6])
1 1 1 Preset Speed 7 (P577 [Preset Speed 7])
DI HOA Start
This digital input function provides Hand-Off-Auto control. It functions like a
three-wire start signal; with the exception, that it does not require the DI Stop to
be high for a full input cycle before the drive looks for a rising edge on DI HOA
Start. Use this feature by configuring P176 [DI HOA Start].
DI Accel 2, DI Decel 2
These digital input functions toggle between primary and secondary ramp rates.
For example, with a digital input programmed to P179 [DI Accel 2], an open
digital input follows P535 [Accel Time 1]. A closed digital input follows P536
[Accel Time 2].
DI Stop Mode B
This digital input function selects between two different drive Stop modes. If the
input is open, then P370 [Stop Mode A] selects which Stop mode to use. If the
input is closed, then P371 [Stop Mode B] selects which Stop mode to use. If this
input function is not configured, then P370 [Stop Mode A] always selects which
Stop mode to use. See also Stop Modes on page 96 for more details.
DI BusReg Mode B
This digital input function selects how the drive regulates excess voltage on the
DC bus. If the input is open, then P372 [Bus Reg Mode A] selects which bus
regulation mode to use. If the input is closed, then P373 [Bus Reg Mode B]
selects which bus regulation mode to use. If this input function is not configured,
then P372 [Bus Reg Mode A] always selects which bus regulation mode to use.
See also Bus Regulation on page 41 for more details.
DI PwrLoss ModeB
This digital input function selects between two different drive power loss modes.
If the input is open, P450 [Pwr Loss Mode A] dictates the drive’s action during
the Power Loss mode. If the input is closed, P371 [Stop Mode B] dictates the
drive’s action during the power loss. If this input function is not configured, P450
[Power Loss Mode A] always dictates the drive’s action during the power loss. See
also Power Loss on page 72 for more details.
DI Pwr Loss
The drive contains a sophisticated algorithm to manage initial application of
power as well as recovery from a partial power loss event. This digital input
function is used to force the drive into a power loss condition. If this input is
open, the drive’s internal algorithm dictates the power loss condition. If the input
is closed, the algorithm is overridden and the drive is externally forced into a
power lost condition. P449 [Power Loss Actn] configures the drive’s response to a
power loss time out condition and P452 [Pwr Loss A Time] or P455 [Pwr Loss B
Time] set the time that the drive remains in Power Loss mode before a fault
occurs. See also Power Loss on page 72 for more details.
DI Precharge
This digital input function is used to manage disconnection from a common DC
bus. If the input is closed, this indicates that the drive is connected to common
DC bus and normal precharge handling can occur, and that the drive can run
(start permissive). If the physical input is open, this indicates that the drive is
disconnected from the common DC bus, and the drive enters the precharge state
and initiates a coast stop immediately to prepare for reconnection to the bus. If
this input function is not configured, then the drive assumes that it is always
connected to the DC bus, and no special precharge handling is done.
DI Prchrg Seal
This digital input function is used to force a unique fault when an external
precharge circuit opens. P323 [Prchrg Err Cfg] dictates the action taken when an
external precharge circuit has opened.
DI PID Enable
If this digital input function is closed, the operation of the Process PID loop is
enabled. If this input function is open, the operation of the Process PID loop is
disabled.
DI PID Hold
If this input function is closed, the integrator for the Process PID loop is held at
the current value. If this input function is open, the integrator for the Process
PID loop is allowed to increase.
DI PID Reset
If this input function is closed, the integrator for the Process PI loop is reset to 0.
If this input function is open, the integrator for the Process PI loop integrates
normally.
DI PID Invert
If this input function is closed, the PI Error is inverted. If this input function is
open, the PI Error is not inverted.
DI Torque StptA
This digital input function is used to force P676 [Trq Ref A Stpt] as the source
for Torque Reference A, regardless of the setting in P675 [Trq Ref A Sel]. Used
when the drive is in a mode that is commanding torque. Refer to P309
[SpdTrqPsn Mode A], P310 [SpdTrqPsn Mode B], P311 [SpdTrqPsn Mode C],
and P312 [SpdTrqPsn Mode D].
Status
For the PowerFlex 753 main control board Digital Inputs (Di) 0, 1, and 2, P220
[Digital In Sts] Bits 0, 1 and 2 represents its respective inputs status. For the
PowerFlex 755 main control board Digital Inputs (Di) 0, P220 [Digital In Sts]
Bit 0 represents its respective digital input status. For the PowerFlex 750-Series
Option Module Digital Inputs (Di) 0, 1, 2, 3, 4, and 5, P1 [Dig In Sts] Bits 0, 1, 2,
3, 4, and 5 represents its respective digital input status. When the bit associated
with the digital input is on, depicted by a 1, this means that the drive recognizes
that the digital input is on. When the bit associated with the digital input is off,
represented by a 0, this means that the drive recognizes that the digital input is
off.
Configuration Conflicts
If you configure the digital inputs so that one or more selections conflict with
each other, one of the digital input configuration alarms is asserted. As long as the
Digital Input Conflict exists, the drive will not start. These alarms are
automatically cleared by the drive as soon as the parameters are changed to
remove the conflicts. These are examples of configurations that cause an alarm:
• Configuring both the “Start” input function and the “Run Forward” input
function at the same time. “Start” is used only in “3-wire” Start mode, and
“Run Forward” is used only in “2-wire” Run mode, therefore, do not
configured at the same time.
• Configuring the same toggle input function (for instance “Fwd Reverse”)
to more than one physical digital input simultaneously.
These alarms, called Type 2 Alarms, are different from other alarms in that it is
not possible to start the drive while the alarm is active. It is possible for any of
these alarms to occur while the drive is running, because all digital input
configuration parameters can be changed only while the drive is stopped.
Whenever one or more of these alarms is present, the drive ready status becomes
“not ready” and the HIM displays a conflict message. In addition, the drive status
light flashes yellow. Refer to the PowerFlex 750-Series Programming Manual,
publication 750-PM001, for a complete list of Type 2 Alarms.
DigIn Cfg B
Digital input conflict. Input functions that cannot exist at the same time have
been selected. Correct Digital Input configuration.
DigIn Cfg C
Digital input conflict. Input functions that cannot be assigned to the same digital
input have been selected. Correct Digital Input configuration.
Block Diagrams
Figure 8 - PowerFlex 753
[Dig In Filt Mask] [Digital In Sts]
In2 Filter
[Dig In Filt]
In1 Filter
Com
In0
(115V AC)
Com
In0
(24V DC)
In0
(115V AC)
Com
[Dig In Filt]
In5 Filter
[Dig In Filt Mask]
[Dig In Filt]
In4 Filter
[Dig In Filt Mask]
[Dig In Filt]
In3 Filter
[Dig In Filt Mask]
[Dig In Filt]
In2 Filter
[Dig In Filt Mask] [Dig In Filt]
In1 Filter
[Dig In Filt Mask]
[Dig In Filt]
In0 Filter
[Dig In Filt Mask]
Com
Digital Outputs The PowerFlex 753 has one transistor output and one relay output embedded on
its main control board.
The transistor output is on TB1 at the lower front of the main control board.
Terminal Name Description Rating
T0 Transistor Output 0 Transistor Output 48V DC, 250 mA maximum load.
Open drain output.
The relay output is on TB2 at the bottom of the main control board.
Terminal Name Description Rating
R0NC Relay 0 N.C. Output Relay 0 normally closed 240V AC, 24V DC, 2A max
contact Resistive Only
R0C Relay 0 Common Output Relay 0 Common
R0NO Relay 0 N.O. Output Relay 0 normally open contact 240V AC, 24V DC, 2A max
General Purpose (Inductive) / Resistive
The PowerFlex 755 has no outputs embedded on its Main Control Board.
There are PowerFlex 750-Series Option Modules that expand the amount of
digital outputs that can be used in both the PowerFlex 753 and 755 drives.
Configuration
Each digital output can be programmed to change state based on one of many
different conditions. These conditions can fall into different categories.
• Drive status conditions (fault, alarm, and reverse).
• Level conditions (DC bus voltage, current, and frequency)
• Controlled by a digital input.
• Controlled by the network.
• Controlled by DeviceLogix software.
For PowerFlex 750-Series drives utilizing an option module, the table below
shows an overview of the selectable configurations for the drive’s digital output
Sel parameters.
Parameter No. Parameter Name Description
(1)
220 Digital In Sts Status of the digital inputs resident on the main control board (Port 0).
227(1) Dig Out Setpoint Controls Relay or Transistor Outputs when chosen as the source. Can be
used to control outputs from a communication device using DataLinks.
233(1) RO0 Level CmpSts Status of the level compare, and a possible source for a relay or transistor
output.
720 PTP PsnRefStatus Displays the current operating status of the Point-To-Point Position
Planner in the Position Referencing.
724 Psn Reg Status Indicates status of position control logic.
730 Homing Status Indicates status of position control logic.
933 Start Inhibits Indicates which condition is preventing the drive from starting or running.
935 Drive Status 1 Present operating condition of the drive.
936 Drive Status 2 Present operating condition of the drive.
937 Condition Sts 1 Status of conditions that can result in the drive taking action (faulting),
based on configuration of protective functions.
945 At Limit Status Status of dynamic conditions within the drive that are either active or a
limit is being applied.
952 Fault Status A Indicates the occurrence of conditions that have been configured as faults.
These conditions are from P937 [Condition Sts 1].
953 Fault Status B Indicates the occurrence of conditions that have been configured as faults.
959 Alarm Status A Indicates the occurrence of conditions that have been configured as
alarms. These events are from P937 [Condition Sts 1].
960 Alarm Status B Indicates the occurrence of conditions that have been configured as
alarms.
961 Type 2 Alarms Indicates the occurrence of conditions that have been configured as
alarms.
1089 PID Status Status of the Process PI regulator.
1103(2) Trq Prove Status Displays the status bits for TorqProve.
1210(2) Profile Status Indicates status of speed profile/position indexer control logic.
1(3)(4) Dig In Sts Status of the digital inputs.
7(3)(4) Dig Out Setpoint Controls Relay or Transistor Outputs when chosen as the source. Can be
used to control outputs from a communication device using DataLinks.
13(3)(4) RO0 Level CmpSts Status of the level compare, and a possible source for a relay or transistor
output.
50(5) DLX DigOut Sts Provides the individual on/off status of the DLX Logic Command word bits.
51(5) DLX DigOut Sts2 Provides the individual on/off status of the 16 DLX DOPs.
(1) PowerFlex 753 drives only.
(2) PowerFlex 755 drives only.
(3) Option modules can be used in Ports 4, 5, and 6 of PowerFlex 753 drives.
(4) Option modules can be used in Ports 4, 5, 6, 7, and 8 of PowerFlex 755 drives.
(5) Port 14: DeviceLogix software parameters.
Example
Below is an example of a PowerFlex 753 drive’s utilizing an embedded digital
output Sel parameter being configured such that the output energizes when a
fault is present on the drive.
Example
For parameters that are not configurable through the parameter properties’
“Value” tab pull-down graphic user interface (GUI), you can utilize the “Numeric
Edit” tab to alternatively configure the digital output for a desired function.
You can see below that you cannot select Port 10, Inverter section in the Value tab
pull-down GUI.
We look through the Port 10, Inverter section parameters and find that P13
[Alarm Status] Bit 0 shows if there is an active alarm on Inverter 1 section.
Within the Numeric Edit tab we can configure the digital output for the desired
function. See below.
Once the parameter is configured within the Numeric Edit tab, you can Click
OK, or you can go back to the Value tab to see what populates in the pull-down
GUI, then Click OK.
Level Conditions
A desired level function needs to be programmed into the “Level Sel” parameter,
depending on the output being used. If the value for the specified function
(frequency, current, and so forth) is greater than equal to or less than the
programmed limit dictated by the “Level” parameter, the output activates or
deactivates depending on how the “Sel” parameter is configured.
Notice that the Level Select parameters do not have units. The drive assumes the
units and the minimum/maximum values from the selected parameter function.
For example, if the “Level Sel” is programmed for P943 [Drive Temp Pct], which
indicates operating temperature of the drive power section (heat sink), its units
are in percentage of the maximum heat sink temperature with minimum/
maximum values of -200/200 percent.
For the PowerFlex 750-Series drives utilizing an Option Module, the table below
shows an overview of the selectable configurations for the drive’s Digital Output
“Level Sel” parameters.
Parameter No. Parameter Name Description
1 Output Frequency Output frequency present at terminals T1, T2, and T3 (U, V & W).
2 Commanded Value of the active Speed/Frequency Reference.
SpdRef
3 Mtr Vel Fdbk Estimated or actual motor speed, with feedback.
4 Commanded Trq Final torque reference value after limits and filtering are applied. Percent
of motor rated
5 Torque Cur Fdbk Based on the motor, the amount of current that is in phase with the
fundamental voltage component.
6 Flux Cur Fdbk Amount of current that is out of phase with the fundamental voltage
component.
7 Output Current The total output current present at terminals T1, T2, and T3 (U, V & W).
8 Output Voltage Output voltage present at terminals T1, T2, and T3 (U, V & W).
9 Output Power Output power present at terminals T1, T2, and T3 (U, V & W).
10 Output Powr Fctr Output power factor.
11 DC Bus Volts DC bus voltage.
13 Elapsed MWH Accumulated output energy of the drive.
14 Elapsed kWH Accumulated output energy of the drive.
260(1) Anlg In0 Value Value of the Analog input after filter, square root, and loss action.
418 Mtr OL Counts Accumulated percentage of motor overload.
419 Mtr OL Trip Time Displays the inverse of the motor overload time.
558 MOP Reference Value of the MOP (Motor Operated Potentiometer) Reference to be used as
a possible source for P545 and P550.
707 Load Estimate Displays an estimated load torque value for the drive.
940 Drive OL Count Indicates power unit overload (IT) in percentage.
943 Drive Temp Pct Indicates operating temperature of the drive power section (heat sink) in
percentage of the maximum heat sink temperature.
1090 PID Ref Meter Present value of the PI reference signal.
1091 PID Fdbk Meter Present value of the PI feedback signal.
1092 PID Error Meter Present value of the PI error.
1093 PID Output Meter Present value of the PI output.
1567(2) FrctnComp Out Displays the torque reference output of the Friction Compensation
function.
50(3)(4) Anlg In0 Value Value of the Analog input after filter, square root, and loss action.
60(3)(4) Anlg In1 Value Value of the Analog input after filter, square root, and loss action.
90 … 97(5) DLX Real Out SP1 - Eight 32-bit Real scratchpad registers for DLX program output use.
SP8
(1) PowerFlex 753 drives only.
(2) PowerFlex 755 drives only.
(3) Option modules can be used in Ports 4, 5, and 6 of PowerFlex 753 drives.
(4) Option modules can be used in Ports 4, 5, 6, 7, and 8 of PowerFlex 755 drives.
(5) Port 14: DeviceLogix software parameters
Related PowerFlex 753 drives Level Select parameter information noted below.
Parameter No. Parameter Name Description
230 RO0 Sel Selects the source that energizes the relay output.
231 RO0 Level Sel Selects the source of the level that is compared.
232 RO0 Level Sets the level compare value.
233 RO0 Level CmpSts Status of the level compare, and a possible source for a relay or transistor
output.
240 TO0 Sel Selects the source that energizes the relay or transistor output.
241 TO0 Level Sel Selects the source of the level that is compared.
242 TO0 Level Sets the level compare value.
243 TO0 Level CmpSts Status of the level compare, and a possible source for the transistor output.
Example
Below is an example of a PowerFlex 753 drive utilizing an embedded digital
output Select, Level Select and Level parameters being configured such that the
output energizes when the drive’s operating temperature of the drive power
section (heat sink) in percentage of the maximum heat sink temperature is greater
than 50 percent.
Example
In this example, the drive is utilizing a 24V DC, Two Relay Option Module in
Port 7. One of the drive’s digital input functions, P164 [DI Run Forward] is
programmed for Port 7: Digital In Sts.Input 1, with Option Module P10 [RO0
Sel] is programmed for Port 7: Dig In Sts.Input 1 and P20 [RO1 Sel] is
programmed for Port 7: Dig In Sts.Input 3.
As you can see with the picture above, when the Digital Inputs 1 (pink highlight)
and 3 (yellow highlight) are true (on) their respective Digital Outputs are true
(on) as well.
Controlled by Network
This configuration is used when it is desired to control the digital outputs over
network communication instead of a drive related function. In the case for the
PowerFlex 753 embedded digital outputs, P227 [Dig Out Setpoint] is utilized
and in the case for the PowerFlex 750-Series Option Module, P7 [Dig Out
Setpoint] is utilized. To complete the configuration for control over a network, a
datalink must be configured for the respective Digital Output Setpoint
parameter.
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Relay Out 0
Options Trans Out 0
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Options
Relay Out 0
Digital Outputs
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
I/O
Example
For this example, our setup includes a PowerFlex 755 utilizing a 20-750-2262C-
2R 24VDC I/O Option Module and a ControlLogix™ L63 processor. The drive’s
Option Module, P10 [RO0 Sel] is configured for Port 7: Dig Out Setpoint.Relay
Out 0. We are utilizing the Logix Designer application, which includes the Drives
Add-On Profiles (AOPs). This gives us the ability to communicate and control
the PowerFlex 755 drive over its embedded ethernet port via a datalink P7 [Dig
Out Setpoint], Relay Out 0.
Utilizing the Drive Add-On Profiles and a datalink, we can use the created
descriptive controller tag (highlighted below) to communicate over a network to
control the relay output.
The picture below shows the result of controlling the digital output over the
network (yellow highlight).
Example
In the example below, we are using two real world inputs, such as limit switches
being wired into a PowerFlex 750-Series Option Module, and using a
DeviceLogix software program to control a digital output.
The picture below shows the DeviceLogix software Digital Input configuration.
P33 [DLX DIP 1] is configured for Port 7: Dig In Sts.Input 1 and P35 [DLX
DIP 3] is configured for Port 7: Dig In Sts.Input 3. This setup lets us bring in two
real world inputs into DeviceLogix software.
We then utilize a DeviceLogix software program so that when both Digital Input
1 and Digital Input 3 are true (on), the resultant is the DeviceLogix software
Digital Output 1 (DOP 1) turns on.
The picture below shows that the Option Module, P10 [RO0 Sel] is configured
for DeviceLogix software Port 14: DLX DigOut Sts2.DLX DOPSts1. This links
together the DeviceLogix software Digital Output 1 (DOP 1) to the drive’s
physical output, such that when the DOP 1 is high (on), the drive’s Option
Module relay output energizes.
The picture below shows the status of the DeviceLogix software inputs and
outputs via P49 [DLX DigIn Sts] and P51 [DLX DigOut Sts2].
The picture below shows the status of the DeviceLogix software inputs and
outputs via P1 [Dig In Sts] and P5 [Dig Out Sts].
Invert
There is a logical invert function associated with the PowerFlex 750-Series drive’s
digital outputs. For the PowerFlex 753, it is configured by P226 [Dig Out Invert],
and for the PowerFlex 750-Series Option Module, it is configured by P6 [Dig
Out Invert]. This invert function changes the output status bit from a zero, false
state, to a one, true state, and vice versa.
This logical invert function requires power to be applied to the drive’s control
module for the drive’s logic to be active. This can be obtained from powering up
the drive’s control module by either applying power to the drive’s input section or
from an external 24VDC being wired into the Auxiliary Power Supply Option
Module.
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Relay Out 0
Trans Out 0
Options
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
0 = Condition False
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 = Condition True
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Options
Relay Out 0
Digital Outputs
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
I/O
Example
In this example, the drive is utilizing a 24VDC, two relay Option Module in Port
7 with P10 [RO0 Sel] is programmed for Port 7: Dig In Sts.Input 1. Notice below
when the Invert bit for Relay Out 0, when the input status is true (1), the digital
output status bit is false (0).
On/Off Time
Each digital output has two user-controlled timers associated with it. The On
timer defines the delay time between a False-to-True transition (condition
appears) on the output condition and the corresponding change in state of the
digital output. The Off timer defines the delay time between a True-to-False
transition (condition disappears) on the output condition and the corresponding
change in the state of the digital output. Either timer can be disabled by setting
the corresponding delay time to zero.
Example
For example, in the diagram below, a digital output is configured for P935 [Drive
Status 1], Bit 27 “Cur Limit,” the On Time is programmed for two seconds and
the Off Time is programmed for 0 seconds.
Relay Activates
On Delay = 2 Seconds
0 5 10
On Delay = 2 Seconds
0 5 10
Status
The [Dig Out Sts] parameter displays the status of the digital outputs and can be
used for troubleshooting the digital outputs. When the bit in associated with the
digital output is on, this means that the logic in the drive is telling that digital
output to turn on. When the bit associated with the digital input is off, this
means that the logic in the drive is telling that digital output to turn off.
Description
File
Relay Out 0
Trans Out 0
Options
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
0 = Condition False
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
1 = Condition True
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
Relay Out 0
Digital Outputs
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
I/O
Block Diagrams
Figure 11 - PowerFlex 753 Drive
30 34
TO1 Sel TO1 On Time
Output Compare
RO0 Level Sel RO1/TO0 Level Sel
11 RO0 Level CmpSts 21 RO1/TO0 Level CmpSts
RO0 Level 13 1 0 RO1/TO0 Level 23 1 0
Source Source
A A≥B Parameter
A A≥B
Parameter
Selection Selection
A<B A<B
RO0 Level B RO1/TO0 Level 22 B
12
PTC Motor Thermistor Input A PTC (Positive Temperature Coefficient) sensing device, also known as a motor
thermistor, embedded in the motor windings can be monitored by the drive for
motor thermal protection. The motor windings are typically equipped with three
PTC sensors (one per phase) wired in series as shown in schematic below. The
miniaturized sensors have a low resistance below the rated response temperature,
and increase their resistance (exponentially) in the rated response temperatures
range. The rated response temperature is defined by the PTC sensor. Motors with
different thermal insulation classes (Class F or H) are equipped with different
PTC sensors, each with its own response temperature such as 120, 130, and 140
Degrees C. Unlike the PT100 or KTY thermistors, which have a linear relation
between temperature and resistance, the PTC thermistor is used for a
temperature level indication rather than a direct measurement in degrees C.
ϑ Temperature
1,330
250
Defined cutoff values
100
R[Ω]
20
10
-20 ˚C TNF – 20K TNF + 15K
0 ˚C TNF – 5K TNF + 5K
TNF
Port X (I/O Module): P40 [PTC Cfg] = 0 “Ignore,” 1 “Alarm,” 2 “Flt Minor,” 3
“Flt CoastStop,” 4 “Flt RampStop,” or 5 “Flt CL Stop”
Status is shown in Port X (I/O Module): P41 [PTC Sts] and Port X (I/O
Module): P42 [PTC Raw Value]
Status is shown in Port X (I/O Module): P41 [ATEX Sts] The fault action is not
configurable when the ATEX module is used.
Topic Page
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
Alarms Alarms are indications of situations that are occurring within the drive or
application that are annunciated to the user. These situations can affect the drive
operation or application performance. Conditions such as power loss or analog
input signal loss can be detected and displayed for drive or operator action.
Leaving P410 [Motor OL Actn] at one of the fault settings or Flash Updating the
drive to a firmware version greater than 8.001 resolves this anomaly. Instructions
on Flash Updating drives are provided in drive firmware Release Notes
publications.
Current Limit There are five ways that the drive can protect itself from over current or overload
situations.
Method Description
Hardware Over Current This is a feature that instantly faults the drive if the output current exceeds this value.
The value is fixed by hardware and is typically 250% of drive rated amps. The fault code
for this feature is F12 “HW OverCurrent.” This feature cannot be defeated or mitigated.
Software Over Current This protection mode occurs when peak currents do not reach the hardware over
current value and are sustained long enough and high enough to damage certain drive
components. If this situation occurs, the drives protection scheme causes an F36 “SW
OverCurrent” fault. The point at which this fault occurs is fixed and stored in drive
memory.
Software Current Limit This is a feature that attempts to reduce current by folding back output voltage and
frequency if the output current exceeds a programmable value. P422/423 [Current
Limit 1/2], selected by P421 [Current Lmt Sel], are programmable up to 150% of drive
rating. The reaction to exceeding this value is programmable with Shear Pin fault.
Enabling this parameter creates an F61 or F62 “Shear Pin n” fault. Disabling this
parameter causes the drive to use fold back to attempt load reduction.
Heat Sink Temperature The drive constantly monitors the heat sink temperature. If the temperature exceeds
Protection the drive maximum, a F8 “Heatsink OvrTemp” fault occurs. The value is fixed by
hardware at a nominal value of 100 degrees C. This fault is generally not used for over
current protection due to the thermal time constant of the heat sink. It is an overload
protection.
Drive Overload Protection Refer to Drive Overload on page 158.
P7 [Output Current] P424 [Active Cur Lmt] P1 [Output Frequency] P3 [Mtr Vel Fdbk]
Load is removed.
Running at 60 Hz Frequency is folded back.
Frequency
Amps
Start
Seconds
DC Bus Voltage/Memory P11 [DC Bus Volts] is a measurement of the instantaneous value. P12 [DC Bus
Memory] is a heavily filtered value or average bus voltage. Just after the pre-
charge relay is closed during initial powerup, bus memory is set equal to bus
voltage. Thereafter it is updated to the six-minute average of the instantaneous
DC bus voltage.
Bus memory is used as a comparison value to sense a power loss condition. If the
drive enters a power loss state, the bus memory is also used for recovery (for
example pre-charge control or inertia ride through) upon return of the power
source. Update of the bus memory is blocked during deceleration to prevent a
false high value caused by a regenerative condition.
Drive Overload The purpose of the drive thermal overload feature is to protect the drive’s power
module when operation exceeds the design limitations. This feature does not
protect the motor, this is handled by the motor overload protection feature (see
Motor Overload on page 168).
The drive thermal overload function utilizes two methods to protect the drive.
Inverse time protection based on the average output current and a thermal
manager that models the temperature of the IGBTs based on measured power
module temperature and operating conditions. Each method can reduce the
PWM switching frequency or reduce current limit. When rated conditions are
exceeded, even after applying one of the measures mentioned above, and the load
on the drive is not reduced, a F64 “Drive Overload” fault is generated. The fault
detection mechanism cannot be disabled. Only the ability to fold back PWM
frequency and current limit can be disabled.
The drive monitors the temperature of the power module based on a measured
temperature and a thermal model of the power module. As the temperature rises
and P940 [Drive OL Count] increases, the drive can lower the PWM frequency
to decrease the switching losses in the power module. If the temperature
continues to rise, the drive can reduce current limit to try to decrease the load.
This is the factory default response, configurable by P420 [Drive OL Mode], to
increasing drive temperature. If the drive temperature becomes critical, P940
[Drive OL Count] = 100%, the drive faults.
If the drive is operated in a low ambient temperature condition the drive can
exceed rated levels of current before the monitored temperature becomes critical.
To guard against this situation the drive thermal overload also includes an inverse
time algorithm. When this scheme detects operation beyond rated limits, current
limit can be reduced or a fault can be generated.
If the load on the drive exceeds the level of current as shown on one of the curves,
the inverse time protection increments the overload counter. Current limit can
fold back to 100% of the drive rating when the drive over load count reaches
97.35% until the 10/90 or 5/95 duty cycle has been achieved. For example, 60
seconds at 110% is followed by 9 minutes at 100%, and 3 seconds at 150% is
followed by 57 seconds at 100%. With the threshold for where to take action
slightly above the rated level the drive only folds back when drive ratings are
exceeded. If fold back of current limit is not enabled in P940 [Drive OL Mode],
an F64 “Drive Overload” fault occurs when operation exceeds the rated levels.
Drive Overload Curve
Thermal Manager
The thermal manager assures that the thermal ratings of the power module are
not exceeded. The operation of the thermal manager can be thought of as a
function block with the inputs and outputs as shown below.
Fault Status B
Current Limit Sel
421
953 2 Drive OL
3 Heatsink OT
4 TransistorOT
5 SinkUnderTmp
6 Excess Load
Configuration
P420 [Drive OL Mode] lets the user select the action to perform with increased
current or drive temperature. When this parameter is set to option 0 “Disabled,”
the drive will not modify the PWM frequency or current limit. When set to 2
“Reduce PWM” the drive only modifies the PWM frequency. This is typically
used on hoisting applications. Option 1 “Reduce CLmt” only modifies the
current limit. When setting this parameter to 3 “Both-PWM 1st” the drive
modifies the PWM frequency first and then the current limit, if necessary, to
keep the drive from faulting with a F64 “Drive Overload” or F8 “Heatsink
OvrTemp” fault.
Temperature Display
The drive temperature is measured (NTC on the heat sink) and displayed as
percentage of drive thermal capacity in P943 [Drive Temp Pct] and IGBT
thermal capacity in P941 [IGBT Temp Pct]. These two parameters are
normalized to the thermal capacity of the drive, which is frame dependent, and
displays thermal usage in percent of maximum (100% = drive Trip). The heat
sink temperature, P944 [Drive Temp C], and IGBT temperature, P942 [IGBT
Temp Pct], in degrees C are also provided as test points. These cannot directly be
related to a trip point as the maximums are defined as a percent.
When operation is below 5 Hz, the IGBT duty cycle is such that heat builds up
more rapidly in the power device. The thermal manager increases the calculated
IGBT temperature at low output frequencies and causes corrective action to take
place sooner. Consult technical support when prolonged operation at low output
frequencies is required so proper drive derating can be applied. Also consider that
when a drive is in current limit the output frequency is reduced to try to reduce
the load. This works fine for a variable torque load, but for a constant torque load
reducing the output frequency does not lower the current (load). Lowering
current limit on a constant torque load pushes the drive down to a region where
the thermal issue becomes worse. In this situation the thermal manager increases
the calculated losses in the power module to track the worst case. So if the
thermal manager normally provides 150% for 3 seconds at high speeds, it can
only provide 150% for one second before generating a fault at low speeds. Some
applications, such as hoisting and lifting, can benefit from the disabling of
current limit fold back.
Faults Faults are events or conditions occurring within and/or outside of the drive.
These events or conditions by default are considered to be of such significant
magnitude that drive operation is discontinued. Faults are annunciated by the
STS (Status) indicator on the drive, a HIM, communications network and/or
contact outputs.
When a fault occurs, the fault condition is latched, requiring the user or
application to perform a fault reset to clear the latched condition. The condition
that caused the fault determines the user response. If the condition that caused
the fault still exists after a fault reset, the drive faults again and the fault condition
is latched.
• The fault code is entered into the first buffer of the fault queue (see Fault
Queue below for rules).
• Additional data on the status of the drive at the time that the fault
occurred is recorded. This information is always related to the most recent
fault queue entry captured by P951[Last Fault Code]. When another fault
occurs, this data is overwritten.
The following data/conditions are captured and latched into non-volatile drive
memory.
• P952 [Fault Status A]
P953 [Fault Status B]
Indicates the occurrence of conditions that have been configured as faults.
• P954 [Status1 at Fault]
P955 [Status2 at Fault]
Captures operating conditions of the drive at the time of the fault.
• P957 [Fault Amps]
Motor amps at the time of the fault.
• P958 [Fault Bus Volts]
DC Bus volts at time of the fault.
• P956 [Fault Frequency]
Output Hertz at the time of fault.
• P962 [AlarmA at Fault]
P963 [AlarmB at Fault]
Captures and displays P959/960 [Alarm Status A/B] at the last fault.
Fault Queue
Faults are also logged into a fault queue such that a history of the most recent
fault events is retained. Each recorded event includes a fault code (with associated
text) and a fault “time of occurrence.” PowerFlex 750-Series drives have a 32 event
queue.
The fault queue records the occurrence of each fault event that occurs while no
other fault is latched. Each fault queue entry includes a fault code and a time
stamp value. New fault events are not logged to the fault queue if a previous fault
has already occurred, but has not yet been reset. Only faults that actually trip the
drive are logged. No fault that occurs while the drive is already faulted is logged.
The fault queue is a first-in, first-out (FIFO) queue. Fault queue entry 1 is always
the most-recent entry (newest). Entry 32 is always the oldest. As a new fault is
logged, each existing entry is shifted by one. The previous entry 1 moves to entry
2, previous entry 2 moves to entry 3, and so on. If the queue is full when a fault
occurs, the oldest entry is discarded.
The fault queue is saved in nonvolatile storage at power loss and its content
retained when power is cycled.
The fault code with descriptive text for each entry can be viewed with a HIM.
Once the fault code is displayed, pressing the enter key again on the HIM
displays the time stamp associated with that fault code. The time stamp is the
elapsed time since the fault occurred.
Resetting faults clears the faulted status indication. If any fault condition still
exists, the fault is re-latched and another entry made in the fault queue.
Fault Configuration
The drive can be configured such that some conditions do not trip the drive.
The following is a brief list of drive configurable faults. Some of these faults are
explained in more detail in their own section of this document.
Input Phase Loss Detection Occasionally, three-phase power sources can fail on one phase while continuing
to deliver power between the remaining 2 phases (single-phase). Operating above
50% output under this single-phase condition can damage the drive. If such a
condition is likely, we recommend that Input Phase Loss Detection be enabled.
The drive can be programmed to turn on an alarm bit or issue a drive fault (minor
or major). The drive accomplishes this by interpreting voltage ripple on the DC
bus.
If a fault action has been selected as a result of an input phase loss, P952 [Fault
Status A] Bit 4 “InPhaseLoss” is set.
If an alarm action is selected as a result for the input phase loss, P959 [Alarm
Status A] Bit 4 “InPhaseLoss” is set.
Sets the threshold at which the DC bus voltage ripple triggers an F17 “Input
Phase Loss” fault. Input phase loss is assumed when the DC bus voltage ripple
exceeds the tolerance set by this parameter for a certain time period of time.
Setting a larger value permits a higher bus voltage ripple without causing the drive
to fault but also results in more heating in the bus capacitors shortening their life
or possibly resulting in failure. The default value of 325 is equal to the expected
ripple level for a full rated motor running at half load with single phase input.
This is just a different way of saying that if you know you are going to run single
phase, derate the drive by 50%.
Loading conditions on the motor could also have an effect on this parameter.
Particularly shock loads.
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
Trip Time (Seconds)
Cold
Hot
P26 [Motor NP Amps] is used by the overload feature to establish the 100% level
(y axis) shown in the graph above.
Setting P410 [Motor OL Actn] to zero disables the motor thermal overload. For
multiple motor applications (more than one motor connected to one drive),
separate external overloads for each motor are required, and the drive’s motor
overload can be disabled.
IMPORTANT Some motors have a service factor that is only for use with sine wave
(non-drive) power. Check with the motor manufacturer to see if the
nameplate service factor is valid or must be reduced when operated by
a drive.
OL % = 1.20
OL % = 1.00
OL % = 0.80
% of Base Speed
• P414 [Mtr OL Hertz] is used to further protect motors with limited speed
ranges. Because many motors do not have sufficient cooling ability at lower
speeds, the overload feature can be programmed to increase protection in
the lower speed areas. This parameter defines the frequency where derating
the motor overload capacity begins. For all settings of overload Hz other
than zero, the overload capacity is reduced to 70% when output frequency
is zero. During DC injection braking, the motor current can exceed 70%
of FLA, but this causes the motor overload to trip sooner than when
operating at base speed. At low frequencies, the limiting factor can be the
drive overload rather than the motor overload.
Charging Overload Hz
Continuous Rating
OL % = 10
OL % = 25
OL % = 50
When the motor is cold, this function enables 3 minutes at 150%. When the
motor is hot, it enables 1 minute at 150%. A continuous load of 102% is allowed
to avoid nuisance faults. The duty cycle of the motor overload is defined as
follows. If operating continuous at 100% FLA, and the load increases to 150%
FLA for 59 seconds and then returns to 100% FLA, the load must remain at
100% FLA for 20 minutes to reach steady state.
1 Minute 1 Minute
150%
100%
20 Minutes
The ratio of 1:20 is the same for all durations of 150%. When operating
continuous at 100%, if the load increases to 150% for 1 second the load must
then return to 100% for 20 seconds before another step to 150%.
%FLA Cold Trip Time Hot Trip Time
105 6320 5995
110 1794 1500
115 934 667
120 619 375
125 456 240
130 357 167
135 291 122
140 244 94
145 209 94
150 180 60
155 160 50
160 142 42
165 128 36
170 115 31
175 105 27
180 96 23
185 88 21
190 82 19
195 76 17
200 70 15
IMPORTANT If the application requires high overload current for long durations (for
example 150% for 60 seconds), heavy duty sizing (between drive and motor)
is required.
Overspeed Limit An overspeed condition results when the motor speed falls outside of its normal
operating range. The forward motor rotation limit is P520 [Max Fwd Speed] +
P524 [Overspeed Limit] and the reverse motor rotation limit is P521 [Max Rev
Speed] - P524 [Overspeed Limit]. In Flux Vector Control mode or Scalar
Control mode with encoder, the motor speed used is a 2msec averaged value of
P131 [Active Vel Fdbk]. In Scalar Control mode without an encoder, the
overspeed check uses P1 [Output Frequency]. The overspeed condition must
exist for at least 16 milliseconds before it causes a fault to occur.
CIP Motion
When a PowerFlex 755 drive is running as a CIP Motion drive, then attribute
695 “Motor Overspeed User Limit” specifies the overspeed trip point directly.
This attribute has units of percent of motor rated speed. So, if attribute 695 is set
to 120% then the overspeed fault occurs at or above 120% rated speed.
Password All parameter configuration settings for the drive and its connected peripherals
can be protected from unauthorized access through the keypad by using a
password.
When the host drive is password protected, parameter settings for the drive and
its connected peripherals can be viewed but not changed until after the existing
password value is entered. When attempting to edit a parameter value while
logged out, the HIM prompts you for the password before allowing access.
Real Time Clock The PowerFlex 755 is equipped with a real-time clock with a battery backup.
This enables programming of real time in the drive, and keeping that time even if
the drives power is removed. This enables actual timestamps instead of runtime
timestamps for faults and events. It is also used in the runtime accumulation of
maintenance items such as total run time, number of times fans are running and
so forth. If a battery is installed and the time values are set, time is accumulated.
Approximate battery life is 4.5 years with drive unpowered, or lifetime if drive is
powered.
The real time clock on the drive can be set two different ways. It can either be set
from the HIM, or from DriveExecutive/DriveExplorer.
To delete an erroneous date (or time) entry, use the ← soft key. Also, a
partial or complete date (or time) value will not update until you press the
► soft key to enter the data. You have to press the ? soft key a second time
to advance to another field or press the ESC soft key to return to the
previous screen.
• Press the ► soft key to select the month in the top line, and use the
numeric keys to enter the correct month.
• Press the ► soft key to select the day in the top line, and use the numeric
keys to enter the correct day.
10. To set the time (set the drive to the current time).
• Press the ► soft key to select the hour in the top line, and use the
numeric keys to enter the correct hour.
• Press the ► soft key to select the minutes in the top line, and use the
numeric keys to enter the correct minute.
• Press the ► soft key to select the seconds in the top line, and use the
numeric keys to enter the correct seconds.
11. Press the ESC soft key to return to the previous screen.
To set the real time clock using a software package like DriveExecutive or
DriveExplorer™ software the procedure is the same.
5. If necessary, change the values in the Set Time Zone and Set Device Time
dialog boxes.
Installing Battery
To install the battery, first locate the main control board. The location of the
main control board is in the far right location of the control POD. The main
control board for the PowerFlex 753 and 755 drives are shown below.
Removing Battery
To remove the battery, simply use a screwdriver to press down on the metal tab
going across the battery. Prying the battery out of its holder can result in
permanent damage to the main control board.
Reflected Wave Reflected waves are a phenomenon associated with long cables and fast changes
in voltage levels. They were first identified on power transmission lines that are
hundreds of miles long. When the power is switched on at one end, the step in
voltage travels the length of the transmission line and is reflected back to the
switch. The voltage at the far end often surges to twice the initial value of the
voltage. Because the voltages involved are quite high, for example 230,000V or
more, a surge of 460,000V can result in a damaging arcing fault.
Adjustable speed drives, using IGBT switches that turn on and off within a few
nanoseconds, experience the same phenomenon at the AC motor terminals. This
can cause motor failures within months or even weeks of commissioning the
motor with a drive.
0 Volts
Ideally, the voltage waveform at the motor looks exactly the same as the output of
the drive. However, the voltage at the motor has individual on/off pulses that
make up the PWM voltage waveform along with a ringing that occurs at every
switching transition. This is shown in Figure 19. The peaks of the ringing
waveform can easily reach two times the peak of the voltage pulses at the drive
(the DC bus voltage). After a short time, the ringing dies away and the motor sees
the normal DC bus voltage level. It is this peak level of the ringing voltage that
causes motor failure.
0 Volts
Shorten the time sweep or magnify these pulses and the ringing effect at the
motor terminals can be seen.
When the voltage at the motor terminals exceeds the insulation rating of the
motor, corona begins to appear. This corona deteriorates the insulation system,
eventually leading to a fault to ground. Such a failure is shown below.
The level of the DC bus voltage has a direct effect on the peak level of the ringing
surge voltage. If the drive operates at 230V AC, the DC bus voltage is about
310V DC and two times peak only reaches 620Vpk. This peak will not damage
most motors. However, a 460V AC drive operates at 620V DC bus voltage and
1240Vpk and a 575V AC drive operates at 775V DC and 1550Vpk.
Non-inverter grade motors have insulation systems rated to 1000V and 1200V
depending on their construction.
• 1000V motors are assembled without phase paper.
• 1200V motors are assembled with phase paper and slot insulation.
Non-inverter grade motors will fail if operated from a 460V or 575V drive.
There are three ways to eliminate the effects of reflected waves on motors.
The Terminator
Is it possible to match the surge impedance of the motor to the cable? There is a
device called the terminator that does this, shown in the figure below. It is an RC
network at the motor that matches the load surge impedance to the cable.
Figure 20 shows the surge voltages when using the terminator. The overshoot is
very low, with no ringing to speak of. Due to losses, this device is good for cable
lengths up to 600 ft, and for carrier frequencies less than or equal to 4 kHz.
However, its key advantage is that this one device works well for any motor in the
range from 0.5 to 500hp because it does not have to handle the motor current,
being a parallel device.
Line Reactor
What if we go the other way, matching the surge impedance of the cable to the
motor? There are several products available that do this. They all consist of the
addition of a line reactor at the output of the drive. See the figure below. A 3%
line reactor by itself also reduces the dV/dt, but a big disadvantage is that it
reduces the voltage available to the motor by 3%. This is useful for cables up to
about 600 ft. A better device is what we call a “reflected wave reduction” device
where the line reactor is reduced to about 0.2%, and a resistor is placed in parallel
with each of the reactors. This reduces the dV/dt and has a voltage drop of only
0.2% instead of 3%. It can be used with cables up to about 1200 ft.
A method to reduce just the dV/dt is to use shielded cable between the drive and
the motor. The inherent capacitance between the lines and the shield help keep
the surge voltage at 1200V up to 600 ft with PWM drives.
Waveforms
The waveforms A, B, and C in the figure below describe the different mitigations
solutions shown on top of each other.
A - Unprotected motor
B - Line Reactor at the Drive
C - Terminator or RWR
Time (μs)
Here are waveforms using a sine wave filter at 30 and 60 Hz. As you can see there
are no issues with reflected wave when using a sine wave filter.
Ports
This feature provides write access protection for individual communication ports
in the drive. The HIM or communication modules with software tools can be
used to change any port to read only.
A password can also be used with the HIM to prevent writing to parameters
through the keypad. See Password on page 173.
By default, every DPI port in the drive is configured to allow read and write
access.
To change the write access on an individual DPI port, change the bit setting of
the associated port in P888 [Write Mask Cfg]. Changing the bit value from 1
(read/write) to 0 with a HIM provides read only capability. Using software such
as DriveExplorer, DriveExecutive, or CCW can also be used to turn the bit off.
Below is an example of using CCW to change port 4 to read only.
Any changes to P888 [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.
• P887 [Write Mask Act] Bit 15 transitions from 1 to 0.
The status of a port’s write access can be verified at P887 [Write Mask Act]. For
example, to verify that write access was disabled, P887 [Write Mask Act] Bit 4
“Port 4” equals 0.
The port that is being used to make security changes (for example a network
adapter connected to Port 5) can only change other ports and not itself to read
only. This is to prevent the complete lockout of a drive with no future way to
regain write access.
DPI (Network)
Network Security can only be activated with external software programs that
have security capabilities, for example, FactoryTalk® software.
When P885 [Port Mask Act] Bit 15 “Security,” P886 [Logic Mask Act] Bit 15
“Security,” and P887 [Write Mask Act] Bit 15 “Security” are set to 1 “Read/
Write,” Network Security has been enabled by an external program like
FactoryTalk and is controlling the logic mask and write mask instead of the
parameter. These bits can only be enabled/disabled via the network program.
A port that is being used to communicate to the drive and set the masks or
network security can only make changes to other ports and not itself. This is to
prevent a complete lockout from a drive.
When the writing capabilities of ports 1, 2, or 3 have been masked, via parameter
888 [Write Mask Cfg] or Network Security, the HIM displays the following
message when trying to edit a parameter.
• A6-HIM: Security is enabled. Access Denied
• A3-HIM with Firmware that has Security Functionality: Security Enable.
Access Denied
• A3-HIM with Firmware that does not have Security Functionality: Device
State has Disabled Function
Software used to interface with the drive also indicates if the writing capabilities
have been disabled by P888 [Write Mask Cfg] or Network Security, via the
communication port being used.
Below are examples of parameters viewed with drive software via DriveExplorer
or CCW when the connected port has been write disabled. The parameter value
is grayed out and a lock is displayed.
Shear Pin As a default, the drive folds 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 otherwise causes a shear pin fault. Also, the
condition can be ignored for a programmable amount of time.
To turn on either Shear Pin 1 or Shear Pin 2, configure [Shear Pin n Actn]. This
activates the function. Selection between P435 [Shear Pin 1 Actn] and P438
[Shear Pin 2 Actn], cannot be made by a digital input. These parameters can be
set over a communication network. The options for each shear pin action are the
same. Default for each is 0 “Ignore.” The following are the settings for P435 and
P438.
• “Ignore” (0) – No action is taken.
• “Alarm” (1) – Type 1 alarm indicated.
• “Flt Minor” (2) – Minor fault indicated. If running, drive continues to
run. Enable with P950 [Minor Flt Cfg]. If not enabled, acts like a major
fault.
• “FltCoastStop” (3) – Major fault indicated. Coast to Stop.
• “Flt RampStop” (4) – Major fault indicated. Ramp to Stop.
• “Flt CL Stop” (5) – Major fault indicated. Current Limit Stop.
There are situations where a fast acceleration of the motor causes the drive to
output current to the motor near or at the current limit value for shear pin and
fault the drive while in acceleration. To avoid this condition set P434 [Shear Pin
Cfg] Bit 0 “Shear1NoAcc” or Bit 1 “Shear2NoAcc” to 1 to ignore during
acceleration.
A shear pin level must be programmed for the drive to monitor. This level, when
exceeded, starts a timer that must expire before performing the [Shear Pin n
Actn]. This level is entered into P436 [Shear Pin 1 Level] or P439 [Shear Pin 2
Level]. The units are amps. Default is drive rated amps. Maximum is rated amps
multiplied by 1.5.
If an immediate action is to be taken, set shear pin time to 0. If the shear pin level
is to be ignored for a period of time, enter that value into P437 [Shear Pin 1
Time] or P440 [Shear Pin 2 Time].
Generally, some value greater than 0 is entered in shear pin time to eliminate any
faults on very short peak current spikes. Thus eliminating nuisance tripping.
Fault Indication
A unique fault (Shear Pin 1, F61) or (Shear Pin 1, F62) is generated if the
function is activated and the condition occurs.
Application Example
By programming the Shear Pin feature, the drive faults, stopping the excess
torque before mechanical damage occurs.
Shear Pin - Gradual Loading
Motor Speed
Drive Faults
Frequency
Amps
Increasing Load
Seconds
Frequency
Amps
Seconds
It is possible for the drive to trip during acceleration on a shear pin fault even
when P434 [Shear Pin Cfg] Bits 0 or 1 in are set. This occurs when the accel time
is set to something very small. The firmware looks at the internal “at speed” bit to
indicate when acceleration is complete. This bit could be set internally faster than
what appears the motor is indicating by sight. For example, if the accel time is set
to something like 0.5 seconds and P434 Bit 0 is set. The drive will most likely trip
on shear pin fault.
to issue the actual fault at a higher current level or a slightly longer Shear Pin
time.
Shear Pin - Alarm then Fault
P7 [Output Current] P436 [Shear Pin1 Level] P439 [Shear Pin2 Level]
P952 [Fault Status A] P959 [Alarm Status A] P3 [Mtr Vel Fdbk]
Drive Faults
Motor Speed
Shear Pin 2 Time
Load Changes
Shear Pin 1
Time
Alarm Alarm
Indication Indication
Fault
Indication
Other Points
The Shear Pin feature is not to be taken as a precise current reactionary feature.
There can be as much as +/- 5% error in the current feedback signal used to
determine shear point levels. Therefore it could be possible that the timer trip
point is being set and reset until the entire current reference is above a setpoint.
Slip Compensation When slip compensation mode is selected, the drive automatically adds the
appropriate amount of output frequency to maintain a consistent motor speed
independent of load. During drive commissioning, P621 [Slip RPM at FLA] is
set based on entered motor nameplate information. This parameter can be
adjusted to provide more or less compensation.
See the motor speed compensation figure below for a comparison of operation
with and without slip compensation. This shows that over time, slip
compensation corrects for changes in load (curved lines). In contrast, open loop
operation shows that no correction is made based on load.
Internally, the drive converts the rated slip in RPM to rated slip in frequency. To
more accurately determine the rated slip frequency in hertz, an estimate of flux
current is necessary. This parameter is either a default value based on motor
nameplate data or the autotune value. The drive scales the amount of slip
compensation to the motor rated current. The amount of slip frequency added to
the frequency command is then scaled by the sensed torque current (indirect
measurement of the load) and displayed.
Slip compensation also affects the dynamic speed accuracy (ability to maintain
speed during shock loading) as illustrated in the rotor speed response figure
below. Initially, the motor is operating at some speed and no load. Some time
later, an impact load is applied and the rotor speed decreases as a function of load
and inertia. Finally, the impact load is removed and the rotor speed increases
momentarily until the slip compensation is reduced based on the applied load.
The responsiveness to an impact load can be adjusted with P622 [Slip Comp
BW]. However, too high setting can cause unstable operation and overshoot.
Impact Load
Removed
Increasing Slip
Impact Load Comp Gain
Applied
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 No. 1
and Drive No. 3 control the speed of the belt conveyor. Slip compensation is used
to maintain the RPM independent of load changes caused by the cutter or dough
feed. By maintaining the required RPM, the baking time remains constant and
therefore the end product is consistent.
Dough Stress
Relief Cookie Line
Cutters Oven
Slip Regulator The slip regulator is used to compensate for temperature changes in an induction
motor when FOC is used. The slip regulator uses a model of the motor to
determine the desired d-axis voltage for a given operating point. A PI regulator is
then used to change the drive’s slip gain controlling the d-axis motor voltage.
This in turn compensates for motor temperature (resistance) changes. The
operation of the slip regulator is limited to regions where there is sufficient
voltage (feedback or estimate) for the regulator to converge.
Do not disable this regulator. If you feel you need to disable this function, consult
the factory for verification.
Motor Control
Topic Page
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
Carrier (PWM) Frequency P38 [PWM Frequency] sets the carrier frequency at which the inverter output
IGBTs (Insulated Gate Bipolar Transistors) switch. In general, use the lowest
possible switching frequency that is acceptable for the particular application. An
increased carrier frequency causes less motor heating and lowers the audible noise
from the motor. However, it causes the IGBTs to heat up faster than by using the
factory default PWM frequency of 4 kHz or 2 kHz depending on drive’s the
frame size. The higher switching frequency smoothes the current waveform. This
reduces vibration in the motor windings and laminations reducing audible noise.
This is desirable in applications where motors are installed close to control rooms
or in domestic environments. See Figure 21 and note the output current at 2 kHz
and 4 kHz. The smoothing of the current waveform continues 12 kHz.
The maximum carrier frequency per frame size and the derating guidelines
according to PWM frequency can be found in the PowerFlex 750-Series AC
Drives Technical Data, publication 750-TD001.
2 kHz 4 kHz
Some applications require a fixed minimum PWM frequency (that is, using a sine
wave filter in the output of the drive). In this case, P40 [Mtr Options Cfg] Bit 9
“PWM FreqLock” should be set to prevent the drive from lowering its carrier
frequency due to a drive overload condition.
Dynamic Braking When an induction motor’s rotor is turning slower than the synchronous speed
set by the drive’s output power; the motor is transforming electrical energy
obtained from the drive into mechanical energy available at the drive shaft of the
motor. This process is referred to as motoring.
When the rotor is turning faster than the synchronous speed set by the drive’s
output power, the motor is transforming mechanical energy available at the drive
shaft of the motor into electrical energy that can be transferred back into the
utility grid. This process is referred to as regeneration.
On most AC PWM drives, the AC power available from the fixed frequency
utility grid is first converted into DC power by means of a diode rectifier bridge
or controlled SCR bridge, before being inverted into variable frequency AC
power. These diode or SCR bridges are very cost effective, but can handle power
in only one direction, and that direction is the motoring direction. If the motor is
regenerating, the bridge is unable to conduct the necessary negative DC current,
and the DC bus voltage increases until the drive trips on a Bus Overvoltage fault.
There are bridge configurations, using either SCRs or Transistors that have the
ability to transform DC regenerative electrical energy into fixed frequency utility
electrical energy but are expensive. A more cost effective solution is to provide a
Transistor Chopper on the DC bus of the AC PWM drive that feeds a power
resistor, which transforms the regenerative electrical energy into thermal heat
energy, which is dissipated into the local environment.
This process is generally called Dynamic Braking, with the Chopper Transistor
and related control and components called the Chopper Module, and the power
resistor called the Dynamic Brake Resistor. The entire assembly of Chopper
Module with Dynamic Brake Resistor is sometime referred to as the Dynamic
Brake Module.
How it Works
There are two different types of control for dynamic braking, hysteretic control
and PWM control. Each used by themselves in a standard stand alone product
has no advantage over the other. The preferred control is the PWM method
when the application is common DC bus. This advantage is described below.
Hysteretic Control
The hysteretic method of dynamic braking uses a voltage sensing circuit to
monitor the DC bus. As the DC bus voltage increases to the Vdc_on level the
brake IGBT is turned on and is left on until the voltage drops to the Vdc_off level,
which is not so desirable in common DC bus applications—see below. Some
PowerFlex drives allow the Vdc_off level, [DB Threshold], to be adjusted if the
application required it. Setting this level lower makes the dynamic braking more
responsive but could lead to excessive DB activation.
Vdc
Vdc
Vdc_on
Vdc_off
on
off t
PWM Control
This type of control to operate the brake IGBT is similar to the way output
voltage to the motor is controlled. As the DC bus voltage increases and hits some
predetermined limit the brake IGBT is turned on/off according to a control
algorithm switched at 1 kHz. This type of control virtually eliminates bus ripple.
The big advantage is when this type of control is in a common bus configuration.
Vdc
Vdc_on+25
Vdc_on+25 –2.5
Vdc_on
t
Brake IGBT
on
off
t
Duty Cycle
Linear PWM Hysteretic Full on
100%
90%
Duty Cycle
Vdc_off
DB IGBT
Drive #1
on
off t
DB IGBT
Drive #2
on
off t
Here are two drives with PWM DB control on a common bus. Because one drive
turns on at a certain duty cycle the bus voltage is likely to continue to rise
guaranteeing that the other drive’s IGBT turns on (at a different duty cycle).
Vdc
Drive #2
Vdc_on
Vdc_off
Vdc
Drive #1
DB IGBT
Drive #1
on
off t
DB IGBT
Drive #2
on
off t
In general, the motor power rating, speed, torque, and details regarding the
Regenerative mode of operation is needed to estimate what Chopper Module
rating and Dynamic Brake Resistor value to use. A rule of thumb to use is that a
Dynamic Brake Module can be specified when regenerative energy is dissipated
on an occasional or periodic basis. When a drive is consistently operating in the
Regenerative mode of operation, consider utilizing equipment that transforms
the electrical energy back to the fixed frequency utility.
The peak regenerative power of the drive must be calculated to determine the
maximum Ohmic value of the Dynamic Brake Resistor and to estimate the
minimum current rating of the Chopper Module. The Rating of the Chopper
Module is chosen from the Brake Chopper Module manual. Once the Chopper
Module current rating is known, a minimum Dynamic Brake Resistance value is
also known. A range of allowable Dynamic Brake Ohmic values is now known.
These values exist from the minimum value set by the Chopper Transistor
current rating to a maximum value set by the peak regenerative power developed
by the drive to decelerate or satisfy other regenerative applications. If a Dynamic
Brake Resistance value less than the minimum imposed by the choice of the
Chopper Module is made and applied, damage can occur to the Chopper
Transistor. If a Dynamic Brake Resistance value greater than the maximum
imposed by the choice of the peak regenerative drive power is made and applied,
the drive can trip off due to transient DC bus overvoltage problems. Once the
choice of the approximate Ohmic value of the Dynamic Brake Resistor is made,
the wattage rating of the Dynamic Brake Resistor can be made.
The wattage rating of the Dynamic Brake Resistor is estimated by applying the
knowledge of the drive motoring and regenerating modes of operation. The
average power dissipation of the Regenerative mode must be estimated and the
wattage of the Dynamic Brake Resistor chosen to be slightly greater than the
average power dissipation of the drive. If the Dynamic Brake Resistor has a large
thermodynamic heat capacity, the resistor element is able to absorb a large
amount of energy without the temperature of the resistor element exceeding the
operational temperature rating. Thermal time constants in the order of 50
seconds and higher satisfy the criteria of large heat capacities for these
applications. If a resistor has a small heat capacity, the temperature of the resistor
element could exceed the maximum temperature limits during the application of
pulse power to the element and could exceed the safe temperature limits of the
resistor.
The following figure is a typical dynamic braking application. The top trace
represents speed and is designated by the omega symbol. In the profile the motor
is accelerated to some speed, it holds that speed for a period of time and is then
decelerated. This deceleration is not necessarily to zero speed. The cycle is then
repeated.
The middle trace represents motor torque. Torque starts out high as the motor is
accelerated then drops down to maintain the commanded speed. Then the
torque turns negative as the motor is decelerated. The cycle is then repeated.
The bottom trace represents motor power. Power increases as the motor speed
increases. Power decreases some to maintain the commanded speed then goes
negative when deceleration starts. (this point called -Pb is the first value that
needs to be calculated). The cycle is then repeated.
ω(t)
0 t1 t2 t3 t4 t1 + t4 t
T(t)
0 t1 t2 t3 t4 t1 + t4 t
P(t)
0 t1 t2 t3 t4 t1 + t4 t
-Pb
The protective fuse is sized to work in conjunction with the Crowbar SCR.
Sensing circuitry within the Chopper Transistor Voltage Control determines if
abnormal conditions exist within the Chopper Module. One of these abnormal
conditions is a shorted Chopper Transistor. If this condition is sensed, the
Chopper Transistor Voltage Control fires the Crowbar SCR, shorting the DC
bus, and melting the fuse links. This action isolates the Chopper Module from
the DC bus until the problem can be resolved.
The Chopper Transistor is an Isolated Gate Bipolar Transistor (IGBT). There are
several transistor ratings that are used in the various Chopper Module ratings.
The most important rating is the collector current rating of the Chopper
Transistor that helps to determine the minimum Ohmic value used for the
Dynamic Brake Resistor. The Chopper Transistor is either ON or OFF,
connecting the Dynamic Brake Resistor to the DC bus and dissipating power, or
isolating the resistor from the DC bus.
The Chopper Transistor Voltage Control regulates the voltage of the DC bus
during regeneration. The average value of DC bus voltage is 375V DC (for 230V
AC input), 750V DC (for 460V AC input), and 937.5V DC (for 575V AC
input). The voltage dividers reduce the DC bus voltage to a low enough value
that is usable in signal circuit isolation and control. The DC bus feedback voltage
from the voltage dividers is compared to a reference voltage to actuate the
Chopper Transistor.
The Freewheel Diode (FWD) in parallel with the Dynamic Brake Resistor
enables any magnetic energy stored in the parasitic inductance of that circuit to
be safely dissipated during turn off of the Chopper Transistor.
Fuse
To -DC Bus
Crowbar
SCR Gate
Equations used for calculating Dynamic Braking values use the following
variables.
2N
(t) = The motor shaft speed in Radians/second, or Rad s = ---------- RPM
60
JT = Jm + GR2 x JL
GR = The gear ratio for any gear between motor and load, dimentionless
JT 2
P b = -----------------
t3 – t2
2N
= rated angular rotational speed, Rad s = ----------
60
Compare the peak braking power to that of the rated motor power, if the peak
braking power is greater that 1.5 times that of the motor, the deceleration time,
(t3 - t2), needs to be increased so that the drive does not go into current limit. Use
1.5 times because the drive can handle 150% current maximum for 3 seconds.
Peak power can be reduced by the losses of the motor and inverter.
2
V
d
R db1 = -------
Pb
Vd = The value of DC bus voltage that the chopper module regulates at and is
equal to 375V DC, 750V DC, or 937.5V DC
Rdb1 = The maximum allowable value for the dynamic brake resistor
Choose a Dynamic Brake resistance value that is less than the value calculated in
Step 3. If the value is greater than the calculated value, the drive can trip on DC
bus overvoltage. Remember to account for resistor tolerances.
In the table above, choose the correct Dynamic Brake Module based upon the
resistance value being less than the maximum value of resistance calculated in
Step 3. If the Dynamic Brake Resistor value of one Dynamic Brake Module is not
sufficiently low, consider using up to three Dynamic Brake Modules in parallel,
such that the parallel Dynamic Brake resistance is less than Rdb1 calculated in
t3 – t2 Pb
P av = ------------------ ------
t4 2
The Dynamic Brake Resistor power rating of the Dynamic Brake Module (singly
or two in parallel) that is chosen must be greater than the value calculated in Step
5. If it is not, then a Brake Chopper Module with the suitable Dynamic Brake
Resistor must be specified for the application.
P av
AL = -------- 100
P db
Pdb = Steady state power dissipation capacity of resistors obtained from the table
in Step 4 (Watts)
Pb
PL = -------- 100
P db
Pdb = Steady state power dissipation capacity of resistors obtained from the table
in Step 4 (Watts)
500
400
Power (%)
300
200
100
0
0 5 10 15 20
Time (Seconds)
If the line you drew lies to the left of the constant temperature power curve of the
Dynamic Brake Resistor, then there is no application problem. If any portion of
the line lies to the right of the constant temperature power curve of the Dynamic
Brake Resistor, then there is an application problem. The application problem is
that the Dynamic Brake Resistor is exceeding its rated temperature during the
interval that the transient power curve is to the right of the resistor power curve
capacity. It is prudent to parallel another Dynamic Brake Module or apply a
Brake Chopper Module with a separate Dynamic Brake Resistor.
Sizing the chopper module is the same as the dynamic brake module with a
couple of added steps. Because the chopper is separate from the resistors, an
additional calculation for current needs to be made. Additionally a calculation
for watt-seconds or joules needs to be made for resistor sizing.
JT = Jm + GR2 x JL
GR2 = the gear ratio for any gear between motor and load, dimensionless
JT 2
P b = -----------------
t3 – t2
2N
= rated angular rotational speed, Rad s = ----------
60
Compare the peak braking power to that of the rated motor power, if the peak
braking power is greater that 1.5 times that of the motor, then the deceleration
time, (t3 - t2), needs to be increased so that the drive does not go into current
limit. Use 1.5 times because the drive can handle 150% current maximum for 3
seconds.
Peak power can be reduced by the losses of the motor and inverter.
2
Vd
R db1 = ------
pb
Vd = The value of DC bus voltage that the chopper module regulates at and is
equal to 375V DC, 750V DC, or 937.5V DC
Rdb1 = The maximum allowable value for the dynamic brake resistor
The choice of the Dynamic Brake resistance value will be less than the value
calculated in Step 3. If the value is greater than the calculated value, the drive can
trip on DC bus overvoltage. Remember to account for resistor tolerances.
Vd
I dl = ----------
R dbl
Idl = The minimum current flowing through the chopper module transistor
The value of Id1 sets the minimum value of current rating for the Chopper
Module. When the Chopper Module choice has been made, the current rating of
the Module Transistor must be greater than or equal to the calculated value for
Id1. See the table below for rating values.
Drive Voltage Turn-On Voltage Cat. No. Peak Transistor Current Minimum DB Resistor
(Volts AC) (Volts DC) Rating (Amps) Value (Ohms)
230 375 WA018 50 9.0
WA070 200 2.3
WA115 400 1.25
460 750 WB009 25 37
WB035 100 9.0
WB110 400 2.5
575 935 WC009 25 46
WC035 75 15.5
WC085 400 3.0
Each chopper module in the table above has a minimum resistance associated
with it. If a resistance lower than the value show in the table is connected to the
chopper module, the brake transistor is most likely be damaged.
To avoid damage to this transistor and get the desired braking performance, select
a resistor with a resistance between the maximum resistance calculated in Step 3
and the minimum resistance of the selected chopper module.
t3 – t2 Pb
P av = ------------------ ------
t4 2
The Dynamic Brake Resistor power rating in watts that is chosen will be equal to
or greater than the value calculated in Step 7.
Pb
P ws = t 3 – t 2 ------
2
Sizing resistors for the internal DB IGBT Uses the same formula's as previous,
and is very similar to the Chopper Module sizing.
J T = J m + GR 2 J L
GR = The gear ratio for any gear between motor and load, dimensionless
JT 2
P b = -----------------
t3 – t2
2N
= rated angular rotational speed, Rad s = ----------
60
Compare the peak braking power to that of the rated motor power, if the peak
braking power is greater that 1.5 times that of the motor, then the deceleration
time, (t3 - t2), needs to be increased so that the drive does not go into current
limit. Use 1.5 times because the drive can handle 150% current maximum for 3
seconds.
Peak power can be reduced by the losses of the motor and inverter.
2
Vd
R db1 = ------
pb
Vd = The value of DC bus voltage that the drive regulates at and is equal to 375V
DC, 750V DC, or 937.5V DC depending on input voltage
Rdb1 = The maximum allowable value for the dynamic brake resistor
The choice of the Dynamic Brake resistance value will be less than the value
calculated in Step 3. If the value is greater than the calculated value, the drive can
trip on DC bus overvoltage. Remember to account for resistor tolerances.
Each drive with an internal DB IGBT has a minimum resistance associated with
it. If a resistance lower than the minimum value for a given drive is connected, the
brake transistor will likely be damaged. Below is a table of minimum resistances
for frame 2 through 7 PowerFlex 750-Series drives.
Frame 400V 480V
ND kW Catalog Code Min Resistance Max DB Current ND HP Catalog Code Min Resistance Max DB Current
2 0.75 C2P1 31.6 25 1.0 D2P1 31.6 25
1.5 C3P5 31.6 25 2.0 D3P4 31.6 25
2.2 C5P0 31.6 25 3.0 D5P0 31.6 25
4.0 C8P7 31.6 25 5.0 D8P0 31.6 25
5.5 C011 31.6 25 7.5 D011 31.6 25
7.5 C015 31.6 25 10 D014 31.6 25
11 C022 22.6 34.9 15 D022 22.6 34.9
3 15 C030 31.6 25 20 D027 31.6 25
18.5 C037 31.6 25 25 D034 31.6 25
22 C043 16.6 47.6 30 D040 16.6 47.6
4 30 C060 15.8 50 40 D052 15.8 50
37 C072 15.8 50 50 D065 15.8 50
5 37 C072 7.9 100 50 D065 7.9 100
45 C085 7.9 100 60 D077 7.9 100
55 C104 7.9 100 75 D096 7.9 100
6 55 C104 3.3 239.4 75 D096 3.3 239.4
75 C140 3.3 239.4 100 D125 3.3 239.4
90 C170 3.3 239.4 125 D156 3.3 239.4
110 C205 3.3 239.4 150 D186 3.3 239.4
132 C260 3.3 239.4 200 D248 3.3 239.4
7 132 C260 2.4 329 200 D248 2.4 329
160 C302 2.4 329 250 D302 2.4 329
200 C367 2.4 329 300 D361 2.4 329
250 C456 1.65 478.8 350 D415 1.65 478.8
270 C477 1.65 478.8 400 D477 1.65 478.8
To avoid damage to this transistor and get the desired braking performance, select
a resistor with a resistance between the maximum resistance calculated in Step 3
and the minimum resistance of the drive IGBT.
t3 – t2 Pb
P av = ------------------ ------
t4 2
The Dynamic Brake Resistor power rating in watts that is chosen will be equal to
or greater than the value calculated in Step 6.
Pb
P ws = t 3 – t 2 ------
2
Flux Braking Flux Braking is an independent feature from the P370/371 [Stop Mode A/B]
available in PowerFlex 750-Series drives. When enabled, flux braking is active
during the decel ramp of a speed change. Flux braking changes the Volts per
Hertz curve ratio outputting a higher voltage, relative to the normal V/Hz curve,
to the motor causing over fluxing thus reducing the speed faster than just the
decel ramp alone. This feature is not intended for high inertia loads because over
fluxing can cause excessive heating in the motor. Very long decel times can build
heat.
Traces
In all of the following plots the Accel/Decel times are 0.5 s. P372/373 [Bus Reg
Mode A/B] is set to option 1 “Adjust Freq.” There is a fair amount of inertia
connected to the motor shaft. P370/371 [Stop Mode A/B] is set to 1 “Ramp” to
stop.
In the plot below the Flux Braking feature is disabled. Note the decel time. Here
the bus regulator is controlling the stop time.
Flux Braking - Disabled
In the next plot all conditions are the same except the Flux Braking feature is
enabled. Note the flux to the motor is increased and the decel time is shorter.
Flux Braking - Enabled
Finally the same test with the gains set to maximum levels. Slightly faster decel.
The use of the gains vary with the connected load.
Flux Braking - Full Gains
Flux Regulator The flux regulator is used to control and limit the overall (fundamental) voltage
applied to an induction motor when FOC is used. The flux regulator controls
field weakening above base speed and maintains voltage margin for a current
regulator. A variation of the induction motor flux regulator is used for PM
motors for operation above base speed.
As default the flux regulator is enabled. When disabled, the current regulator
becomes de-tuned.
Do not disable this regulator. If you feel you need to disable this function, consult
the factory for verification.
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 Automatic during a normal start. Flux is established as the
output voltage and frequency are applied to the motor. While the flux is being
established, the unpredictable nature of the developed torque can cause the rotor
to oscillate even though acceleration of the load can occur. In the motor, the
acceleration profile may not follow the commanded acceleration profile due to
the lack of developed torque.
Rated Flux
Frequency
Stator
Rotor
The second method is Manual. In this mode, DC current is applied to the motor
so that the flux is established before rotation. The flux up time period is based on
the level of flux up current and the rotor time constant of the motor. The flux up
current is not user adjustable.
Flux Up Current
Rated Flux Rated Motor Flux
Current
Motor Flux
0
T1
T2
T3
T4
Flux Up Time
Once rated flux is reached in the motor, normal operation begins and the desired
acceleration profile is achieved.
IR Voltage - SVC
Greater of IR Voltage or
Voltage Boost - V/Hz
Flux Up Stator Voltage
Voltage Rotor Speed
Motor Flux
Stator Freq
Once rated flux is reached in the motor, normal operation begins and the desired
acceleration profile is achieved.
Parameters
Read-Write
No. Display Name Values
Data Type
Full Name
Group
Description
File
“Automatic” (1) – Flux is established for a calculated time period based on motor
nameplate data before acceleration. P44 [Flux Up Time] is not used.
44 Flux Up Time Units: Secs RW Real
Flux Up Time Default: 0.0000
The amount of time the drive will use to try to achieve full motor stator flux. When a Min/Max: 0.0000 / 5.0000
Start command is issued, DC current at P26 [Motor NP Amps] level is used to build stator
flux before accelerating.
Applications
High Resolution Feedback The Universal Feedback option module, PowerFlex 755 drives only, interpolates
any sine/cosine signal into 1,048,576 counts per revolution.
Inertia Adaption Inertia adaption is used to compensate for lost motion, which occurs when a gear
box and/or a springy coupling is present. Lost Motion describes the condition in
which an input to a mechanism creates no corresponding displacement at the
output. This is most noticeable in systems with large inertia ratios using a gear-
box or flexible couplings. The term inertia adaption refers to how this function
adapts or changes the dynamic inertia seen by the speed regulator. Inertia
adaption can allow an increase in the speed regulator bandwidth, normally
limited by the mechanical transmission, by up to four times. This feature is only
available on PowerFlex 755 drives. P35 [Motor Ctrl Mode] must be set to vector
control and use a motor speed feedback device. Inertia adaption is not enabled by
default.
M1 M2
This gearbox can be represented by a spring (K) and gear backlash (BL).
Motor Load
K BL
M1 M2
When the speed of the motor increases, there is a period of time (represented by
Δ x = backlash) before the teeth of the gearbox engage. After that time, there is
some twisting (like a spring) in the shaft after the teeth of the gearbox engage.
This lost motion causes mechanical instability and limits how high the speed
regulator bandwidth can be set without causing instability. Inertia adaption
detects the lost motion and a higher speed regulator bandwidth can be achieved
without instability.
f
Slope due to springy nature
(K) of shafts after gearbox
teeth engage.
Δx
Configuration
Inertia adaption only works if there is valid inertia value entered in P76 [Total
Inertia]. Total inertia is measured during an assisted startup procedure executed
from the HIM or software wizard. The inertia tune can be executed manually by
setting P70 [Autotune] to option 4 “Inertia Tune” and starting the drive.
Inertia Torque Add
Inertia Adapt 679
Total Inertia 1
76 Inertia
Motor Acceleration Feedback Adaption
0
0 Filtered Trq
Disabled Ref
Inertia Adapt BW 705
InertiaAdaptGain 677 657
Zero
Selected Trq Ref
Trq Ref Limited Torq Ref
From
Speed Reg + 0 –
685 + II + 662
Output + +
R
1 Notch Limit
0
When Inertia adaption is activated, disable the two lead-lag filters present in the
speed regulator (setting OFF). These filters are in the speed feedback path P637
[SReg FB Fltr Sel] and at the output of the speed regulator P657 [SReg OutFltr
Sel]. Both filters are disabled by default.
Inertia Compensation Inertia Compensation is active only in PowerFlex 755 drive and in Flux Vector
(FV) motor control modes selected by P35 [Motor Ctrl Mode].
During speed changes, a certain level of torque to respond is required due to load
inertia. That level of torque is above the torque used to run at constant speed.
Inertia compensation attempts to predict the motor torque required to accelerate
and decelerate an inertial load. The Inertia compensation function calculates a
feed forward torque signal based on proportional acceleration or deceleration
rate of change of speed input and total inertia, also known as the derivative of
speed with respect to time. Then that P699 [Inertia Comp Out] signal torque
can be fed forward into the torque control, becoming an available input to the
P313 [Actv SpTqPs Mode] selector to be summed with P660 [SReg Output]
making for smoother accelerations and decelerations, especially with high inertia
loads.
Inertia Comp
Parameter 76 [Total Inertia] is calculated during the autotune and is used along
with the calculated acceleration or deceleration rate to calculate the torque adder.
Parameter 696 [Inertia Acc Gain] determines the gain for the inertia
compensation during acceleration. A gain of 1 results in 100% compensation.
Parameter 697 [Inertia Dec Gain] determines the gain for the inertia
compensation during deceleration. A gain of 1 results in 100% compensation.
Parameter 698 [Inertia Comp LPFBW] Inertia Compensation Low Pass Filter
Bandwidth. Sets the bandwidth of a low pass filter for the inertia compensation
function. The output of this filter supplies P699.
Parameter 699 [Inertia Comp Out] Inertia Compensation Output. Displays the
output of the inertia compensation function.
Parameter 700 [Ext Ramped Ref ] External Ramped Reference. This parameter is
meant for an external motor speed ramp input signal. This signal will be used by
the inertia compensation function when P695 [Inertia CompMode] = 2 “Ext
Ramp Ref.” This parameter will be entered in units of Hz or RPM, depending on
the value of P300 [Speed Units].
Parameter 596 [Speed Rate Ref ] Speed Rate Reference. This parameter is shared
by both the Inertia Compensation and Speed Compensation functions.
For example, if the controller provides a 10 second reference ramp, the controller
would also supply a Speed Rate Ref value of 1 pu / 10 sec = 0.1 sec-1 while the
reference is accelerating. When the reference is constant, Speed Rate Ref should
be zero.
For additional illustration of the control refer to PF755 Control Block Diagrams
in the PowerFlex 750-Series Programming Manual, publication 750-PM001.
Load Observer The PowerFlex 755 load observer feature compensates for and greatly reduces
load disturbances and gives quicker system response. It minimizes the load torque
requirements of the speed regulator. The load observer attempts to determine a
load estimate value that matches the load torque present in the simplified load
model. This is a simplified motor/load model.
Load Torque (Disturbance)
–
Applied Torque + 1 Velocity Output
M*s
From a control point of view, load torque is an input that is just as real as velocity
reference, but lacks a parameter. Load torque is unavoidable because it is
effectively torque times speed that creates the power to run a load. Considering
this load model, the applied torque is the electromagnetic torque generated by
the motor control and load torque is clearly shown. M is the combined motor/
load mass (inertia). The applied torque must be greater than the load torque to
accelerate the system.
Load torque is not a parameter and thus is not directly accessible, but it can be
indirectly measured. Referring to the plant model we can directly measure the
applied torque, output velocity and the inertia is generally known or calculated.
This leaves load torque as the only unknown value. If we place all three known
quantities in a box that we call an observer, load torque can be estimated.
As the output of the load observer is added to the output of the speed regulator
the function minimizes the load torque requirement for the output of the speed
regulator. Because load observer affects the torque reference and the acceleration
feedback is required, this method can only be applied on P35 [Motor Ctrl Mode]
Flux Vector control modes with motor feedback device. This feature is available
only on PowerFlex 755 drives.
Selected Filtered Trq
Trq Ref Ref
From
Speed Reg + –
685 + II + 689
Output + +
R
Notch
Load
Estimate
707
Load
2 Observer
Total Inertia 76 Load
Motor Acceleration Feedback Observer/ Disabled
Estimator 0
0
Load Observer BW 711
704
InAdp LdObs Mode
Configuration
The Load Observer can also be used in conjunction with P695 [Inertia
CompMode]. When used together, both the load torque and acceleration torque
required from the speed regulator are minimized.
Load Observer can be used on systems where load disturbances are preventing a
further increase in drive performance. The Load Observer can be applied to both
periodic load disturbances, such as a piston pump, and random load disturbances.
Load observer can be applied on systems that are not suitable for Inertia
Adaption. Load Observer cannot be active at the same time as Inertia Adaption.
Motor Control Modes P35 [Motor Ctrl Mode] selects the output mode of the drive to match the type of
motor control to use. The Default selection is a value of 1 = “Induction SV.” This
parameter is set during any of the assisted start up routines either via the HIM or
connected software tool wizard. The parameter settings follow.
• InductionVHz (0) – Induction motor, volts per Hertz control mode.
Connected to an induction motor. Used for variable torque applications
with improved efficiency energy savings and variable speed constant
torque applications such as conveyors. Can also be used in multi-motor or
synchronous motor applications.
• Induction SV (1) – Induction motor, sensorless vector control mode.
Connected to an induction motor. Used for most constant torque
applications. Provides excellent starting, acceleration, and running torque.
• Induct Econ (2) – Induction motor, economize control mode.
Used for additional energy savings in constant torque applications that
have constant speed reduced load periods.
Volts/Hertz
Gate
Frequency Ref. V Ref. Voltage Signals
V/Hz Inverter Motor
Control
0 = “Custom V/Hz”
Custom Volts/Hertz enables a wide variety of patterns using linear segments. The
default configuration is a straight line from zero to rated voltage and frequency.
This is the same volts/hertz ratio that the motor sees if started across the line. As
seen in the diagram below, the volts/hertz ratio can be changed to provide
increased torque performance when required by programming five distinct
points on the curve.
• P60 [Start Acc Boost] - Used to create additional torque for breakaway
from zero speed and acceleration of heavy loads at lower speeds.
• P61 [Run Boost] - Used to create additional running torque at low speeds.
The value is typically less than the required acceleration torque. The drive
will lower the boost voltage to this level when running at low speeds (not
accelerating). This reduces excess motor heating that could be caused if the
higher start / accel boost level were used.
• P62 [Break Voltage] and P63 [Break Frequency] - Used to increase the
slope of the lower portion of the Volts/Hertz curve, providing additional
torque.
• P25 [Motor NP Volts] and P27 [Motor NP Hertz] - Set the upper portion
of the curve to match the motor design. Marks the beginning of the
constant power region.
• P36 [Maximum Voltage] and P37 [Maximum Frequency] - Slope the
portion of the curve used above base speed.
Maximum Voltage
Base Voltage
(Nameplate)
Break Voltage
Start/Accel Boost
Run Boost
1 = “Fan/Pump”
When this option is chosen, the relationship is 1/x2. Therefore, at full frequency,
full voltage is supplied. At 1/2 rated frequency, 1/4 voltage is applied. This
pattern closely matches the torque requirement of a variable torque load
(centrifugal fan or pump – load increases as speed increases) and offers the best
energy savings for these applications.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
Sensorless Vector
Sensorless Vector mode uses a V/Hz core enhanced by excellent current
resolution, a slip estimator, a high performance current limiter and the vector
algorithms. The basic functions for SV are similar for all three motor types,
induction motor, permanent magnet motor, and synchronous reluctance motor,
however PM and SyncRel SV do not require Slip Frequency adjustments.
IM Sensorless Vector
Current Feedback - Total
Current Current Feedback
Torque 1 Est. Resolver
V/Hz Control
Gate
Speed Freq. + Freq. Ref. Current Elec. Freq. V Ref. Voltage Signals
V/Hz Inverter Motor
Limit Control
+
Torque 1 Est.
Vector V Vector
Torque 1 Est. Control
Gate
Speed Freq. Freq. Ref. Current Elec. Freq. V Ref. Voltage Signals
V/Hz Inverter Motor
Limit Control
Vector V Vector
Torque 1 Est. Control
The algorithms operate on the knowledge that motor current is the vector sum of
the torque and flux producing components of current. Values can be entered to
identify the motor values or an autotune routine can be run to identify the motor
values (see Autotune on page 35). Sensorless vector offers better torque
production and a wider speed range than V/Hz. However, it is not appropriate to
use when more than one motor is connected to the same drive.
Maximum Voltage
Base Voltage
(Nameplate)
urve
ul l L oad C
ate F ve
oxim d Cur
Appr No Loa
a te
oxim
Ap p r
Ir Voltage
Maximum Voltage
Motor Nameplate Voltage
Increasing
Rated Flux Current Load
Vtotal
In Flux Vector mode, the flux and torque producing currents are independently
controlled and speed is indirectly controlled by a torque reference. Alternatively,
the drive can control torque instead of speed in flux vector mode. In either case,
this mode can be operated either with or without feedback and will provide the
fastest response to load changes.
Flux Vector control is used with AC squirrel cage induction motors for high
performance. Motor data and an autotune is required for correct operation in this
mode (refer to Autotune on page 35 for details). In Flux Vector control, the drive
takes the speed reference that is specified by the Speed Reference Selection block
and compares it to the speed feedback. The speed regulator uses Proportional
and Integral gains to adjust the torque reference for the motor. This torque
reference attempts to operate the motor at the specified speed. The torque
reference is then converted to the torque producing component of the motor
current.
Flux Vector
High Bandwidth Current Regulator
Current Feedback
V mag
Flux Reg.
Speed Freq. Speed Current Voltage
Torque Ref. Inverter Motor
Reg. Reg. Control
V ang
Autotune Parameters
Speed Feedback
Permanent magnet motor control is selected by setting P35 [Motor Ctrl Mode]
to the appropriate choices of motor type. Refer to Appendix D of the PowerFlex
750-Series Programming Manual, publication 750-PM001 for compatible list of
Allen-Bradley Servo motors and resolution criteria.
The torque is produced because the interaction of the magnetic fields causes the
rotor to rotate. In permanent magnet motors, one of the magnetic fields is created
by permanent magnets and the other is created by the stator coils. The maximum
torque is produced when the magnetic vector of the rotor is at 90 degrees to the
magnetic vector of the stator.
Motor data and an autotune are required for correct operation in this mode.
Refer to Autotune on page 35 for details.
PM Sensorless Vector
Current Feedback - Total
Current Current Feedback
Torque 1 Est. Resolver
V/Hz Control
Gate
Speed Freq. Freq. Ref. Current Elec. Freq. V Ref. Voltage Signals
V/Hz Inverter Motor
Limit Control
Vector V Vector
Torque 1 Est. Control
High Performance and precise control will require encoder feedback. Refer to the
PowerFlex 750-Series AC Drives Installation Instructions, publication 750-
IN001, for a list of compatible High Resolution Stegmann encoder and
Heidenhain encoder feedback on the motor.
High Bandwidth Current Regulator
Current Feedback
V mag
Flux Reg.
Speed Ref. Speed Current Voltage
Inverter Motor
Reg. Reg. Control
Torque Ref. V ang
Speed Feedback
The Iq/Id reference calculation block will produce optimum Iq/Id current
reference that will try to establish maximum torque per amp control
performance.
Current Feedback
Id V mag
Iq/Id
Speed Freq. Speed Reference Current Voltage
Inverter Motor
Reg. Calculation Reg. Control
V ang
Iq
Torque Ref. Encoder
Speed Feedback
Motor Types The following explanation and descriptions of AC motor types are condensed
summaries derived from a variety of sources that focus on the history, evolution,
and feature benefits of the variety of motor designs. These designs are utilized in
all sectors of use and in vast variations of machinery, equipment, and processes.
The types of AC motors described here, powered by fixed utility frequency, are
limited to speeds based on the number of poles and winding construction.
Variable Frequency Drives (VFDs) broaden practical speed ranges of these motor
types by converting utility power and applying appropriately selected VFD
electronic control modes specifically matched to these unique motor type
designs. Motor control modes set by P35 [Motor Ctrl Mode] are also discussed in
Motor Control Modes on page 226 and the PowerFlex 750-Series Programming
Manual, publication 750-PM001.
AC Induction Motors
P35 [Motor Ctrl Mode] induction motor options.
• 0 = “Induction VHz”
• 1 = “Induction SV”
• 2 = “Induction Econ”
• 3 = “Induction FV”
AC Induction Motors (ACIMs) are the simplest and most rugged electric motor
and consist of two basic electrical assemblies: the wound stator and the rotor
assembly. The induction AC motor derives its name from currents flowing in the
secondary member (rotor) that are induced by alternating currents flowing in the
primary member (stator). The combined electromagnetic effects of the stator and
rotor currents produce the force to create rotation.
There are five basic NEMA designs for AC motors: A, B, C, D, and F. The speed-
torque curves for all five designs are shown on the following graph.
300
275
250
225
D
200
Torque - Percent of Full-Load
C
A B
175
F
150
125
Full-Load Torque
100
75
50
25
0
0 10 20 30 40 50 60 70 80 90 100
Speed - Percent
Speed - Torque Curves of NEMA A, B, C, D, and F Motors
AC Motors - Design C have high starting torque with normal starting current
and low slip. NEMA design C motor has a higher starting torque than either the
A or B designs. This torque is in the vicinity of 225% of full-load torque. Design
C AC motors are normally used where breakaway loads are high at starting, but
which normally run at rated full load and are not subject to high overload
demands after running speed has been reached.
AC Motors - Design F exhibit low starting torque, low starting current, and low
slip. These AC motors are built to obtain low locked-rotor current. Both locked-
rotor and breakdown torque are low. Normally these AC motors are used where
starting torque is low and where high overloads are not imposed after running
speed is reached.
Wound-rotor AC Motors
Squirrel-cage AC motors are relatively inflexible with regard to speed and torque
characteristics, but a special wound-rotor AC motor has controllable speed and
torque. Application of wound-rotor AC motors is markedly different from
squirrel-cage AC motors because of the accessibility of the rotor circuit. AC
motor performance characteristics are obtained by inserting different values of
resistance in the rotor circuit.
Multispeed AC Motors
P35 [Motor Ctrl Mode] induction motor options.
• 0 = “Induction VHz”
• 1 = “Induction SV”
• 3 = “Induction FV”
Two-winding AC motors have two separate windings that can be wound for any
number of poles so that other speed ratios can be obtained. However, ratios
greater than 4:1 are impractical because of AC motor size and weight.
When retrofitted with a VFD, the motor is generally wired for the speed range
intended to be optimized. Autotuned per representative nameplate information
and operated as a single winding single speed induction motor.
Synchronous AC Motors
P35 [Motor Ctrl Mode] induction motor options.
• 0 = “Induction VHz”
There are two major types of synchronous AC motors: non-excited and direct-
current excited electric motors. Application of a VFD is to vary the desired
synchronous speed of the machine.
Permanent magnet motor control is selected by setting P35 [Motor Ctrl Mode]
to the appropriate choices of motor type. Refer to the PowerFlex 750-Series
Programming Manual, publication 750-PM001, Appendix D for compatible List
of Allen-Bradley Servo motors and resolution criteria.
SPM or PMSM is a rotating electrical machine that has the stator phase windings
and rotor permanent magnets. The air gap magnetic field is provided by these
permanent magnets therefore it remains constant.
The torque is produced because the interaction of the magnetic fields causes the
rotor to rotate. In permanent magnet motors, one of the magnetic fields is created
by permanent magnets and the other is created by the stator coils. The maximum
torque is produced when the magnetic vector of the rotor is at 90 degrees to the
magnetic vector of the stator.
Motor data and an autotune are required for correct operation in this mode.
Refer to Autotune on page 35 for details on the autotune.
Field Oriented Control is the most popular control technique used with PMSMs.
As a result, torque ripple can be extremely low, on par with that of ACIMs.
PMSM motors provide higher power density for their size compared to ACIMs.
This is because with an induction machine, part of the stator current is required
to “induce” rotor current in order to produce rotor flux. These additional
currents generate heat within the motor. In a PMSM, the rotor flux is already
established by the permanent magnets on the rotor.
Most PMSMs utilize permanent magnets which are mounted on the surface of
the rotor. This makes the motor appear magnetically “round,” and the motor
torque is the result of the reactive force between the magnets on the rotor and the
electromagnets of the stator. This results in the optimum torque angle being 90
degrees, which is obtained by regulating the d-axis current to zero in a typical
FOC application.
Some PMSMs have magnets that are buried inside of the rotor structure. These
motors are called Interior Permanent Magnet, or IPM motors. As a result, the
radial flux is more concentrated at certain spatial angles than it is at others. This
gives rise to an additional torque component called reluctance torque, which is
caused by the change of motor inductance along the concentrated and non-
concentrated flux paths.
This causes the optimum Field Oriented Control torque angle to be greater than
90 degrees, which requires regulating the d-axis current to be a fixed negative
ratio of the q-axis current. This negative d-axis current also results in field
weakening, which reduces the flux density along the d-axis, which in turn
partially lowers the core losses. As a result, IPM motors boast even higher power
output for a given frame size.
Motor data and an autotune are required for correct operation in this mode.
Refer to Autotune on page 35 for details on the autotune.
Synchronous reluctance motors have an equal number of stator and rotor poles.
The projections on the rotor are arranged to introduce internal flux “barriers,”
holes which direct the magnetic flux along the so-called direct axis. Typical
numbers of poles are 4 and 6. Following example of a 4 pole rotor and 6 pole
stator.
The first linear electric motor was conceived by Wheatstone more than 100 years
ago. But large air gaps and low efficiencies prevented linear electric motors from
being widely used until recent advances in design and VFD controls.
A linear electric motor in concept has rotary electric motor stator cores, unrolled
out over a linear path. The circular stator becomes a linear stator, being defined as
a single-sided linear induction electric motor (SLIM). Likewise, if the circular
stator is cut into two sections and flattened, the electric motor becomes a double-
sided linear induction electric motor (DLIM). The DLIM and SLIM both
require a two or three-phase stator (primary) winding and a flat metallic or
conductive plate-type armature (secondary) instead of a rotor.
There are several important differences between linear and rotary electric
induction motors that require understanding. Unlike rotary electric motors, the
linear motor has a beginning and an end to its travel. First, the moving secondary
material enters the primary (stator field) at one end of the electric motor and exits
at the opposite end. Induced currents in the secondary material at the entry edge
resist air-gap flux buildup. And at the exit edge, the material retards the air-gap
flux decay. This results in an uneven air-gap flux distribution which contribute to
challenges in sizing VFDs and optimizing set up of control frequency and
voltage. VFD control uses either fixed V/Hz, or independently controlled
frequency and voltage.
Linear Synchronous Motors (LSMs) are similar in concept with stator cores,
arranged along a path for motion, rather than contained in a frame for rotary
motion. But the field in a LSM moving secondary element is usually provided by
permanent magnets. There are no significant currents induced. Magnets are
embedded in the moving element. This does allow for more definitive position
control and holding position without excessive heat generation. Generally some
sort of position sensor and feedback are necessary to implement control of LSMs
via VFD are necessary.
At the time of this writing there has been minimal experience applying VFDs to
control Linear Synchronous Motors (LSMs). Only this short description of its
construction is included.
Notch Filter A notch filter exists in the torque reference loop to reduce mechanical resonance
created by a gear train. P687 [Notch Fltr Freq] sets the center frequency for the 2
pole notch filter, and P688 [Notch Fltr Atten] sets the attenuation of the notch
filter in the vector control torque reference section. Attenuation is the ratio of the
notch filter input signal to its output at the P687 [Notch Fltr Freq]. An
attenuation of 30 means that the notch output is 1/30th of the input at the
specified frequency.
The notch filter is valid only in Flux Vector Motor Control modes (P35).
Example
A mechanical gear train consists of two masses (the motor and the load) and
spring (mechanical coupling between the two loads).
Bm BL
Kspring
Jm Jload
Jm + Jload
ResonanceHz = Kspring ---------------------------------
Jm Jload
• Jm is the motor inertia (seconds)
• Jload is the load inertia (seconds)
• Kspring is the coupling spring constant (rad2 / sec)
The following graph shows a two mass system with a resonant frequency of 62
radians/second (9.87 Hz). One Hertz is equal to 2p radians/second.
Figure 26 - Resonance
Motor Torque
Motor PU
Roll PU
The following represents the same mechanical gear train but with [Notch Filter
Freq] set to 10.
Figure 27 - 10 Hz Notch
Motor Torque
Motor PU
Roll PU
To see the effects of the notch filter use test points T65 and T73 in torque
control. T65 is before the filter and T73 after. And test point Txx (before) and
Txx (after) in position control. See the partial block diagram below.
Notch Filter
Notch
PsnNtchFltrDepth
PsnNtchFltrFreq
Regen Power Limit The P426 [Regen Power Lmt] 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 overvoltage can occur. When using the bus regulator [Regen
Power Lmt] can be left at factory default, -50%.
When using dynamic braking or a regenerative supply, [Regen Power Lmt] can be
set to the most negative limit possible (–800%). When you have dynamic braking
or regenerative supply, but want to limit the power to the dynamic brake or
regenerative supply, [Regen Power Lmt] you can set a specific level. Values in this
parameter are valid only in a Flux Vector mode.
The following series of plots describes the difference between changing Regen
Power Limit versus changing the Negative Torque Limit. The beginning part of
every plot is identical, this is the acceleration of the motor. Once the stop is
commanded and deceleration begins, note the red trace in each. This represents
torque current. Because power is proportional to speed, as the speed decreases,
the torque current increases allowing more power to be dissipated.
Note the speed feedback in the RPL = -20%, the slower the motor gets the faster
it’s brought to zero speed and the torque current increases. The higher the value
in Regen Power Limit the more power is allow to pass through.
Focus on the torque current (red) trace as you scroll through the plots and note
the change in the shape as the regen power limit was increase. Then see how it is
clamped at a particular level when Negative Torque Limit is changed.
RPL = -20%
RPL = -50%
RPL = 100%
RPL = -200%
DB Active
NTL = -20%
NTL = -50%
NTL = -100%
Speed Reference The speed reference can come from a variety of sources. Some can be selected
through digital inputs or via bit manipulation of the Network Logic Command
Word:
• HIM (local or remote)
• Analog Input
• Preset Speed Parameters
• Jog Speed Parameters
• Auxiliary Velocity Feedback
• Network Communication
• Process PID Loop
• MOP Reference
• DeviceLogix software
Spd Ref
Command
Spd Ref A
Ref A
Auto Speed Reference Control
Trim Ref A
+
Trim % Ref A
Jogging/ Limited
Spd Ref B Selected Spd Ref Oil Pump/ Limit Spd Ref
Direction Skip Fiber Speed Ref
Ref B
Auto
+ Autotune/
Homing/ Mode
Switch
Control Bands App. Stop
Trim Ref B
+ Overrides
Limit
Trim % Ref B
From
PI Regulator
Presets 3-7 Auto (Exclusive Mode)
DPI Ports 1-6 Manual
ENet Spd Ref
Speed
Comp
Vector Ramp S-Curve
Flux Ramped
Vector Linear Vel Ref Motor Spd Ref
Vel Ref
Ramp & x Velocity Reg
Filter
S Curve Ref
Limit
From From Max Speed
Pt-Pt Profile PI Regulator Speed Ref
Generator (Trim Mode) Scale
Rate
Select From Pos Reg
Position Output
Regulator Filter
V/F Speed Control
Ramped
VF or SV Linear Speed Ref
Ramp & Frequency
S Curve Ref
Limit Limit
V/F Ramp S-Curve
Max Speeds Max Speed +
Droop From Overspeed Limit
Velocity Trim
Regulator Speed
From Status
PI Regulator Speed Feedback Status
From
(Trim Mode) Slip Comp Vector Ramp Status
F/F Ramp Status
Spd Ref
Command
Spd Ref A
Ref A
Auto Speed Reference Control
Trim Ref A
+
Trim % Ref A
Profiling/ Limited
Spd Ref B Jogging/
Selected Spd Ref Direction Limit Spd Ref Speed Ref
Lift App/ Skip Fiber
Ref B
Auto
+ Autotune/ Mode
Switch
Control Bands App.
Stop / Torque
Proving
Trim Ref B
+ Homing/
Overrides Limit
Trim % Ref B
From
PI Regulator
Presets 3-7 Auto (Exclusive Mode)
DPI Ports 1-6 Manual
ENet Spd Ref
Rate
Select From Pos Reg
Position Output
Regulator Filter
V/F Speed Control
Ramped
VF or SV Linear Speed Ref
Ramp & Frequency
S Curve Ref
Limit Limit
V/F Ramp S-Curve
Max Speeds Max Speed +
Droop From Overspeed Limit
Velocity Trim
Regulator Speed
From Status
PI Regulator Speed Feedback Status
From
(Trim Mode) Slip Comp Vector Ramp Status
F/F Ramp Status
Network Reference
Speed Reference A is the normal speed reference used. To choose a source for this
reference, make a selection in P545 [Spd Ref A Sel]. Also, when the network
(Logic Command Word) is used as the speed reference, refer to the following
documentation for details of operation:
• PowerFlex 750-Series AC Drives Programming Manual, 750-PM001
• PowerFlex 755 Drive Embedded EtherNet/IP Adapter User Manual,
750COM-UM001
• PowerFlex 20-750-ENETR Dual-port EtherNet/IP Option Module User
Manual, 750COM-UM008
• EtherNet/IP Network Configuration User Manual, ENET-UM001
The Reference is a 32-bit REAL (floating point) piece of control data produced
by the controller and consumed by the adapter. The Feedback is a 32-bit REAL
(floating point) piece of status data produced by the adapter and consumed by
the controller.
For a PLC-5®, SLC™ 500 or MicroLogix™ 1100/1400 controller, the 32-bit REAL
Reference word is always words 2 (Least Significant Word) and 3 (Most
Significant Word) in the output image and the 32-bit REAL Feedback is always
words 2 (Least Significant Word) and 3 (Most Significant Word) in the input
image.
When using a drive Add-On Profile, the Reference and Feedback are
automatically formatted properly and displayed as a controller tag. When using
the Generic Profile, the I/O image is integer-based and the Reference and
Feedback are floating point. Because of this, a COP (Copy) instruction or User
Defined Data Type (UDDT) is required to correctly write values to the
Reference and read values from the Feedback. Refer to the PowerFlex 755
Embedded EtherNet/IP Adapter User Manual or to the PowerFlex 20-750-
ENETR Dual-port EtherNet/IP Option Module User Manual for ladder logic
program examples.
When using the drive Add-On Profile, the controller tags for Reference and
Feedback are automatically and properly formatted. This eliminates the need for
data conversion using COP (copy) instructions or a UDDT to copy the DINT
data into a REAL word.
The Reference and Feedback 32-bit REAL value represents drive speed. The
scaling for the speed Reference and Feedback is dependent on drive P300 [Speed
Units]. For example, if P300 is set to Hz, a 32-bit REAL Reference value of 30.0
equals a Reference of 30.0 Hz. If P300 is set to RPM, a 32-bit REAL Reference
value of 1020.5 equals a Reference of 1020.5 RPM. Note that the commanded
maximum speed can never exceed the value of drive P520 [Max Fwd Speed].
Table 12 shows example References and their results for a PowerFlex 755 drive
that has its:
• P300 [Speed Units] set to Hz.
• P37 [Maximum Freq] set to 130 Hz.
• P520 [Max Fwd Speed] set to 60 Hz.
When P300 [Speed Units] is set to RPM, the other parameters are also in RPM.
Jog
When the drive is not running, pressing the HIM’s Jog soft button or a
programmed Jog digital input function or by Logic Command (sent over a
communication network) causes the drive to jog at a separately programmed jog
reference. This jog speed reference value is entered in P556 [ Jog Speed 1] or P557
[ Jog Speed 2].
Jogging
Drive Status 1
(Jogging)
935 17
0
1,0 1
Jog Speed 1 556
0,1
Jog Speed 2 557
Polarity
The polarity configuration can be selected as unipolar, bipolar, or reverse
disabled via P308 [Direction Mode]. When in Unipolar mode, the sign of the
speed reference value (and therefore direction of motor rotation) is determined
by P879 [Drive Logic Rslt] Bit 4 “Forward” and Bit 5 “Reverse.” When in Bipolar
mode, the sign of the speed reference value determines the direction of motor
rotation. When in Reverse Disable mode, negative speed reference values are
rejected and a zero speed value is used in their place.
Direction Mode Control
Direction Mode
308
Bipolar 1
Rev Disable 2
Max
0
Unipolar 0
X
Forward
Command Logic
Unipol 1
(+1)
Fwd
Unipol 0
(-1)
Rev
Trim
The speed reference source, specified in P545 [Spd Ref A Sel] or P550 [Spd Ref
B Sel], can be trimmed by variable amount. You have the option to trim the speed
reference by a percentage of the reference and/or by a fixed amount and can
dictate whether it is a positive or negative value. Refer to the PowerFlex 750-
Series Trim Block Diagram below.
Speed Ref A Sel
545
* Note: Analog Hi, Lo
scaling only used when 930 Speed Ref Source
‘d’ Prefix Refers to Diagnostic Item Number (ex. d33) – Reference Symbol Legend Speed Units
Analog Input is selected 300
(Hz / RPM) 616 SpdTrimPrcRefSrc
Disabled (0)
617 Spd Trim Source
Spd Ref A Stpt 546 591 Spd Ref Sel Sts
TrmPct RefA Sel Trim Ref A Sel
Example 1
The following example shows the configuration and resultant of the percent trim
function:
• P545 [Spd Ref A Sel] = P546 [Spd Ref A Stpt]
• P546 [Spd Ref A Stpt] = 20.00 Hz
• P608 [TrmPct RefA Sel] = P609 [TrmPct RefA Stpt]
• P609 [TrmPct RefA Stpt] = 25%
• P2 [Commanded SpdRef ] = 25.00 Hz
If the speed reference = 20 Hz and if the trim percentage = 25%, the resulting
trim is 20 Hz x 25% = 5 Hz, which when added to the speed reference = 25 Hz.
As the speed reference changes, the amount of trim also changes because it is a
percent of the speed reference. If the trim percentage = -25%, then the resulting
trim is 20 Hz x -25% = -5 Hz, the speed reference = 15 Hz.
Example 2
The following example shows the configuration and resultant of the fixed
amount trim function:
• P545 [Spd Ref A Sel] = P546 [Spd Ref A Stpt]
• P546 [Spd Ref A Stpt] = 20.00 Hz
• P600 [Trim Ref A Sel] = P601 [Trim Ref A Stpt]
• P601 [Trim Ref A Stpt] = 10.00 Hz
• P2 [Commanded SpdRef ] = 30.00 Hz
If the speed reference = 20 Hz, and if the trim set point = 10 Hz, the speed
reference is 20 Hz + 10 Hz = 30 Hz. If the trim set point = -10 Hz, then the
speed reference = 10 Hz.
Example 3
The following example shows the configuration and resultant of utilizing both
the perfect and fixed amount trim function:
• P545 [Spd Ref A Sel] = P546 [Spd Ref A Stpt]
• P546 [Spd Ref A Stpt] = 20.00 Hz
• P608 [TrmPct RefA Sel] = P609 [TrmPct RefA Stpt]
• P609 [TrmPct RefA Stpt] = 25%
• P600 [Trim Ref A Sel] = P601 [Trim Ref A Stpt]
• P601 [Trim Ref A Stpt] = 10.00 Hz
• P2 [Commanded SpdRef ] = 35.00 Hz
If the speed reference = 20 Hz, and if the trim percentage = 25%, that resulting
trim is 20 Hz x 25% = 5 Hz, and if the trim set point = 10 Hz, the speed reference
is 20 Hz + 5 Hz + 10 Hz = 35 Hz. If the trim percentage = -25% and the trim set
point = -10 Hz, then the speed reference = 5 Hz.
Maximum and minimum speed limits are applied to the forward and reverse
reference. The minimum speed limits create a band that the drive will not run
continuously within, but ramps through. This is due to the forward or reverse
minimum speeds, P522 [Min Fwd Speed] and P523 [Min Rev Speed]
respectively. If the reference is positive and less than the Min Fwd Speed, it is set
to the Min Fwd Speed minimum. If the reference is negative and greater than
Min Rev Speed minimum, it is set to the Min Rev Speed minimum. If the
minimum is not 0, hysteresis is applied at 0 to prevent bouncing between the Min
Fwd Speed and Min Rev Speed minimums. If the reference is greater than the
forward or reverse maximum speeds, P520 [Max Fwd Speed] and P521 [Max
Rev Speed] respectively, the speed reference is clamped to the their respective
maximum limit.
Speed Ref Limits
Limit Limit
The picture below depicts how the Min/Max Fwd/Rev Speed bands and its
influence the drive. The BLUE line depicts the desired speed reference (set point)
and the RED line depicts the drive’s commanded speed reference (actual). Notice
there are different results, depicted by the grey dotted line, along the graph.
2 [Commanded SpdRef]
546 [Spd Ref A Stpt]
520 [Max Fwd Speed]
Maximum Frequency
P37 [Maximum Freq] defines the maximum reference frequency. The actual
output frequency can be greater as a result of slip compensation and other types
of regulation.
Overall Operation for Sensorless Vector Control and Volts per Hertz
Control
The drive takes the speed reference and adjusts it using a proportional and
integral regulator to compensate for slip and the programmed limits.
The drive takes the speed reference that is specified by the speed reference control
loop and compares it to the speed feedback. The speed regulator uses
proportional and integral gains along with other advanced tuning features to
adjust the torque reference that is sent to the motor. The torque reference is used
to operate the motor at the specified speed. The regulator is designed for optimal
bandwidth for changing speed and load. If an alternate feedback device is used
with automatic tachometer switchover, the alternate values of these parameters
are used.
The Speed Regulator Bandwidth sets the speed loop bandwidth and determines
the dynamic behavior of the speed loop. As bandwidth increases, the speed loop
becomes more responsive and can track a faster changing speed reference. A
change to this parameter causes an automatic update of P645 [Speed Reg Kp],
P647 [Speed Reg Ki], and P644 [Spd Err Fltr BW]. To disable the automatic gain
and filter update, set this parameter to a value of zero. The configuration settings
for Inertia Adaption (PowerFlex 755 only) is automatically selected when this
feature is enabled.
The maximum allowable value of this parameter is limited by the ratio of P646
[Spd Reg Max Kp] to P76 [Total Inertia], and the type of speed feedback source
in use (encoder versus open loop). For operation following an automatic tach
switchover, the bandwidth specified in P648 [Alt Speed Reg BW] is used.
Sets the damping factor of the vector speed loop’s characteristic equation.
Damping affects the integral gain when a non-zero bandwidth has been entered.
A damping factor of 1.0 is considered critical damping. Lowering the damping
produces faster load disturbance rejection, but can cause a more oscillatory
response. When the speed regulator bandwidth is zero, gains are set manually and
damping factor has no effect.
Sets the integral gain of the speed regulator (in FV Motor Control modes). This
value is automatically calculated based on the bandwidth setting in P636 [Speed
Reg BW], P645 [Speed Reg Kp] and P653 [Spd Loop Damping]. Integral gain
can be manually adjusted by setting P636 [Speed Reg BW] to a value of zero.
Integral gain has effective scaling of (per unit torque/sec) / (per unit speed).
Servo Lock Gain - P642 [Servo Lock Gain] (PowerFlex 755 only)
Sets the gain of an additional integrator in the Vector Control mode speed
regulator. The effect of Servo Lock is to increase stiffness of the speed response to
a load disturbance. It behaves like a position regulator with velocity feed forward,
but without the pulse accuracy of a true position regulator. Gain is normally set
to less than 1/3 speed regulator bandwidth, or for the desired response. A value of
zero disables this feature.
Torque Reference The Torque Reference is a reference value in percent that represents the rated
torque development capability of the motor. During the autotune process,
measurements are made to determine the motor equivalent circuit including
connected impedance from drive terminals to the motor. Based on entered motor
nameplate information and autotune results, the Torque Reference is established
as 100% or 1 PU equal to the rated N•m (lb•ft) torque development capability
of the motor at Full Load ampere rating within ±5% without encoder feedback,
possibly within ±2% with encoder feedback.
True Torque control at the motor shaft can only occur when P35 [Motor Ctrl
Mode] is configured for one of the Flux Vector control mode choices. Likewise,
Torque Reference parameters are only active when Flux Vector control modes in
P35 [Motor Ctrl Mode], options 3 “Induction FV,” 6 “PM FV,” and 10 “IPM FV.”
The inherent Torque Reference source (default setting in any of the applicable
FV Control modes only) is the output from the Speed Regulator parameter,
P660 [SReg Output] in percent. As it passes through trimming and limiting
functions, it ultimately becomes a commanding torque reference, P690 [Limited
Trq Ref ], and an input to and for the inverter Current control to output voltage
and frequency to the motor and regulate torque producing vector of current
accordingly. Consequently, the motor develops torque as necessary to aid the
Speed Regulator to maintain minimal speed error between commanded speed
and speed feedback.
Actv SpTqPs
Mode
313 Torque Step
686 Inertia
Adaption
Limited Trq Ref
690
+
+ FOC
Speed/
FrctnComp Torque/ Perm Magn
Mode
+ Notch -
FrctnComp Position + +
Filter & Vector
1560 Out Mode + +
Control
1567 Selection Limit
640
Torque
Filtered 685 Limit
SpdFdbk Generation Motor
Selected Trq Ref
Trq Ref A Sel E1
675
Torque
Ref Gear
Trq Ref B Sel
Selection
680
Load
E2
PID Torque
Trim / Excl
Selection
1079
There are additional internal Torque Reference sources within the drive such as
from a variety of Position Regulator outputs for the motor to develop the
corresponding amount of torque necessary to follow a point to point position
profile, cam profile, maintain a set position or follow a Motion Planner directed
profile.
Sel] and P680 [Trq Ref B Sel], the output can be summed together and along
with the output of “Torque Trim,” to become P4 [Commanded Trq].
0.0 ( Disabled )
Trq Ref A Stpt
676 ( Setpoint ) Default
Other
Trq Ref A Mult 679 x
3
0
For additional and expanded illustration of the Torque Control, refer to the
PowerFlex 755 Control Block Diagrams starting on page 375.
The following are key parameters related to the Torque Reference control
illustrated in Figure 30 and Figure 31.
P675 [Trq Ref A Sel] and P680 [Trq Ref B Sel] - Torque Reference A, B Select
Selects the source for a torque reference, used when the drive is configured to
command torque according to P309…312 [SpdTrqPsn Mode n]. The values of
the torque reference sources are added together to provide a single torque
reference.
P676 [Trq Ref A Stpt] and P681 [Trq Ref B Stpt] - Torque Reference A, B
Setpoint
A digital torque value to be used as a possible source for P675 and P680
respectively.
P677 [Trq Ref A AnlgHi] and P682 [Trq Ref B AnlgHi] - Torque Reference A,
B Analog High
Used only when an analog input is selected as a torque reference according to
P676 or P681. Sets the torque value that corresponds to [Anlg Inn Hi] on an I/O
module or on the main control (product dependent). This establishes scaling
throughout the range.
P678 [Trq Ref A AnlgLo] and P683 [Trq Ref B AnlgLo] - Torque Reference A,
B Analog Low
Used only when an analog input is selected as a torque reference according to
P676 [Trq Ref A Stpt] or P681 [Trq Ref B Stpt]. Sets the torque value that
corresponds to [Anlg Inn Lo] on an I/O module or on the main control (product
dependent). This establishes scaling throughout the range.
P679 [Trq Ref A Mult] and P684 [Trq Ref B Mult] - Torque Reference A, B
Multiplier
A multiplier that is applied to the values referenced by P675 [Trq Ref A Sel] and
P680 [Trq Ref B Sel] respectively. A value of 1 leaves the reference unaffected.
Negative values invert the reference.
Refer to Speed Torque Position on page 266 for an explanation of Speed Torque
Position mode choices for operating in various specific modes utilizing Internal
and/or External torque reference sources.
Speed Torque Position The PowerFlex 750-Series drives have the ability to have four separate Speed
Torque Position modes with the following parameters:
• P309 [SpdTrqPsn Mode A]
• P310 [SpdTrqPsn Mode B]
• P311 [SpdTrqPsn Mode C]
• P312 [SpdTrqPsn Mode D]
These modes selections only apply to the Flux Vector control modes in P35
[Motor Ctrl Mode], options 3 “Induction FV,” 6 “PM FV,” and 10 “IPM FV.”
These parameters select between speed regulation, torque regulation, or position
regulation operation of the drive. The source of P685 [Selected Trq Ref ] is
determined by the selection in these parameters when P181 [DI SpTqPs Sel 0]
and P182 [DI SpTqPs Sel 1] have selected “Disabled” or selected bits that are
logic low. In P935 [Drive Status 1], three bits are provided that indicate the
Regulation mode of the drive when it is running. Bit 21 “Speed Mode” is set
when the drive is running with the speed regulator active. Similarly, Bit 22
“PositionMode” and Bit 23 “Torque Mode” indicate when their respective
regulation modes are active. Under some conditions, the active Torque mode can
be forced into Speed mode regardless of the setting of Speed/Torque/Position.
P313 [Actv SpTqPs Mode] indicates this and reflects the mode selection that is in
use.
Psn Camming 8
[6A1], Load Observer BW 711
[6D2], 704
Commanded Trq Psn PLL 9 [10D5],
[11D2], InAdp LdObs Mode
From Torq Ref 4
[21H4] Psn Direct 10 [11I1],
[12H5],
[16H2]
SpdTrqPsn Mode A Actv SpTqPs
309
ABCD
Mode
Select
SpdTrqPsn Mode B 310 313
0 0 Drive Status 1
SpdTrqPsn Mode C 0 1
311 935 21 22 23
1 0 Select
SpdTrqPsn Mode D 312 1 1 Logic Torque Mode
PositionMode
DI SpTqPs Sel 1 182 SLAT Err Stpt 314 Speed Mode
DI SpTqPs Sel 0 181 SLAT Dwell Time 315
Mtr Option Cnfg
(Zero TrqStop)
(Trq ModeStop) 40 0 1 2
(Trq ModeJog)
The following are key parameters related to the Torque Reference control
illustrated in Figure 32.
P314 [SLAT Err Stpt] - Speed Limited Adjustable Torque, Error Setpoint
Sets the magnitude of P641 [Speed Error] at which the SLAT function will
release its Forced Speed Mode signal. This condition must exist for the time
specified by P315 [SLAT Dwell Time]. Once released, the drive can operate as a
torque regulator, depending on the relative levels of P660 [SReg Output] and P4
P315 [SLAT Dwell Time] - Speed Limited Adjustable Torque, Dwell Time
Sets the time period that P641 [Speed Error] must exceed the P314 [SLAT Err
Stpt] magnitude in order to return to min/max torque mode.
P675 [Trq Ref A Sel] and P680 [Trq Ref B Sel] - Torque Reference A, B Select
Selects the source for a torque reference, used when the drive is configured to
command torque according to P309…312 [SpdTrqPsn Mode n]. The values of
the torque reference sources are added together to provide a single torque
reference.
Attenuation
Freq (Hz)
For additional and expanded illustration of the Torque Control, refer to the
PowerFlex 755 Control Block Diagrams starting on page 375.
Zero Torque
Operation in Zero Torque mode enables the motor to be fully fluxed and ready to
rotate when a speed command or torque command is given. This mode can be
used for a cyclical application where throughput is a high priority. The control
logic can select zero torque during the rest portion of a machine cycle instead of
stopping the drive. When the cycle start occurs, instead of issuing a start to the
drive, a Speed Regulator mode can be selected. The drive immediately accelerates
the motor without the need for flux up time.
IMPORTANT Zero Torque can excessively heat the motor if operated in this mode for
extended periods of time. A load or flux current is still present when the drive is
operating in Zero Torque mode. A motor with an extended speed range or
separate cooling methods (blower) can be required.
Speed Regulation
Operating as a speed regulator is the most common and simplest mode to set up.
Examples of speed regulated applications are blowers, conveyors, feeders, pumps,
saws, and tools. In a speed regulated application, the speed regulator output
generates the torque reference. Note that under steady state conditions the speed
feedback is steady while the torque reference is a constantly adjusting signal. This
is required to maintain the desired speed. In a transient state, the torque reference
changes dramatically to compensate for a speed change. A short duration change
in speed is the result of increasing or decreasing the load very rapidly.
For the PowerFlex 755 drive, the Inertia Compensation, Inertia Adaption, and
the Friction Compensation influence the output of the speed regulator.
Torque Regulation
element set the speed. Configuring the drive for torque regulation requires P309
[SpdTrqPsn Mode A] to be set to 2 “Torque Ref.” In addition, a reference signal
must be linked to the torque reference. For example, when Analog Input 0 is used
for the torque reference, P675 [Trq Ref A Sel] needs to be configured for “Anlg
In0 Value.”
When operating in a Torque mode, the motor current is adjusted to achieve the
desired torque. If the material being wound or unwound breaks, the load
decreases dramatically and the motor can potentially go into a runaway
condition.
SLAT Minimum
Choose SLAT minimum mode when material direction and speed reference is
considered “Forward” and a positive speed reference value for the Speed
Regulator. The Speed Regulator output then creates a positive Torque Reference
command value.
Typically configure a positive speed reference value slightly greater than what is
equivalent to maintain planned material line speed. This will in turn force the
speed regulator into saturation (the speed reference is slightly above the speed
feedback) commanding a “more positive” torque reference than what the torque
mode torque reference value is. In this scenario the drive would follow the torque
reference until there was a breakage or slippage in the application.
When the drive is following a torque reference (torque mode in SLAT minimum
mode), either one of two conditions will force the drive into following the speed
reference in (speed mode):
• The output of the speed regulator becomes less than the torque reference.
The reaction when triggered at the very point that the torque reference
value in speed mode is mathematically less than the value in torque mode,
generally results in greater velocity overshoot. This is the same condition
that would exist in minimum torque /speed mode without SLAT features.
The following plot represents the result without using SLAT features.
Internal Torque
Command
At Speed
Relay
Load Step
(Decreased)
Speed
Feedback
Or
• The speed error becomes negative (the speed feedback becomes greater
than the speed reference). This would force the control into speed
regulator mode, a condition called Forced Speed Mode FSM.
By forcing the drive to enter speed mode FSM, the transition occurs earlier than
it would have if the reaction was triggered at the very point that the torque
reference value in speed mode is mathematically less than the value in torque
mode, generally resulting in less velocity overshoot.
P314 [SLAT Err Stpt] and P315 [SLAT Dwell Time] allow setting some
hysteresis for turning off the forced speed mode. They are set to 0 as default so
that there is no hysteresis. In SLAT minimum mode, [SLAT Err Stpt] sets how
much less the speed feedback should be than the speed reference before turning
off the forced speed mode. The SLAT dwell time sets how long the speed error
must exceed the SLAT error set point before turning off the forced speed mode.
At the time that the drive switches from torque mode to forced speed mode, the
speed regulator output is loaded with the internal motor torque reference to
create a smooth transition. In order for the drive to switch from speed mode back
to torque mode, forced speed mode (if active) must first be turned off. Forced
speed mode will turn off when the speed error is greater than the SLAT error set
point for the SLAT dwell time.
With default parameter settings, this will occur when the speed error becomes
positive.
When forced speed mode is off, the drive will switch back to Torque mode when
the speed regulator output becomes greater than the torque reference.
Empirically setting values P314 [SLAT Err Stpt] and P315 [SLAT Dwell Time]
other than default may help create even smoother transitions.
P314 [SLAT Err Stpt] Speed Error < 0
P315 [SLAT Dwell Time] Forced Speed
Low Pass Off On Mode (FSM)
Filter
The drive is set for SLAT Minimum mode, so that the drive normally runs in
Torque mode and follows P675 [Trq Ref A Sel]. [Trq Ref A Sel] comes from an
external controller and is approximately 60% of motor torque during the
snapshot (shown below). The speed reference, also from an external controller, is
set just above the speed feedback to saturate the speed regulator while in Torque
mode. The following snapshot captures what occurs in the drive during a break in
the web.
Choose SLAT Maximum mode when material direction and speed reference is
considered “Reverse” and a negative speed reference value for the Speed
Regulator. The Speed Regulator output then creates a negative Torque Reference
command value.
In SLAT Maximum mode, the drive switches from Torque mode to Speed mode
when either one of the two following conditions occur.
• The output of the speed regulator becomes more than the torque
reference. This is the same condition that exists in Maximum Torque/
Speed mode without SLAT features.
Or
• The speed error becomes positive (the speed feedback becomes less than
the speed reference). This forces the control into speed regulator mode, a
condition called Forced Speed Mode (FSM).
By forcing the drive to enter FSM, the transition occurs earlier than it would have
if the reaction was triggered at the very point that the torque reference value in
speed mode is mathematically more than the value in torque mode, generally
resulting in less velocity overshoot.
P314 [SLAT Err Stpt] and P315 [SLAT Dwell Time] allow for setting some
hysteresis for turning off the forced speed mode. They are set to 0 as default so
that there is no hysteresis. In SLAT maximum mode, [SLAT Err Stpt] sets how
much more the speed feedback (algebraically sign sensitive) should be than the
speed reference before turning off the forced speed mode. [SLAT Dwell Time]
sets how long the speed error must be less than the SLAT error set point before
turning off the forced speed mode.
At the time that the drive switches from torque mode to speed mode the speed
regulator output is loaded with the value from the torque reference to create a
smooth transition.
In order for the drive to switch from speed mode back to torque mode, forced
speed mode (if active) must first be turned off. FSM will turn off when the speed
error is less than the SLAT error set point for the SLAT dwell time.
With default parameter settings, this will occur when the speed error becomes
negative. When forced speed mode is off, the drive will switch back to torque
mode when the speed regulator output becomes less than the torque reference.
Sum
Notes:
Drive Features
Topic Page
Data Logging 277
Energy Savings 282
High Speed Trending 283
Position Homing 292
Data Logging This wizard logs the values of up to six parameters in a single drive at a specified
interval for some period of time, with the minimum sample rate one second. The
information is saved as a comma delimited *.csv file for use with Microsoft Excel
or any other spreadsheet program. Clicking Next lets you configure the data
logger. When data logging is completed, click Finish to close the wizard. If you
click Finish before the data logging is completed, only the data collected up to
that point is saved in the file. You can cancel the wizard at any time by clicking
Cancel or the Close icon. All logged data is lost, and the file is deleted.
Configuration Example
1. Connect to the drive that you want to trend via DriveExecutive,
DriveExplorer, Logix Designer Drive AOPs, or Connected Components
Workbench software tool.
Depending if you click the wand icon or down arrow icon a particular
wizard selection dialog box appears. Select the Data Logging Wizard.
4. To find a parameter that you want to log, select the Port, and then scroll
through the parameter lists, file folders, diagnostic items or use the find
function.
5. To add the parameter to the data log list, select the parameter on the left-
side list and click the right arrow .
That parameter appears in the first available line entry on the right side.
6. To remove a parameter from the data log list, select the parameter on the
right side and click the left arrow .
That parameter disappears from that line entry and all subsequent entries
are moved up.
7. Click Next.
This prompt for a save as dialog box that saves the data log information as a
comma delimited *.csv file for use with Microsoft Excel or any other
spreadsheet program.
Energy Savings Setting the motor control mode P35 [Motor Ctrl Mode] to 2 “Induct Econ” or
Induction Economizer mode enables additional energy savings within the drive.
To be specific, additional energy savings can be realized in constant torque
applications that have constant speed reduced load periods.
Induction Economizer
Induction Economizer mode consists of the sensorless vector control with an
additional energy savings function. When steady state speed is achieved, the
economizer becomes active and automatically adjusts the drive output voltage
based on applied load. By matching output voltage to applied load, the motor
efficiency is optimized. Reduced load commands a reduction in motor flux
current.
High Speed Trending The high speed trending wizard configures the internal trending of the drive,
downloads that trend configuration to the drive, and uploads the trended data
from the drive when finished. This information is saved as a comma delimited
*.csv file for use with Microsoft Excel or any other spreadsheet program.
The high speed trending can be configured to trend up to eight parameters with
4096 samples for each parameter, at a minimum sample rate of 1.024
milliseconds. It can also be configured to trend up to four parameters with 1024
samples for each parameter, at a minimum sample rate of 256 microseconds.
These are defined by the drive. Future drives may offer different options.
The PowerFlex 755 drives have the High Speed Trending functionality.
PowerFlex 753 drives do not have the High Speed Trending functionality.
Configuration Example
The Configure Trend window lets you customize the following high speed trend
details:
• Trend Mode – dictates number of trend buffers, total number of samples,
and the minimum interval sample rate.
• Pre-Trigger samples – dictates number of samples to include in the trend
before the trigger.
• Sample Interval – the time interval between trend data samples.
• Trigger Setup – dictates how the data trend is triggered
a. Comparing two parameters
b. Comparing a parameter against a constant
c. A test bit in a parameter
5. To configure the Trigger Setup and Trend Buffers, click the Ellipse button
6. Select the parameter that you want to log by selecting the Port, and then
scroll through the parameter lists, file folders, diagnostic items or use the
find function and click Apply.
The best way to remove a parameter selection is to uncheck the check box in the
Use column.
“Not used” is downloaded instead of the selected parameter. The next time you
launch the wizard, that buffer has no parameter set.
In the example below, the trend buffers are configured with five drive parameters
consisting of Output Frequency, Motor Velocity Feedback, DC Bus Voltage,
Output Current, Output Voltage parameter values. The trend is configured for a
total of 4096 samples that include 500 samples before the trigger, at a sample rate
of 1.024 ms. The trigger of the high speed trend is the Motor Velocity Feedback
greater than zero.
8. Click Start .
The Trend Status is Running and Download, Upload and Start buttons are
unavailable.
The trending is in process when you see the Trend Status is in the Finishing
state. You can stop the trend at any point in time by clicking Stop. You can
then upload all of the data gathered so far.
The trending has ended when the Trend Status has changed from
Finishing state to the Complete state.
Click Upload . This prompts a process that uploads the trend data
from the drive and saves the information as a comma delimited *.csv file for
use with Microsoft Excel or any other spreadsheet program.
Block Diagram
Position Homing The Homing function is a standalone function of the drive that moves the motor
to a home position defined by a switch that is connected to a homing input on a
feedback option module, digital input resident on the Main Control Board, or on
an I/O option module if there is no feedback module. This function is typically
run only once after the drive is powered up or if the drive has become lost. If a
universal feedback option module is used, the homing input is part of the general
Registration hardware. To perform the homing sequences that require this
module, the drive has to configure the Registration function on the module itself.
The Find Home state is entered from the Initialize Step state when the profile is
enabled with the Find Home bit set in the Profile Command parameter. The
drive performs a procedure to establish the home position. The procedure
consists of a move in Speed mode at the specified Find Home Speed. A digital
input is used to sense when the home position limit switch has been traversed. If
there is an encoder, the registration logic is used to latch the motor position when
the limit switch is reached as the home position. The Find Home function
handles three possible cases; Switch and Marker, Switch only, and Marker only.
Homing Activation
When the Find Home function is selected by either a digital input or a parameter,
either Bit 1 “Home DI” or Bit 2 “Home Maker” or both must be selected in P731
[Homing Control].
Speed Control
Speed
Position
Pt-Pt Control
Homing to Marker Pulse with Feedback Upon activation of homing the drive
starts moving in Speed Control mode, and ramps to the speed and direction set
in P735 [Find Home Speed] at the rate set in P736 [Find Home Ramp]. When
the Marker Pulse input is set the position count is latched and is considered the
home position count after the marker pulse is reached, the drive then ramps to
zero in P736 [Find Home Ramp]. The drive then performs a point-to-point
position move back to the home position count in speed of 1/10 of P735 [Find
Home Speed]. When the motor is “At Position” and “At Zero Speed,” the homing
sequence completes.
holding zero velocity; the drive then transfers velocity reference back to its
previous source once it receives a start command.
Marker
Find Home Speed
Speed Control
Speed
Position
Pt-Pt Control
Upon activation of homing the drive starts moving in Speed Control mode, and
ramp to the speed and direction set in P735 [Find Home Speed] at the rate set in
P736 [Find Home Ramp]. As the motor moves toward the limit/proximity
switch, the marker pulse is triggering a register on the feedback module to latch
the current position count. When the limit/proximity switch is reached the
“Homing Input” is set. The last maker pulse position count that was latched prior
to the “Homing Input” being set is considered the home position count. The
drive then ramps to zero at the rate set in P736 [Find Home Ramp]. The drive
then performs a point-to-point position move back to the home position count
in speed of 1/10 of P735 [Find Home Speed]. When the motor is “At Position”
and “At Zero Speed”, the homing sequence completes.
holding zero velocity; the drive then transfers velocity reference back to its
previous source once it receives a start command.
Marker DigIn
Find Home Speed
Speed Control
Speed
Position
Pt-Pt Control
Upon activation of homing the drive starts moving in Speed Control mode, and
ramp to the speed and direction set in P735 [Find Home Speed] at the rate set in
P736 [Find Home Ramp]. When the limit/proximity switch is reached the
“Homing Input” is set.
If P35 [Motor Ctrl Mode] = 3 “Induction FV” P847 [Psn Fdbk] count is latched
and is considered the home position count. The drive then ramps to zero at the
rate set in P736 [Find Home Ramp]. The drive then performs a point-to-point
position move back to the home position count in speed of 1/10 of P735 [Find
Home Speed]. When the motor is “At Position” and “At Zero Speed, the homing
sequence completes.
holding zero velocity; drive then transfers velocity reference back to its previous
source once it receives a start command.
DigIn
Find Home Speed
Speed Control
Speed
Position
Pt-Pt Control
holding zero velocity; drive then transfers velocity reference back to its previous
source once it receives a start command.
DigIn
Find Home Speed
Speed Control
Speed
Position
Pt-Pt Control
Topic Page
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 301
Network
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 345
Operation
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
Additional Resources for These documents contain additional information on the Integrated Motion on
the EtherNet/IP Network for PowerFlex 755 AC drive applications.
Integrated Motion on the
EtherNet/IP Network Resource Description
PowerFlex 750-Series Drive Programming Manual, Provides detailed information on:
Information publication 750-PM001 • I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 750-Series Drive Installation Instructions, Provides instructions for:
publication 750-IN001 • Mechanical installation
• Connecting incoming power, the motor, and basic
I/O
PowerFlex 750-Series Drive Technical Data, Provides detailed information on:
publication 750-TD001 • Drive specifications
• Option specifications
• Fuse and circuit breaker ratings
Integrated Motion on the Ethernet/IP Network User Manual, Use this manual to configure an Integrated Motion on
publication MOTION-UM003 the Ethernet/IP network application and to start up
your motion solution using the ControlLogix™ system.
Logix5000 Controllers Motion Instructions Reference Provides details about the motion instructions that are
Manual, publication MOTION-RM002 available for a Logix5000 controller.
Kinetix® Motion Control Selection Guide, This selection guide is meant to help make initial
publication GMC-SG001 decisions for the motion control products best suited for
your system requirements. In addition, there are
technical data publications with product specifications
and design guide publications with selection
information, specific to each drive family, to determine
the accessories needed for your application.
The design guides also include the recommended
motor cables, performance specifications, and torque/
speed (rotary) and force/velocity (linear) curves for
each drive and motor/actuator combination.
Software Tools
Integrated Architecture Builder can be downloaded at:
http://www.rockwellautomation.com/en/e-tools/configuration.html
Coarse Update Rate The position loop for the PowerFlex 755 drive is updated at a rate of 1.024 ms
(1024 sec). During each position loop update the drive can either read or write
data to the embedded Ethernet port, but cannot do both operations during the
same update. Therefore the drive can receive only new updates every other
position loop update event. To read new information from the Motion Planner
(that is controller), the minimum coarse update rate must be 2.5 ms or greater to
be sure that no data packets are lost. If the PowerFlex 755 drive is operated at a
coarse update rate of less than 2.5 ms, data packets can be lost (resulting in the
drive interpolating between missed updates), and/or the drive can fault if enough
data packets are missed consecutively. Rockwell Automation recommends a
minimum coarse update rate of 3 ms for the PowerFlex 755 drive.
Control Modes for PowerFlex Integrated Motion on the EtherNet/IP network is a feature available with
firmware revision 2.xxx and later for PowerFlex 755 drives. This feature provides
755 Drives Operating on the a common user experience as with Kinetix 6500 drives when used with Logix
Integrated Motion on the controllers, revision 19 and later, on the EtherNet/IP network:
EtherNet/IP Network
• The same motion profile provides a common configuration experience.
The PowerFlex 755 drive uses the Motion Properties/Axis Properties and
the same motion attributes as the Kinetix 6500 drive.
For the PowerFlex 755 drive, the MDS instruction is valid only when the axis
configuration is set to one of these control modes:
• Frequency Control
• Velocity Loop
• Torque Loop
The MDS instruction is not valid when the axis configuration is set to Position
Loop.
Start
Increase Speed
The speed is changed by updating the speed reference and then re-executing the
MDS instruction.
Decrease Speed
The speed is changed by updating the speed reference and then re-executing the
MDS instruction.
Torque Mode
When the axis configuration is in Torque Loop, the Speed attribute within the
MDS instruction is not used to command the speed of the drive. The speed is
determined by the amount of torque specified in the CommandTorque and/or
TorqueTrim attributes.
IMPORTANT You must command zero torque in the CommandTorque and TorqueTrim
attributes before you use the Motion Axis Stop (MAS) instruction to stop a
specific motion process on an axis or to stop the axis completely. To use the
MAS instruction, you must set Change Decel to No. Otherwise an instruction
error can occur. The deceleration rate is set based on the Ramp Deceleration
attribute. The Motion Servo Off (MSF) instruction is used to deactivate the drive
output for the specified axis and to deactivate the axis’ servo loop. If you
execute an MSF instruction while the axis is moving, the axis coasts to an
uncontrolled stop.
Ramp Attributes
The MDS instruction is validated if the Integrated Motion on EtherNet/IP drive
device supports the following five ramp attributes:
• RampAcceleration
• RampDeceleration
• RampVelocity - Positive
• RampVelocity - Negative
• RampJerk - Control
These ramp attributes are available only when the PowerFlex 755 drive axis
configuration is set to Frequency Control or Velocity Loop. These ramp
attributes are not available when the axis configuration is set to Torque Loop or
Position Loop.
This table provides a cross reference between the PowerFlex 755 Integrated
Motion on the EtherNet/IP Network Motion Ramp Attributes and the
corresponding drive parameters.
Ramp Attribute Drive Parameter
RampAcceleration P535 [Accel Time 1]
RampDeceleration P537 [Decel Time]
RampVelocity - Positive P520 [Max Fwd Speed]
RampVelocity - Negative P521 [Max Rev Speed]
RampJerk - Control P540 [S Curve Accel]
P541 [S Curve Decel]
The Ramp Attributes listed in the previous section are accessible via a Set System
Value (SSV) instruction, as shown in this example:
The selection options of the axis configuration within the Logix Designer
application, Axis Properties, General tab are shown here.
When the axis configuration is set to Frequency Control, you can select one of
the following control methods that best suits the application:
• Basic Volts/Hertz
• Fan/Pump Volts/Hertz
• Sensorless Vector
• Induction FV
The selection options of the axis configuration within the Logix Designer
application Axis Properties, Frequency Control tab are shown here.
This table contains the possible axis configurations and corresponding control
modes of the PowerFlex 755 drive on the Integrated Motion on the EtherNet/IP
Network.
Axis Configuration P35 [Motor Ctrl Mode] P65 [VHz Curve]
Frequency Control:
Basic Volts/Hertz InductionVHz Custom V/Hz
Fan/Pump Volts/Hertz InductionVHz Fan/Pump
Sensorless Vector Induction SV Custom V/Hz
Sensorless Vector economy Induct Econ Custom V/Hz
Position Loop Induction FV Custom V/Hz
Velocity Loop Induction FV Custom V/Hz
Torque Loop Induction FV Custom V/Hz
For more detailed examples on PowerFlex 755 axis configurations, refer to the
Axis Configuration Examples for the PowerFlex 755 Drive chapter in the
Integrated Motion on the Ethernet/IP Network Configuration and Startup User
Manual, publication MOTION-UM003.
Frequency Only
For information on the specific Frequency Control details, see the Motion
Instructions and Integrated Motion Control Modes appendix in the Logix5000
Controllers Motion Instructions Reference Manual, publication
MOTION-RM002.
Drive Nonvolatile (NV) A Kinetix drive can automatically read configuration data in a permanent magnet
motor/encoder’s nonvolatile memory, whereas the motor/encoder configuration
Memory for Permanent data must be manually entered and tuned in a PowerFlex 755 drive when
Magnet Motor Configuration configuring the drive and a permanent magnet motor for operation on the
Integrated Motion on the EtherNet/IP Network.
The Drive NV option (shown in the screen example below) lets you start up a
PowerFlex 755 drive and permanent magnet motor using the motor/encoder
data that is entered and stored in the drive’s nonvolatile memory. This is useful
for a drive running in standalone mode that is being converted to operation on an
Integrated Motion on the EtherNet/IP Network.
Dual Loop Control This section explains how to configure a dual loop feedback application by using
Integrated Motion on the EtherNet/IP Network for a PowerFlex 755 drive.
A dual loop control application uses two encoders, one mounted on the motor
(typical), and one mounted on the load (as depicted in this block diagram). The
two encoders are connected to the PowerFlex 755 drive via separate feedback
option modules, one installed in port 5, and another installed in port 4.
Load
Motor
Mechanical Transmission
5:1 ratio
(Gearbox and Belt)
E E
These steps assume that you have created an axis for the PowerFlex 755 drive in
the Motion group and added a new PowerFlex 755 drive module in the Logix
Designer application. See the Integrated Motion on the EtherNet/IP Network
Configuration and Startup User Manual, publication MOTION-UM003, for
complete procedures. Follow these steps to configure the dual loop control
(encoder) axis.
2. Open the PowerFlex 755 drive module and click the Associated Axis tab.
3. From the Axis 1 pull-down menu, choose the feedback axis you created
(Dual_Loop_Axis in this example).
4. From the Motor/Master Feedback Device pull-down menu, choose Port 5
Channel A.
5. From the Load Feedback Device pull-down menu, choose Port 4 Channel
A.
6. Click OK.
This example uses 30 position units for every 1.0 load encoder revolution
on a rotary axis (for example a dial), that unwinds to zero position after 90
units accumulate.
24. To verify that the Motor to Load ratio is correct, select the Parameter List
category.
25. View the value of the FeedbackUnitRatio parameter. In this example the
ratio is 5:1, or 5 motor encoder revolutions to per load encoder revolution.
If the velocity loop is not performing well, that is, not following the
command and not accelerating or decelerating properly, verify that this
ratio is correct.
26. Continue by tuning this axis.
Dual-Port EtherNet/IP Option The Dual-Port EtherNet/IP option module has two modes of operation, Adapter
mode (default) and Tap mode.
Module (ETAP)
The Tap mode is intended for use with PowerFlex 755 drives and uses the
ENET3 (DEVICE) port as a connection point to transfer Integrated Motion on
the EtherNet/IP Network data to the PowerFlex 755 drive’s embedded
EtherNet/IP adapter. The operation mode is selected by using the Operating
Mode jumper ( J4). For more information about setting the Operating Mode
jumper, see the PowerFlex 20-750-ENETR Dual-Port EtherNet/IP Option
Module User Manual, publication 750COM-UM008.
IP Address Assignment
Hardware Over Travel When a PowerFlex 755 drive is configured for Integrated Motion on the
EtherNet/IP Network none of the I/O option modules are supported.
Considerations Therefore, inputs associated with over-travel limits must be wired into controller
input modules and then control must be programmed in the Logix Controller.
The sample ladder logic code below depicts a possible solution for performing
hardware over travel control (the code is an example only and is not the only
solution for monitoring hardware over travel limits). Each individual application
determines the requirements for the necessary hardware over travel control. This
example monitors digital inputs and issues a motion axis stop if either input goes
false and generates an output indicator that could be used to annunciate the stop.
Integrated Motion on This section cross-references the Logix Designer Module Properties and Axis
Properties instance to the corresponding PowerFlex 755 drive parameter. See the
EtherNet/IP Instance to PowerFlex 755 Standard and Safety Drive Module Optional Attributes appendix
PowerFlex 755 Drive in this manual for details on optional attributes and the corresponding control
Parameter Cross-Reference mode functionality supported by a PowerFlex 755 drive module.
Motor Brake Control When a PowerFlex 755 drive is configured for Integrated Motion on the
EtherNet/IP Network none of the I/O option modules are supported. Normal
means of having the drive control the brake and utilizing drive’s I/O are not
supported. Motor brake control must be user-configured in the Logix controller.
The basic functionality involved is to enable the drive using an MSO instruction,
verify that the drive is enabled, and then apply power to disengage the motor
brake. The specific motor used and the application often dictates a time delay
between when the drive is enabled and the brake is disengaged. A very similar
sequence is followed with disabling the drive using an MSF instruction. In this
case the brake is engaged, and after a user-configured amount of time, the drive is
disabled. Figure 35 depicts this operation.
Enable
Brake
MSO MSF
Time
The sample ladder logic code in Figure 36 on page 339 depicts a possible solution
for performing brake control (the code is an example only and is not the only
solution for performing brake control). Each individual application determines
the requirements for the necessary brake control.
Network Topologies This topic provides examples of network topologies that can be used when
implementing an Integrated Motion on EtherNet/IP Network application by
using on of the following programming software applications.
• RSLogix 5000, version 19 and later
• Studio 5000 environment, version 21 and later
Star Topology
A switch-level star configuration is a traditional Ethernet network layout where
devices are connected to a centralized network switch, point-to-point. The star
configuration is most effective when the devices are near a central network
switch. In a star network topology, all traffic that traverses the network (that is,
device-to-device) must pass through the central switch.
ControlLogix
1756-EN2T
or
1756-ENxTR
1585J-M8CBJM-x
Stratix 8000 Ethernet (Shielded) Cable
Other EtherNet/IP
Network
Compatible Devices
Programming Software
Advantages/Disadvantages
The primary disadvantage of a star topology is that all end devices must typically
be connected back to a central location, which increases the amount of cable
infrastructure that is required and also increases the number of available ports
required by the central switch leading to a higher cost per node solution.
Linear Topology
In a linear topology, the devices are linked together via a two port embedded
switch or through an EtherNet/IP network tap (1783-ETAP), instead of being
connected back to a centralized network switch.
Programming Software
ControlLogix
HMI
1756-ENxTR
1585J-M8CBJM-x
EtherNet (shielded) Cable
Point I/O
Advantages/Disadvantages
Ring Topology
A ring topology, or device-level ring (DLR), is implemented in a similar fashion
to linear topology. However, an extra connection is made from the last device on
the line to the first, closing the loop or ring. It is crucial to configure the Ring
Supervisor before connecting your linear topology into a ring topology.
ControlLogix
1585J-M8CBJM-x
EtherNet (shielded) Cable
1756-ENxTR
Point I/O
HMI
Advantages/Disadvantages
Linear/Star Topology
Network switches can be added to the end of the line, creating a linear/star
topology. Ethernet devices that do not have embedded switch technology can be
connected in a star topology off of the switch.
Programming Software
ControlLogix
1756-EN2T
or 1585J-M8CBJM-x Other EtherNet/IP
1756-ENxTR EtherNet (shielded) Cable Compatible Devices
Stratix 8000
Ring/Star Topology
Network switches can also be connected into a DLR via an Ethernet/IP tap,
creating a ring/star topology.
PowerFlex 755 1756-EN2T
or
1756-ENxTR
1585J-M8CBJM-x
EtherNet (shielded) Cable
Programming Software
1783-ETAP
Other EtherNet/IP
Compatible Devices
Stratix 8000
PowerFlex 755 and Kinetix The PowerFlex 755 drive can be configured for a normal duty or heavy duty
operation. The heavy duty rating has a lower continuous current rating and
7000 Drive Overload Rating therefore can produce more current during an overload.
Comparison for Permanent
Duty Rating 0 Hz 100% 110% 150% 180%
Magnet Motor Operation Normal 50% 100% One minute 3 seconds Not applicable
Heavy 65% 75% of normal – One minute of 3 seconds of
duty normal duty normal duty
The Kinetix 7000 drive overload capability is specific for each power structure.
However, the Kinetix 7000 can produce 100% current at 0 Hz.
PowerFlex 755 Drive Option When the PowerFlex 755 drive is configured for an Integrated Motion on the
EtherNet/IP Network application, only specific option modules are supported,
Module Configuration and and in some cases, the port in which the option module is installed in the control
Restrictions pod is restricted.
If an unsupported option module is installed, the drive stops responding and the
HIM displays “CONFIGURING.”
This restriction and configuration setting must be used when using either of these
safety option modules with the Integrated Motion on the EtherNet/IP Network:
• The option modules must be installed in port 6 of the drive control pod
only.
• The specific drive module and option catalog number must be selected
when adding the drive to the I/O tree in the project. For example, when
adding a PowerFlex 755 drive with a Safe Speed Monitor option module,
choose 755-EENET-CM-S1.
Regenerative/Braking When using a PowerFlex 755 drive with a dynamic brake (shunt regulator) in an
Integrated Motion on the Ethernet/IP network the dynamic brake must be set up
Resistor as part of the I/O connection of the PowerFlex 755 embedded Ethernet/IP
module (EENET-CM-xx) properties. Failure to set up the dynamic brake
correctly could lead to mechanical damage of the machine. Dynamic brake
(shunt) resistor sizing is not covered in this document. For more information on
resistor sizing, see the Drives Engineering Handbook, publication DEH-1300-
10.
Follow these steps to configure a dynamic brake (shunt regulator) for a PowerFlex
755 drive in the Logix Designer application.
2. Click the Power tab and configure the appropriate boxes according to your
application.
Regenerative Power Limit The amount of energy that the drive allows during regeneration. If an
external regenerative power supply or shunt (dynamic brake) resistor is used,
it is recommended that this value be set to -200.0%.
Important: If this value is set too low, the ability of the drive to stop a
motor is limited.
Bus Regulator Action • Disabled - This selection disables the drive’s internal DC bus voltage
regulation feature. Select this option if there is an external regenerative
brake or regenerative line supply connected to the drive DC bus.
• Shunt Regulator - This selection is used when either an external shunt
resistor is connected to the drive or the internal IGBT is controlling the
power dissipation to the resistor (the type of shunt resistor is selected
below).
• Adjustable Frequency - This selection let the drive either change the
torque limits or ramp rate of the velocity to control the DC bus voltage.
This option is not recommended for positioning applications because it
overrides the velocity and the system can overshoot or may not stop.
• Shunt then Adjustable Frequency - This selection lets the Shunt resistor
absorb as much energy as it is designed for, then transitions to adjustable
frequency control if the limit of the resistor has been reached.
• Adjustable Frequency then Shunt - This selection enables adjustable
frequency control of the DC bus. If adjustable frequency control cannot
maintain the DC bus within limits, the shunt resistor is activated.
Shunt Regulator Resistor Select the type of resistor connected to the drive. Internal resistors include
Type 20-750-DB1-D1 or 20-750-DB1-D2 for frames 1 and 2 drives, respectively.
External identifies that a user-selected resistor is used.
External Shunt When using an external shunt resistor select “Custom.”
External Shunt Resistance Enter the resistance of the external resistor connected to the drive terminal
block connections, BR1 and BR2. Verify that the resistance is equal to or
greater than the minimum resistance for the drive capabilities. See
“Minimum Dynamic Brake Resistance” in the PowerFlex 750-Series AC Drives
Technical Data, publication 750-TD001.
External Shunt Power Enter the continuous power dissipation rating (kW) of the external resistor.
Failure to specify the correct value can cause the drive to either stop sending
energy to the resistor prematurely or overheat the resistor. For example, if an
800 W rated resistor is installed, enter 0.8 in this field.
External Shunt Pulse The Watt-Second or Joules rating (kW) of the resistor. This is the amount of
Power energy that the resistor can withstand for one second to reach the maximum
temperature. Failure to specify the correct value can cause the drive to either
stop sending energy to the resistor prematurely or overheat the resistor.
3. Click OK.
Safe Speed Monitor Option When a PowerFlex 755 drive is configured for Integrated Motion on the
EtherNet/IP Network the configuration of the Safe Speed Monitor functions are
Module (20-750-S1) accomplished via a web page.
Configuration
Configuring the Safe Speed Functions
The Safe Speed Monitor module web page differs from the Embedded EtherNet/
IP adapter (port 13) web page that is enabled by setting adapter parameter P52
[Web Enable] to 1 “Enabled.” The Safe Speed Monitor module web page is not
accessible until the drive has established a network connection to a Logix
processor and the Integrated Motion on the EtherNet/IP Network connection
has been established. The web page is then accessed by entering the IP address of
the drive into a web browser (for example, http://192.168.1.20/). Currently,
safety configuration settings cannot be saved in the drive or downloaded to other
drives.
TIP The Safe Speed Monitor module parameters are not currently part of the Logix
platform and therefore, are not overwritten when a drive establishes a
Integrated Motion on the EtherNet/IP Network connection. Therefore, it is
possible to program the Safe Speed Monitor functions with configuration
software (for example, Connected Components Workbench) or a HIM before a
network connection is established. This lets you save the safety configuration
in the software application or HIM. Configuration of the safety functions can be
accomplished in one of the following ways:
• Program the Safe Speed Monitor functions and then download the
program that includes the drive parameters to the Logix controller and
establish the network connection.
• Inhibit the drive in the Logix I/O tree and program the Safe Speed Monitor
functions.
• Disconnect the network cable between the drive and the controller and
program the Safe Speed Monitor functions.
While there are different selections when operating the drive and Safe Speed
Monitor option module in Standard mode versus the Integrated Motion on the
EtherNet/IP Network mode, the equivalent functions operate the same. In the
Integrated Motion on the EtherNet/IP Network mode of operation, the Stop
Command is programmed in the Actions Category of the Module Properties
dialog box. It is important to realize that there is no option to have a ramped stop
selected here; only current limit and motor brake options are available. These
selections do not ensure that a consistent ramp is implemented each time. If a
repeatable ramped stop is desired, then the user can program a Stop Monitor
Delay as a part of the Safe Speed Monitor configuration and then monitor the
Safe Speed inputs from the controller and issue a ramped stop prior to the safety
core issuing the Stop Command signal (as shown in this diagram).
Safe Torque-off
[Standstill Speed] Active
Time
SS_In Signal
SS_Out Signal
Motion Power (1)
(1) This signal is internal between the safety option module and the drive.
(2) The DC_Out output is shown configured as Power to Release.
Speed Limited Adjustable This topic describes how to configure a PowerFlex® 755 AC drive with embedded
Ethernet/IP for Speed Limited Adjustable Torque (SLAT) operation using an
Torque (SLAT) Integrated Motion on the Ethernet/IP network in Logix Designer application.
For more information on SLAT refer to the following publications:
• See Speed Limited Adjustable Torque (SLAT) Min Mode and SLAT Max
Mode in the PowerFlex 700S AC Drives with Phase II Control Reference
Manual, publication PFLEX-RM003.
Program Commands
When using SLAT with Integrated Motion on the Ethernet/IP network you
must start the PowerFlex 755 drive with the MDS instruction as shown below.
The Speed reference is sent in the MDS instruction. Also, the torque command is
sent to “AxisTag.CommandTorque.” To make changes to the speed reference you
need to re-trigger the MDS instruction.
To use the Motion Axis Stop (MAS) instruction, you must set Change Decel to
“No.” Otherwise an instruction error occurs. The deceleration rate is set based on
the Ramp Deceleration attribute.
To view help for the MDS instructions, right-click MDS in the function block
and choose Instruction Help, or select the instruction and press F1. Additionally,
see “Speed Limited Adjustable Torque (SLAT) Min Mode and SLAT Max
Mode” in the PowerFlex 700S AC Drives with Phase II Control, Reference
Manual, publication PFLEX-RM003.
If you are using the MDS instruction, the drive accelerates and decelerates at the
planner Max Acceleration and Deceleration values. To set the
“RampAcceleration” and “RampDeceleration” you need to use SSV instructions
to change the ramp rates. Below is an example of the SSV instructions:
• Set the RampAcceleration / RampDeceleration attribute to “x” revs/sec2
• Class Name = Axis
• Instance Name = “Axis Name”
• Attribute Name = RampAcceleration/RampDeceleration
• Source = Tag for value
Example: Velocity (Speed) command is 30 revs/sec and you want to reach that
speed from zero in 6.5 seconds. Ramp Acceleration needs to be set to 4.615 revs/
sec2.
Supported Motors The PowerFlex 755 can be used with a variety of both induction and permanent
magnet (PM) motors.
AC Induction Motors
An AC induction motor uses slip between the rotor and the stator to create
torque. Some motor manufacturers specify the synchronous speed instead of slip
speed on the motor nameplate. For example, a 4 pole, 60 hertz motor has a
synchronous speed of 1800 rpm. The drive algorithm cannot use the
synchronous speed, it needs the slip rpm. The slip rpm is the rotor speed when
the stator is at rated frequency and the motor is at full load. The rotor slips
behind the stator to create the torque. For a 4 pole, 60 hertz motor the slip rpm
range is 1700…1790 rpm. If the nameplate is showing synchronous speed (in our
example 1800 rpm), please contact the motor manufactures to receive the slip
rpm.
Some AC motors have two voltage ratings, a high voltage and a low voltage.
Follow the motor manufacture's wiring diagram to correctly wire the motor for
the proper voltage.
This list contains the name of manufacturers that produce motors that are
recommended for use with PowerFlex 755 drives.
Manufacturer Notes
Baldor Electric Company Work well with PowerFlex 755 drives.
Baumuller Work well with PowerFlex 755 drives.
Elin Work well with PowerFlex 755 drives.
Electrical Apparatus Company (EAC) Induction motors work well with PowerFlex 755 drives.
Lenze Some Lenze motors have been stamped with synchronous speed versus slip
speed. Please contact Lenze to get the slip speed.
Marathon Electric Work well with PowerFlex 755 drives. Marathon stamps all pertinent
information on their nameplate including electrical model equivalent.
Reliance RPM AC motors are used in industry and work well with PowerFlex 755 drives.
Reuland Electric Company, Inc. Work well with PowerFlex 755 drives. Reuland stamps the motor with
synchronous speed and then supplies the slip frequency. You must calculate
the slip frequency in rpm and then subtract the slip rpm from the synchronous
speed to get the slip speed. Before contacting Rockwell Automation Technical
Support, please obtain the electrical specification sent with the motor.
Rockwell Automation 8720 and HPK motors work well with PowerFlex 755 drives. See the
appropriate motor manual for the proper nameplate voltage.
SEW-EURODRIVE SEW-EURODRIVE gear motors are widely used in industry and work well with
PowerFlex 755 drives. Some of the older motors were stamped with
synchronous speed versus slip speed. Please contact SEWS if the motor is
stamped with synchronous speed. If you are using an SEW motor with an
integral brake, please verify that the brake is properly suppressed for noise.
Manufacturer Notes
WEG Electric Corp. WEG motors can have a start winding and a run winding. Always wire the
drive to the run winding.
Wittenstein Work well with PowerFlex 755 drives.
Wound rotor manufacturers Wound Rotors work with PowerFlex 755 drives. You must short the external
resistors when using these motors.
PowerFlex 755 drives cannot accept a resolver. Therefore, the motors must have
either a pulse encoder or absolute feedback device (for example, SSI, Heidenhain,
Stegmann/Sick hyperface).
This list contains the name of manufacturers that produce motors that are
recommended for use with PowerFlex 755 drives.
Manufacturer Notes
Baldor Electric Company Work well with PowerFlex 755 drives. Verify that you are using either the
Surface Mount (SM) or Interior Mounted (IPM) motors and select the
appropriate control algorithm.
KollMorgan Work well with PowerFlex 755 drives.
Oswald Electric Motors
PowerTec Work well with PowerFlex 755 drives, but cannot use resolver feedback.
Rockwell Automation MPL, MPM, and RDB motors work well with PowerFlex drives. Use Heidenhain
feedback for RDB motors.
HPK-B1307E-MA42AA 2970 29.8 405 57.5 100 96 165 104 26.1 0.0485 0.0338 0.371 0.423 8.79
HPK-B1307E-MB44AA 2970 29.8 405 57.5 100 96 165 104 26.1 0.0485 0.0338 0.371 0.423 8.79
HPK-B1307E-MC44AA 2970 29.8 405 57.5 100 96 165 104 26.1 0.0485 0.0338 0.371 0.423 8.79
HPK-B1307E-SA42AA 2970 29.8 405 57.5 100 96 165 104 26.1 0.0485 0.0338 0.371 0.423 8.79
HPK-B1307E-SB44AA 2970 29.8 405 57.5 100 96 165 104 26.1 0.0485 0.0338 0.371 0.423 8.79
HPK-B1308E-MA42AA 2970 33.5 405 64.8 100 115 230 135 28.8 0.037 0.0275 0.296 0.364 7.71
HPK-B1308E-MB44AA 2970 33.5 405 64.8 100 115 230 135 28.8 0.037 0.0275 0.296 0.364 7.71
HPK-B1308E-SA42AA 2970 33.5 405 64.8 100 115 230 135 28.8 0.037 0.0275 0.296 0.364 7.71
HPK-B1308E-SB44AA 2970 33.5 405 64.8 100 115 230 135 28.8 0.037 0.0275 0.296 0.364 7.71
HPK-B1609E-MA42AA 2965 48.4 405 88.2 100 156 270 154 31.4 0.0326 0.0227 0.288 0.319 7.23
HPK-B1609E-SA42AA 2965 48.4 405 88.2 100 156 270 154 31.4 0.0326 0.0227 0.288 0.319 7.23
HPK-B1609E-SB44AA 2965 48.4 405 88.2 100 156 270 154 31.4 0.0326 0.0227 0.288 0.319 7.23
HPK-B1609E-X169 2965 48.4 460 88.2 154 156 270 154 154 154 154 154 154 154
HPK-B1611E-MA42AA 2975 57 408 105.7 100 183 400 240 47.6 0.0205 0.0152 0.167 0.219 4.82
HPK-B1611E-MB44AA 2975 57 408 105.7 100 183 400 240 47.6 0.0205 0.0152 0.167 0.219 4.82
HPK-B1611E-SA42AA 2975 57 408 105.7 100 183 400 240 47.6 0.0205 .0.0152 0.167 0.219 4.82
HPK-B1613E-MA42AA 2970 73.7 407 135.3 100 237 520 312 54.5 0.0164 0.0127 0.136 0.179 4.21
HPK-B1613E-MB44AA 2970 73.7 407 135.3 100 237 520 312 54.5 0.0164 0.0127 0.136 0.179 4.21
HPK-B1613E-SA42AA 2970 73.7 407 135.3 100 237 520 312 54.5 0.0164 0.0127 0.136 0.179 4.21
HPK-B1613E-SB44AA 2970 73.7 407 135.3 100 237 520 312 54.5 0.0164 0.0127 0.136 0.179 4.21
HPK-B2010E-SA42BA 2985 112 400 216 100 358 35 0.00519 0.00419 0.0626 0.097 2.03
HPK-E1308E-MA42AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1308E-MB44AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1308E-MC44AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1308E-SA42AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1308E-SB44AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1308E-SC44AA 2975 33.5 330 80 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1609E-MA42AA 2965 48.4 405 88.2 100 108 216 160 39 0.0233 0.0176 0.189 0.242 4.92
HPK-E1613E-SA42AA 2975 73.7 400 172 385 237 520 385 385 385 385 385 385 385
The PowerFlex 755 drive can support third-party permanent magnet motors
without the need of custom profiles. However, the motor nameplate information
sometimes needs to be modified. Rockwell Automation Technical Support
requires the following information to assist you in modifying the motor data for
use with the drive. Please complete the following tables and email the
information to Rockwell Automation Technical Support at:
support@drives.ra.rockwell.com.
Feedback Device
Type of Feedback If resolver, please complete resolver information
Feedback Manufacturer
Feedback Model Number
Technical Specifications
Item Symbol Value Units Notes
Maximum Mechanical Speed n rpm
Continuous Stall Torque Ms Nm (RMS not 0-peak)
Continuous Stall Current A A (RMS not 0-peak)
Peak Torque Mj Nm (RMS not 0-peak)
Torque Weight Ratio Tw Nm/Kg
EMF Constant Ke Vs/rad Vs/1000rpm
Torque constant Kt Nm/A
Reluctance Torque Tr Nm
(with respect to Stall Torque)
Winding Resistance R Ohms line to line
Winding Inductance L mH line to line
Rotor Inertia J kg-m2
Mechanical Time Constant Тm ms
Electrical Time Constant Тe ms
Mass M Kg
Radial Load Fr N
Axial Load Fa N
Insulation
Protection
Zpu
IXO Voltage drop Volts
IR Voltage Droop Volts
P523 Back Emf Volts
Power (kW)
Overload Torque
Overload Power
Rated Power S1
Rated Torque
Speed (1/min)
System Tuning When using the Integrated Motion on the Ethernet/IP Network connection
with the PowerFlex 755 drive, the tuning of the motion system is accomplished
via the Logix Designer application. This topic describes the axis hookup tests,
motor tests, and autotuning of the motion system required to measure the system
inertia. Manual tuning of the axis is also described in this section:
• For additional information on axis attributes and the Control Modes and
Methods, see the Integrated Motion on the Ethernet/IP Network
Reference Manual, publication MOTION-RM003.
This topic assumes that you have completed all the steps necessary to configure
the drive module.
The axis Hookup tests are the first tests to run when autotuning an axis. If you are
using a permanent magnet motor in your application, the Commutation test
must be run first, as part of the Hookup tests.
Motor and Feedback: This test is used to run the motor and verify the correct
direction of rotation, and also tests the motor feedback for the proper direction:
• The Test Distance value can be defined to be sure that the system does not
rotate too far.
• Click Start to initiate the test. The test completes and prompts you to
verify that the motor rotation direction was correct.
• When the test has been completed, click Accept Test Results to save the
results.
Motor Feedback: This test is used to test the polarity of the motor feedback:
• Click Start and manually rotate the motor in the positive direction for the
distance indicated in the Test Distance box.
• When the test has been completed, click Accept Test Results to save the
results.
Commutation: When using a permanent magnet motor, this test must be run
first. The Commutation test is used to measure the commutation offset angle for
the permanent magnet motor.
• When the test has been completed, click Accept Test Results to save the
results.
• Use the resulting Controller Offset value.
Marker: This test is used to check for the marker pulse on an incremental
encoder:
• Click Start and manually move the motor until a marker pulse is detected.
• When the marker pulse is detected the test stops. Click Accept Test
Results to save the results.
Motor Analyzer
The Motor Analyzer category offers three choices for calculating or measuring
motor electrical data.
Dynamic Motor Test: This test is the most accurate test method to determine
the motor model parameters. When this test is run the Resistance and Reactance
are measured then the motor is rotated to measure the flux current of the
Induction motor. The Rated Slip frequency is also calculated:
• This test is best run with the motor disconnected from the load as the
motor spins for some time and there are no travel limits.
• When the test has been completed, click Accept Test Results to save the
results.
Static Motor Test: This test is used if the motor cannot rotate freely or is already
coupled to the load. When this test is run the Resistance and Reactance are
measured then the flux current of the motor is calculated. The Rated Slip
frequency is also calculated:
• The motor will not turn during this test.
• When the test has been completed, click Accept Test Results to save the
results.
Calculate Model: This method calculates the Resistance, Reactance, and Flux
Current of the motor from basic model parameters and the motor parameters
data. No measurements are taken when using this calculation:
• Click Start to start the calculation.
• When the test has been completed, click Accept Test Results to save the
results.
The Autotune category measures the system inertia and calculates system
bandwidth tuning numbers. This table summarizes the application type tuning
defaults. An “X” indicates that the system value is selected by default and that the
Velocity and Acceleration Feedforward values are set to 100%.
• Custom: This option lets you select the type of gains to use in the system.
You can individually select gains to be used with the check boxes that
display below Customize Gains to Tune heading.
• Basic: This selection is used for applications where following error and
final position is not critical. Basic tuning gains include Position Loop
proportional and Velocity Loop proportional.
• Point to Point: This selection is used for applications that use a move-to-
position and do not need to include a following error. Tuning gains for this
selection include Position Loop proportional, Position Loop integral, and
Velocity Loop proportional.
Load Coupling: The Load Coupling attribute is used to determine how the loop
gains are de-rated based on the Load Ratio.
In high performance applications with relatively low Load Ratio values or rigid
mechanics, typically Rigid is selected. The gains are not de-rated.
For applications with relatively high Load Ratios and compliant mechanics,
Compliant is selected. The autotune algorithm divides the nominal loop
bandwidth values by a factor of the Load Ratio + 1.
Measure Inertia using Tune Profile: Check this box to calculate the inertia
tuned values as part of the autotune. The Inertia Test results are shown in the
Inertia Tuned grid control (bottom right of the dialog box) when the test
completes.
When Measure Inertia using Tune Profile is selected as a part of the Autotune
test, the PowerFlex 755 drive first jogs or rotates the motor in a single direction to
remove any backlash present in the system (as depicted in the chart below). After
the backlash has been removed, the “bump” profile is then applied to measure the
system inertia (system acceleration). Note that systems with a mechanical
restriction or travel limit may not complete the Autotune test.
Backlash Removal
• Motor with Load: Choose this selection to calculate tuning values based
on the load inertia. If selected, the load inertia is measured and then
applied to the Total Inertia attribute or Total Mass attribute. The Load
Ratio is also updated.
• Travel Limit: Enter a value that specifies the maximum distance to travel
for the selected tune operation when the system has a limited travel
distance. If the tuning test cannot complete within the distance specified
the tune fails and faults the axis.
• Speed: Enter a value that specifies the speed of the tune operation. A
speed that translates to a minimum of 25% of the motor nameplate RPM is
recommended.
• Torque: Enter a value in the range of 0…300 that specifies the torque value
to be applied to the tune operation. The default value is 100.
• Direction: Choose the direction of the move for the tune operation. The
available values include:
When the autotune has completed, click Accept Tuned Values to accept the
tuning results and before you can change any tuning categories.
Manual Tune
The Integrated Motion on the Ethernet/IP network axis includes a method for
manual tuning the axis gains. Clicking Manual Tune (as indicated in the example
here) opens the Manual Tuning window.
Tuning gains are measured in Hertz in the Integrated Motion on the Ethernet/IP
network connection compared to the radians/second in the stand alone drive.
6.283185 Rad/Sec = 1 Hz.
Manual Tuning Section: This section lets you customize the configuration of
system tuning. The following two selections can be made:
• System Bandwidth: Changing this value adjusts the Position Loop and
Velocity Loop response. The value selected in this field changes the
Application Type selection in the Autotune window. Therefore, care must
be taken to NOT change this value after the individual gains have been
manually configured.
• Position Loop: You can manually adjust the Loop Bandwidth, Integrator
Bandwidth, Integrator Hold and Error Tolerance values.
• Velocity Loop: You can manually adjust the Loop Bandwidth, Integrator
Bandwidth, Integrator Hold, and Error tolerance (when used as a Velocity
Loop) values.
• Compensation Tab: Lets you adjust the System Inertia percentage and
Torque Offset percentage.
• Filters Tab: Lets you adjust the Torque Low Pass Filter Bandwidth and
Torque Notch Filter Frequency.
• Limits Tab: Lets you adjust the Peak Torque Limit Positive / Negative
percentages and Velocity Limit Positive / Negative Units per Second
values.
Using an Incremental The PowerFlex 755 drive supports incremental encoder feedback when using a
Rockwell Automation MPx motor. However, the Motor Device Specification
Encoder with an MPx Motor category in the Axis Properties configuration for the Logix Designer application
does not currently support MP-Series™ motors with incremental feedback catalog
numbers, as shown below. Only MP-Series motors with the suffix –M (Stegmann
Multi-turn Absolute), or –S (Single Turn Absolute) motors are supported.
1. In the Axis Properties dialog box for the drive, select these options (as
shown below):
• From the Data Source pull-down menu, choose Nameplate Datasheet.
• From the Motor Type pull-down menu, choose Rotary Permanent
Magnet.
2. You must manually enter the Nameplate / Datasheet – Phase to Phase
parameters information. See Appendix D - Permanent Magnet Motors in
the PowerFlex 750-Series Programming Manual, publication 750-PM001,
for a list of motor nameplate specification data.
TIP If you do not have a Programming Manual readily available, from the Data
Source pull-down menu, choose Catalog Number. Then, from the Motor Type
pull-down menu, choose the equivalent motor with the -M (Stegmann Multi-
turn Absolute) device. The Logix Designer application populates the
Nameplate / Datasheet – Phase to Phase parameters information with the
data that is stored in the database. Record this information for reference. Then,
change the Data Source selection to “Nameplate Datasheet.” The configuration
is transferred to the new selection. The motor data is the same regardless of
the selected feedback device.
PowerFlex 755 Integrated The block diagrams in this section highlight the Integrated Motion on the
Ethernet/IP Network attributes and path used in PowerFlex 755 drives control.
Motion on the EtherNet/IP When viewed in electronic format (PDF), or when printed in color, the standard
Network Block Diagrams drive control attributes and path appear in blue and the Integrated Motion on the
EtherNet/IP Network attributes appear in black and the path appears in black
and uses heavier line weights.
593
Skip Bands
[6H4] 0
Skip Bands
935 17
Integrated Motion on
the Ethernet/IP Network
Attributes and Path
( ) = Enumerated Parameter
[ ] = Page and Coordinate
ex. 3A2 = pg 3, Column A, Row 2
= Constant value
‘d’ = Prefix refers to Diagnostic Item Number
ex. d33 = Diagnostic Item 33
Adaption
550 Comp Out 690
PLL Speed
PID Torque
Trim / Excl
Process Control (pages: 26,27) ( PID Output Meter ) Selection
PID LP
PID Prop Gain 1086 1084
Filter BW
PF755 Rev_9.a
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Chapter 6
378
Chapter 6
A B C D E F G H I
Bus/Current +
Preset Speed 1 571 556 Limiter + V/Hz
572 (Freq Ramp)
Preset Speed 2 Jog Speed 1
Limit Current
Preset Speed 3 573 ( Ramp Rate )
557 Processing
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
PID LP
PID Prop Gain 1086 1084
Filter BW
Alternate
d 1
Velocity Fdbk
Processing dt
Derivative
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Chapter 6
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Chapter 6
A B C D E F G H I
1 Spd Ref
Speed Control – Reference Overview
Command
Spd Ref A
Ref A
Auto Speed Reference Control
Trim Ref A
+
Trim % Ref A
Profiling/ Limited
Spd Ref B Jogging/
Selected Spd Ref Direction Limit Spd Ref Speed Ref
2 Lift App/ Skip Fiber
Ref B Switch Stop / Torque
+ Autotune/ Mode Bands App.
Trim Ref B Auto Control Proving
Homing/
+ Overrides Limit
Trim % Ref B
From
PI Regulator
Presets 3-7 Auto (Exclusive Mode)
DPI Ports 1-6 Manual
ENet Spd Ref
3
Inertia Inertia Comp
Vector Speed Control Comp Torque Ref
Virtual
Encoder
Speed
Comp Friction Friction Comp
Comp Torque Ref
Vector Ramp S-Curve
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Flux Ramped
Vector Linear Vel Ref Motor Spd Ref
Speed Control - Reference Overview
Rate
Page 5
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Chapter 6
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Chapter 6
A B C D E F G H I
Direction Mode Control Autotune Control Limit Switch Control Speed Ref Limits
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Commanded
Start/Stop Speed Control – Reference (3)
SpdRef
Drive Status 1
1 Vector Ramp and Rate Select
467 Velocity Integrator Control Flux Vector
2 (Running)
Fiber Application
Skip Bands 935 16 Spd Options Ctrl Spd Options Ctrl
Drive Status 1 OR Ramped Spd Ref (Delayed Ref)
(Stopping) (Ramp Disable) 635 1
1 936 9 635 8
Limited Spd 935 18 594 [28C2]
Ref Drive Status 2 (StpNoSCrvAcc) 635 2
Sync (Autotuning)
0 Traverse/ 0 1 0
593 Speed
Change P-Jump Not Stopping Spd Options Ctrl
Skip and Active
Virtual Encoder
[6H4] 935 17 0 (Ramp Hold) Ramp
Bands 0
1 635 0 S Curve Delayed Spd Ref
Drive Status 1 0 One 1
Skip Speed 1 526 1122 Sync Time Stopping 139
(Jogging) 376 Ramp Acceleration Accel Time 1 535 1,0 Scan
or Not Active
2 P Jump 1126 0,1 Delay
Skip Speed 2 527 370 Skip Speed 1 Accel Time 2 536
Virtual Enc EPR Virtual Enc Psn
371 Skip Speed 2 Max Traverse 1125 (Edges Per Rev)
[35H3] Drive Logic Rslt 879 8 9 142 [11C5]
Skip Speed 3 528 (Accel Time 1, 2) 141
372 Skip Speed 3 1,0
Traverse Inc 1123 Decel Time 1 537
Skip Speed 529 373 Skip Speed Band 377 Ramp Deceleration Virtual EncDelay
Band 0,1
Traverse Dec 1124 Decel Time 2 538 One
140 [11C5]
Drive Logic Rslt Scan
Fiber Control 1120 [35H3] 879 10 11
Int Ramp Ref (Decel Time 1, 2) Delay
539 Virtual Encoder
To Torq Ctrl Jog Acc Dec Time
Fiber Status 1121
(Friction Comp) 378 Ramp Jerk Control S Curve Accel, Decel 540 541
[23A1] Speed Control
3
0 LPF FF 667
Comp Ramped Ref 1 d Psn Ref
Int Ramp Ref 1 d To Torq 1 Spd Ref Filter 588
496 Kj 0 [11I5]
Ctrl dt
dt 76 Total Inertia [23B3] Rate Ref
4 Ext Ramped Ref 2 Speed 848 Spd Ref Fltr BW 589
596 935 17
2 d Comp
700 696 Inertia Acc Gain Speed Rate Psn Gear Ratio
dt Drive Status 1
3 Ref (Jogging)
596 697 Inertia Dec Gain Speed Comp Gain 666
Speed Rate Ref Final Speed Ref Limits
460 Kaff
Page 7
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Chapter 6
384
Chapter 6
A B C D E F G H I
Commanded
Start/Stop
Speed Control – Reference (4)
1 SpdRef
Limited Spd Ref Drive Status 1
VF (V/Hz), SV
2 (Running) V/F Ramp and Rate Select 467 Velocity Integrator Control
593 Fiber Application
Skip Bands Drive Status 1 935 16 Spd Options Ctrl
OR Ramp Rate
(Stopping) (Ramp Disable) 635 1 [9E4]
1 936 9
935 18 Ramped
Drive Status 2 (StpNoSCrvAcc) 635 2 Previous
Sync Spd Ref Scan
[9E5]
0 Traverse/ 0 (Autotuning) 1
[6H4] Speed 594
Change P-Jump Not Stopping Spd Options Ctrl
Skip Bands and Active (Ramp Hold) [9A2], [28C2]
935 17 0 Ramp
0
1 635 0 S Curve
2 526 Drive Status 1 0 Ramp Input
Skip Speed 1 1122 Sync Time Stopping
(Jogging) [9E4] Accel Time 1 535 1,0
or Not Active
Skip Speed 2 527 P Jump 1126 0,1
370 Skip Speed 1 Accel Time 2 536
Skip Speed 3 528 371 Skip Speed 2 Max Traverse 1125 376 Ramp Acceleration [35H3] Drive Logic Rslt 879 8 9
372 Skip Speed 3 (Accel Time 1, 2)
Traverse Inc 1123 1,0
Skip Speed 529 373 Skip Speed Band 377 Ramp Deceleration Decel Time 1 537
Band 0,1
Traverse Dec 1124 Decel Time 2 538
Drive Logic Rslt
Fiber Control 1120 [35H3] 879 10 11
(Decel Time 1, 2)
Jog Acc Dec Time 539
Fiber Status 1121
3 378 Ramp Jerk Control S Curve Accel, Decel 540 541
Speed Control
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Max Speed
Limits
4
Spd Ref After
Final Limit
Limit [9A2]
473 Velocity Limit – Positive Max Fwd Speed 520
From 2 0
1093
Process Ctrl
[28E3] PID Output Meter ≠2 1
0 0
5
1079 935 17
PID Output Sel Drive Status 1
(Speed Trim) (Jogging)
6
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A B C D E F G H I
594
At Limit Status 453 Velocity Reference
Ramped Spd Ref Limit (MaxSpeed Lmt) Final Speed Ref (Max Fwd/Rev +
[8G2] Overspeed Limit)
Max Fwd/Rev To Fdbk
Speed Limit OR 945 2 597 Speed Limit Limited
VF or SV [3B5] Limited
Speed Adder Freq Adder
(0-2,4,5,7,8)
(Hz)
X
621 Slip RPM at FLA
Limit Limit
At Limit Status
3 Filtered (100 R/S) 1.5
Iq Feedback (pu) 945 3 (OverSpd Lmt)
1352 – Induction Motor
RPM Hz X X Hz RPM 600 – Output Frequency
Rated Slip Speed
1 1 *Poles Speed to Freq Output
RPM Hz [NP Freq] [NP Spd]*Poles
Scaling Selected Frequency
[NP Spd] [NP Freq] 120 120
1 1 *Poles Freq Ref Freq Integral
(Hz) 1
[NP Spd] [NP Freq] 120 (Hz)
620 Droop RPM at FLA Ramp Input X
Bus/Current
Speed Control Reference (Sheet 5)
6
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Chapter 6
386
Chapter 6
A B C D E F G H I
2 704
0,2
4
SReg FB Fltr BW 639 Hold / Reset I Gain 658
945 Spd Reg
At Limit Status 654 SReg Out
462 Kvi Int Out
1434+o Feedback n Velocity 469 Velocity Low Pass Filter FltrGain 0
PTP PsnRefStatus Speed Reg Ki* 647 456 Velocity Integrator Output
Filter Bandwidth Bandwidth 720 2
( PTP Int Hold) Alt Speed Reg Ki* 650
6
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A B C D E F G H I
PF755 Rev_9.
Page 1
387
Chapter 6
388
Chapter 6
A B C D E F G H I
Homing -
Σ +
[13D4] Psn Reg Status R
[17H3] Xzero P Gain Limit Notch
Preset Σ 724 5 Spd Lmt Lo
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Psn Fdbk
724 6 Spd Lmt Hi
847 Psn Gear Ratio 848 437 Position Integrator Output
Motor Speed 441 Kpp 839
( Gear Output Spd ) 831
[3H4] 780 Position Integral Feedback PsnReg IntgrlOut
4 Psn Reg Kp 844 200 PsnNtchFltrDepth
434 Position Feedback Psn Load Actual 837 842
PReg Pos Spd Lmt
830
Calib ki
Load Psn FdbkSel 136 + Σ Const
+ 845 -200 PsnNtchFltrFreq
- - s
PReg Neg Spd Lmt 783 Position Notch Filter
Psn Fdbk [3H4]
Σ I Gain Limit Psn Reg Status
1
Position Control – Aux Functions
PsnWatch1 Stpt 747 Psn Reg Status PsnWatch2 Stpt 750 Psn Reg Status
724 9 PsnW1Detect 724 10 PsnW2Detect
Other Ref Other Ref
Sources Parameter Sources Parameter
Selection Position Watch 1 Selection Position Watch 2
3 PsnWatch1 Select 745 PsnWatch2 Select 748
746 749
PsnWatch1 DtctIn PsnWatch2 DtctIn
Position Control - Aux Functions
In Position Detect
6
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Page 13
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Chapter 6
390
Chapter 6
A B C D E F G H I
PLL Control
1 Velocity FF
2 Ext Vel FF
3 Accel Comp - Bit4 enables PCAM function with PLL.
2 - Bit5 enables PTP function with PLL
PLL Ext SpdScale 4 PCAM Enable
- Bit6 enables Profiler function with PLL
798 5 PTP Enable Can not select multiple bits.
PLL Control PLL Control PLL Control PLL LPFilter BW PLL references must connect to
6 Prof Enable
appropriate outputs of the function.
795 2 795 1 795 3 802
PLL Ext Spd Stpt 797 Ext Velocity Accel
Vel FF FF Comp
1
X PLL Control
Other Ref
Sources Parameter 0 1 PLL BW 795 0 PLL Enable
Selection LPF
801
3 0 Delay 807 PLL Speed Out
PLL Ext Spd Sel 796 0 [11F5]
1
808 PLL Speed OutAdv
X to V [11F5]
Conv 0
0
Delay 809 PLL Enc Out
PLL Psn Stpt 800 [11F5]
+
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Loop 1
+ + VE 810 PLL Enc Out Adv
Other Ref - Filter [11F5]
Sources 0
Position Control - Phase Locked Loop
Parameter
Selection
0
4
806 PLL Psn Out Fltr
PLL Psn Ref Sel 799
EGR
[ ]
803 PLL Virt Enc RPM
5
PLL EPR Input 804 X X
6
PF755 Rev_9.a
Page 14
A B C D E F G H I
Y-span
Unwind X 1472 PCAM Vel Out
PCAM Psn Stpt 1393 [11G3]
Page 15
391
Chapter 6
392
Chapter 6
A B C D E F G H I
1
Position Control – Profiler/Indexer (1)
Step Step Step Step Step Step
1 2 3 4 15 16
Speed/Position
Type 1230 1240 1250 1260 1370 1380
Velocity 1231 1241 1251 1261 1371 1381
Spd Ref
Accel 1232 1242 1252 1262 1372 1382
To Spd Ref
Move Table [6C3]
Decel 1233 1243 1253 1263 1373 1383
1234 1244 1254 1264 1374 1384 Actv SpTqPs Mode
Value
Dwell 1235 1245 1255 1265 1375 1385 313 [22D5]
2
Batch 1236 1246 1256 1266 1376 1386
Profiler
Next 1237 1247 1257 1267 1377 1387 PTP
Action 1238 1248 1258 1268 1378 1388 Command
Time Other
Dig In 1239 1249 1259 1269 1379 1389 0 784
[11E2]
6
PF755 Rev_9.a
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Page 17
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Chapter 6
394
Chapter 6
A B C D E F G H I
X X
*1 *1
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
4
Gear Ratio
*1: Product need to be within 32-bits integer range
RP Psn Out
RP Unwind 1509
Position
0 Feedback
Input
6
PF755 Rev_9.a
Page 18
A B C D E F G H I
SO Config
1580 0 Home DI
1
1
Home DI
Rising
0 Edge SO Status SO Config
Marker Pulse 1581 0 At SO Speed 1580 0 Home DI
0 SO Unit Out
X 1590
135
1594
0 Position Feedback Input
6
SO Rev Vel Lmt
PF755 Rev_9.a
Page 19
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
395
Chapter 6
396
Chapter 6
A B C D E F G H I
2
Torque
4
1518 1519 1520 1522 1524
PsnTrqBstPsnOfst PsnTrqBst UNWCnt PsnTrqBst Ps X1 PsnTrqBst Ps X3 PsnTrqBst Ps X5
1521 1523
PsnTrqBst Ps X2 PsnTrqBst Ps X4
6
PF755 Rev_9.a
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A B C D E F G H I
1
Torque Control – Overview
Induction Motor (IM) &
Surface Permanent Magnet Motor (SPM)
Speed /
Filtered
Torque / Torque Ref
Te
+ - Torque
Position + Notch + Iq Current
Mode + Filter + Torque Current Rate Ref
Limit Calc Limit Limit
Select
Friction
Torq Ref 1
Torque
3 Comp
Reference
Torq Ref 2 Scale Load
and Observer/
Torq Trim Estimator
Trim
6
PF755 Rev_9.a
Torque Control Overview - Induction Motor and Surface Permanent Magnet Motor
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Page 21a
397
Chapter 6
398
Chapter 6
A B C D E F G H I
Voltage
Limit
Id
Te Current
Id Current Ref
Calc Limit
Spd Reg PI Out Inertia
Speed
Adaption
Inertia Comp Reg Select
2
Output
Trim Torque Step
Speed / Id
Filtered
Torque / + - Torque Ref Te Iq
Position + Notch + Iq Current
Mode + Filter + Torque Current Rate Ref
Limit Calc Limit Limit
Select
3 Friction
Torq Ref 1
Torque
Comp
Reference
Torq Ref 2 Scale Load
and Observer/
Torq Trim Estimator
Trim
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Current
Limit
Pos Torque Limit
Regen Power Limit Processing
4
and
Drive Voltage and
Current Ratings
Selection
Pwr
Bus + Torque
Te
DC Bus Voltage Voltage + Limit
Regulator Select
6
PF755 Rev_9.a
Page 21b
A B C D E F G H I
2
0.0 ( Disabled )
6
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Chapter 6
400
Chapter 6
A B C D E F G H I
FrctnComp InertiaTrqAdd
FrctnComp Mode
Out
708 [25B4]
1 1560 1567
Torque Control – Torque Inertia
Disabled
496 - Kj Adaption
0 Friction
801 – Load Observer
0 1
Comp Total Inertia 76 Inertia Acceleration Estimate
From 1435 – Feedback n Accel Motor Acceleration Adaption Disabled
Spd Ref Int Ramp Ref 1 0
[7A3] Filter Bandwidth Feedback 0
1561 FrctnComp Trig
Ext Ramped Ref 1562 FrctnComp Hyst
2 Inertia Adapt BW 705
700
1563 FrctnComp Time
Filtered SpdFdbk InertiaAdaptGain 706
3 1564 FrctnComp Stick ***INTERNAL CONDITION ONLY*** 809 - Kof
640
1565 FrctnComp Slip Logic Ctrl State Min/Max Cntrl 493 – Torque
2
1566 FrctnComp Rated (Forced Spd) (Forced Spd) Reference Filtered
Zero Torque 0
0 Selected Filtered Trq
457 Velocity Loop Output Trq Ref Ref
Speed Reg 1 - To Torq Ctrl
0 0 +
From Spd Reg 660 + 685 + + 689 Current
+ + II +
[10I3] SReg Output Torq Reg 2 R [24a B2],
1 [10D5]
Notch [24b B2],
SLAT
492 – Torque Reference [25D2],
Inertia Comp Out Min 3 1 [26D2]
Min 491 – Torque Trim
From Spd Ref 699 Notch Fltr Freq 687
Torque
[7C4] SLAT 686 Notch Fltr Atten 688
3 Max
Step
452 – Acceleration 4
Max
Feedforward 503 – Torque Notch 802 – Load Observer Load
Torque Control - Torque
6
Load 2
Profiler Total Inertia 76
Observer/
Motor Acceleration Disabled
Psn P2P 7 Estimator 0
Feedback 0
4
Psn Camming 8 [6A1],
[6D2], Load Observer BW 711
[10D5], 704
Commanded Trq Psn PLL 9 806 - Kop
[11D2], InAdp LdObs Mode
From Torq Ref [11I1],
Power VF or SV
1320 – Motor Rated Peak Current Current Lmt 1 422 Thermal Mgr Current Limit (0-2,4,5,7,8)
Unit
533 – Current Vector Limit 424 Active Cur Lmt
Thermal
Current Lmt 2 423
Parameter Protection [36D2]
Selection
{Therm RegLmt} Motor Ctrl Mode 35
{Cur Lmt FV}
6
1315 – Motor Type
Torque Control - Current, Induction Motor and Surface Permanent Magnet Motor
PF755 Rev_9.a
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Page 24a
401
Chapter 6
402
Chapter 6
A B C D E F G H I
4 Voltage Ref/
{Mtr Vltg Lkg} Limit
Generation
5
Current Lmt Sel 421
Power
Current Lmt 1 422 Thermal Mgr Current Limit
Unit
424 Active Cur Lmt
Thermal
Current Lmt 2 423
Parameter Protection [36D2]
Selection
{Therm RegLmt}
{Cur Lmt FV}
6
PF755 Rev_9.a
Page 24b
A B C D E F G H I
1
Torque Control – Inertia Adaption
Adaption 1 Else X
Filter X From Fdbk
[3E3]
Else LPass 1
4 0
0
801 – Load Observer Sensorless
708 1435 – Feedback n
Acceleration Estimate 705 706 76
InertiaTrqAdd Accel Filter Bandwidth
InertiaAdaptGain Total Inertia
[23H1] Inertia Adapt BW
809 - Kof 496 - Kj
6
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Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
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Chapter 6
404
Chapter 6
A B C D E F G H I
1
Torque Control – Load Observer / Estimator
2
520 – Iq Current Command
493 – Torque Reference - Filtered 494 – Torque Reference - Limited
Filtered Limited
Drive Status 2
Trq Ref Trq Ref [24a E2], [24b E2]
(Fdbk Loss Sw0)
Torque
[23H2] 689 690 936 5 [3E1]
Limits
1 Position
d
Notch Filter Primary FIR 0
Encoder dt
Output Total Inertia Filter Velocity Accel
504 – Torque Limit - Positive Derivative
Limit IA LdObs 1
3 505 – Torque Limit - Negative System Model
Delay
Pos Torque Limit 670
709
Neg Torque Limit 671 d
FIR
Position dt
Alternate Filter Velocity Accel
Encoder Derivative
805 – Load
***INTERNAL CONDITION ONLY***
Observer
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Configuration
Load Observer BW
InAdp LdObs Mode
711 806 - Kop Speed Sensor
704 Type
Load Motor Acceleration Feedback
4 2
Observer Else
X From Fdbk
Torque Control - Load Observer / Estimator
Filter
Else
[3E3]
LPass 1
0 0
Sensorless
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A B C D E F G H I
Page 27
405
Chapter 6
406
Chapter 6
A B C D E F G H I
Parameter
Selection
MOP Reference
4 [29F2] Float Types
558
0 0
2 1065
936 10
PID Cfg
(Zero Clamp) Drive Status 2
(PID FB Loss)
6 [27C4]
PF755 Rev_9.a
Page 28
A B C D E F G H I
1
DI MOP Inc 177 MOP Control
MOP Rate Parameter
Indirect Option Port:
560
Digital In
MOP High Limit
MOP Inc
561
2
Calc 0
+ MOP Reference
Step
0 558
562
3 Parameter
Disabled (0) Default Option Port: Indirect MOP Low Limit
MOP Init Stpt 567 Digital In
MOP Inc
559 0 933 11
Save MOP Ref Start Inhibits
(At Pwr Down) (Bus PreChg)
6
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Chapter 6
408
Chapter 6
A B C D E F G H I
Outputs
In2
Filter
*-1R2T (1-Relay / 2-Transistor) I/O Modules Only
Dig In Fltr Mask
Inputs and Outputs - Digital
Output Compare
RO0 Level Sel RO1/TO0 Level Sel *-1R2T (1-Relay / 2-Transistor) I/O Modules Only
6
PF755 Rev_9.a
Page 30
A B C D E F G H I
Inputs
Hold 6 Outputs
Input
Anlg Out0 Val
7
Set Input Lo 82
3
8 Anlg Out0 DataHi V/mA
Set Input Hi
Anlg Out0 Data 78 Anlg Out0 Hi Analog Out Type Voltage
77 80 70 0 +
V/mA
Inputs and Outputs - Analog
Page 31
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Chapter 6
410
Chapter 6
A B C D E F G H I
Outputs
3 In0 20 24
Filter NO
RO1/TO0 Sel RO1/TO0 On Time
Dig In Fltr Mask
Com 2 0
*-1R2T (1-Relay / 2-Transistor) I/O Modules Only
Transistor Out1 0
11-Series Inputs and Outputs – Digital
Timer
4 Source NO
Parameter 1
Selection Inv
30 34
RO0 Level Sel RO1/TO0 Level Sel *-1R2T (1-Relay / 2-Transistor) I/O Modules Only
6
PF755 Rev_9.a
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A B C D E F G H I
Input
5
Flt CL Stop
Hold 6 Output
Input
Anlg Out0 Val
7
Set Input Lo 82
3
8 Anlg Out0 DataHi V/mA
Set Input Hi
Anlg Out0 Data 78 Anlg Out0 Hi Analog Out Type Voltage
77 80 70 0 +
V/mA
4
Anlg Out0 Lo
79
Anlg Out0 DataLo
6
PF755 Rev_9.a
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
Page 33
411
Chapter 6
412
Chapter 6
A B C D E F G H I
Motor PTC
+
PTC/Thermostat Buffer & PTC
Comparator
41 0 Thml Snsor OK
Input Monitor
2 - 1 Short Cirkt
2 Over Temp
3 Voltage Loss
13 Thermostat
14 PTC Selected
Common
ATEX Relay Output
Fault AND
Logic
Transistor
Latch
Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
NO
Reset AND
11-Series Inputs and Outputs – ATEX
Logic
6
PF755 Rev_9.a
Page 34
A B C D E F G H I
1
Note: Control Logic
The following parameters are typically referenced
0 when configuring or monitoring Control Logic;
P933 [Start Inhibits]
Digital Inputs
15
0
DPI Port 1
2 (Drv Mounted HIM)
15
0
888 Write Mask Cfg
DPI Port 2
Logic Parser To Spd Ref
15 [5G2], [6E3], [7F2],
0 [7F3], [8F2], [8F3]
Control Logic
Mask Evaluation
DPI Port 4 Owner Logic Logic Evaluation
Logic
15 31
0
DPI Port 5
4 15
0
DPI Port 6
15
6
PF755 Rev_9.a
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Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
413
Chapter 6
414
Chapter 6
A B C D E F G H I
960 0 IGBT OT
Current Limit 1 422
1 Heatsink OT
Current Limit 2 423
4 Drive OL
Parameter
Other Ref Sources Selection 5 CurLmt Reduc
3
1320 – Motor Rated Peak Current 6 PWMFrq Reduc
Inverter Overload IT
Current
5 SinkUnderTmp 416 MtrOL Reset Time
624 – Bus Regulator Action
Mtr OL Actv 410
6 Excess Load
Mtr OL at Pwr Up 411 418 Mtr OL Counts
4 DB resistor
Bus Reg Mode A 372 635 – Motor Capacity
Mtr OL Alarm Lvl 412 150% right of curve
Bus Reg Mode B 373 419 Motor OL Trip Time
Mtr OL Reset Lvl 415
12 DC Bus Memory
dc bus 102%
Bus Reg Lvl Cnfg 374 621 – DC Bus Voltage
- Nominal 60 (Hot) time (sec)
Bus Reg Level 375
1
Friction Compensation
2 Torque Torque
+ +
+ [FrctnComp Rated]
3
+ [FrctnComp Slip]
[FrctnComp Time]
Friction Compensation
[FrctnComp Hyst]
- - [Motor NP RPM] - [FrctnComp Trig] + [Motor NP RPM] + - - [FrctnComp Trig] +
Speed Speed
+ [FrctnComp Trig] + [FrctnComp Trig]
[FrctnComp Hyst]
4
[FrctnComp Time]
- [FrctnComp Slip]
- [FrctnComp Rated]
5
- -
6
PF755 Rev_9.a
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Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
415
Chapter 6
416
Chapter 6
A B C D E F G H I
5 1536 6
Status Update Max Boost VB STATUS
1536 7
Hold Freq
6
PF755 Rev_9.a
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A B C D E F G H I
Diagnostic Tools
1 Peak Detect Numeric Constants
NOTE: 1035 PkDtct Stpt Real
The change bit, Peak x Chng (where x = 1 or 2), is set TRUE if the
peak detect value changes, else the change bit is set FALSE. 1036 PkDtct Stpt Dint
Change is also set to FALSE if the detector is in HOLD or SET.
Bit
Digital Switches Bit Peak1 Cfg
Source Bit To Numeric Conversion 1039 2
Source (Peak1 Set)
Dig Sw Parameter Dig Sw Parameter
Peak1 Cfg Peak1 Cfg
d57 d61 1039 0 1039 1
Real Sel Selection Dint Sel Selection (Peak1 Peak) (Peak1 Hold)
Dig Sw Real Out Dig Sw Dint Out PeakDetect1 Out
1 1 PkDtct1 In Sel
Sw On Stpt Real d59 d60 Sw On Stpt Dint d63 d64 on 1041
1037
2 0 0 off
Sw Off Stpt Real d58 Sw Off Stpt Dint d62 Peak 1 PkDtct1
Input Data 1038
Real PresetSel
Source
Real
‘d’ Prefix Refers to Diagnostic Item Number (ex. d33) – Reference Symbol Legend (numeric) Parameter Peak 1
Selection Peak Detect Preset Data
Source Parameter
Peak 1 Change 1040 0 (numeric) Selection
(Peak1Change)
Peak2 Cfg
1044 2
(Peak2 Set)
Peak2 Cfg Peak2 Cfg
1044 0
Diagnostic Tools
6
PF755 Rev_9.a
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Integrated Motion on the EtherNet/IP Network Applications for PowerFlex 755 AC Drives
417
Chapter 6
418
Chapter 6
A B C D E F G H I
Not
Trend Sample Configuration Configured Trend Status
8 buffers of 4096 samples; minimum interval of 1.024 ms Download
or Running
Trend Mode Ready or Start
4 buffers of 1024 samples; minimum interval of 256 us (select one)
Complete Stop Gather pre-trigger
samples
Pre-Trigger 0 to maximum (4096 or 1024) samples
2 Buffers Full Finishing
Trigger Condition
Sample Interval Mimimum (1.024 ms or 256 us) Met
Gather post-
Stop trigger samples
6
Trend Buffer Contents
PF755 Rev_9.a
Page 40
Appendix A
PowerFlex 755 Standard and Safety Drive Module Optional Attributes
The following table specifies what optional attribute and corresponding control
mode functionality is supported by a PowerFlex 755 drive module when using
the Logix Designer application.
Control Modes
• N = No Control Mode
• F = Frequency Control Mode
• P = Position Control Mode
• V = Velocity Control Mode
• T = Torque Control Mode
For more information on the Control Modes, see Integrated Motion on the
Ethernet/IP Network Reference Manual, publication MOTION-RM003.
A Controller, DriveLogix 10
AC induction motors Conventions, Manual 11
recommended 357 Current Limit 156
Accel/Decel 124 Current Limit Stop 121
Accel/Decel Time 16
Adjustable Voltage 17 D
Alarms 155
Data Packets
Analog I/O 105
lost 301
Analog Input DC Bus Voltage 158
Square Root 111 Decel Time 16
Analog Inputs 105
Detection
Analog Output 114
Input Loss 112
Analog Outputs 113 DHCP persistence
Analog Scaling 107 IP address assignment 315
Auto Restart 25 Dig Out Invert
Auto/Manual 27 No. 226 – Main Control Board 147
Autotune 35 No. 6 – Option Module 147
Auxiliary Fault 121 Dig Out Setpoint
Auxiliary Power Supply 41 No. 227 – Main Control Board 142
auxiliary power supply option module No. 7 – Option Module 142
Dig Out Sts
installation and configuration 347
axis configuration No. 225 – Main Control Board 149
No. 5 – Option Module 150
control modes 307
Digital Inputs 119
Digital Outputs 130
B Digital Outputs Parameters 142, 147, 149
Braking 216 Drive Nonvolatile Memory 308
bulletin HPK-series motors Drive NV option 308
recommended 359 Drive Overload 158
Bus Memory 158 DriveLogix™ Controller 10
Bus Regulation 41 Drives Technical Support 11
Bus Regulation Mode 125 dual loop control
application 309
configuration 309
C Dual-Port EtherNet/IP option module 315
Carrier Frequency 196 install and configure 347
IP address assignment 315
Clear Fault 121
port assignment 315
Coarse Update Rate 301 dynamic brake
Coast Stop 121 configure for Integrated Motion on the EtherNet/IP
Compensation 192 Network 347
Configuration Conflicts 127 Dynamic Braking 197
configure dynamic IP address assignment by port 315
hardware over travel limits 316
incremental encoder feedback with an MPx motor
372 E
MDS instruction 302 Enable 121
Configureation
ETAP. See Dual-Port EtherNet/IP option module
Analog Output 114
Control Mode
axis attributes F
no control mode 419
position control mode 419 Faults 162
torque control mode 419 Feedback Devices 54
velocity control mode 419 feedback option modules
control modes install and configure 346
axis configuration 307 Flux Braking 216
Integrated Motion on the EtherNet/IP Network 301
S T
safety option modules Technical Support 11
restrictions for Integrated Motion on the EtherNet/IP Thermistor 152
Network 346 Third-party permanent magnet motors
Scaling, Analog 107 data modifications 361
Security 185 Torque
Shear Pin 188 Mode 306
shunt regulator Position 266
configuration for Integrated Motion on the EtherNet/ Reference 262
IP Network 347 Torque Loop
Signal Loss 112 RSLogix 5000 instance to parameter cross reference
SLAT. See Speed Limited Adjustable Torque 323
torque overload capability 345
Slip Compensation 192
Slip Regulator 194 Torque Reference 262
Software Torque Setpoint 126
Integrated Architecture Builder 300
Motion Analyzer 300 V
Speed Limited Adjustable Torque
configure for Integrated Motion on the EtherNet/IP Velocity Control
Network 353 RSLogix 5000 instance to parameter cross reference
Speed Reference 251 321
Speed Regulation 260 Velocity Mode 306
In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more
information, contact your local distributor or Rockwell Automation representative, or visit
http://www.rockwellautomation.com/services/online-phone.
Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
manual. You can contact Customer Support for initial help in getting your product up and running.
United States or Canada 1.440.646.3434
Outside United States or Canada Use the Worldwide Locator at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local
Rockwell Automation representative.
Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the
manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your
distributor to complete the return process.
Outside United States Please contact your local Rockwell Automation representative for the return procedure.
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Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this
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