Digital Reference DR-1600 User manual

Reference Manual
PowerFlex 70/700 Adjustable Frequency AC Drives
PowerFlex 70 Firmware Versions – Standard Control 2.001 and Below, Enhanced Control 2.xxx and Below
PowerFlex 700 Firmware Versions – Standard Control 3.001 and Below, Vector Control 3.002
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.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Summary of Changes
The information below summarizes the changes to the PowerFlex 70/700
Reference Manual, publication PFLEX-RM001 since the last release.
New and Updated
Information
Manual Updates
Description of Changes
Refer to:
Removed the Specification and Dimension information (Chapter 1)
20A-TD001 or 20B-TD001
Removed Fuse information and tables
20A-TD001 or 20B-TD001
Removed Appendix A - Dynamic Brake Guide
PFLEX-AT001
Added Motor Overload Protection section
page 119
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
3
Summary of Changes
Notes:
4
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Summary of Changes
New and Updated Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 1
Preface
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
Detailed Drive Operation
Accel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Advanced Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Auto/Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Autotune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Bus Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Cable, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cable, Motor Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cable Trays and Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Carrier (PWM) Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CE Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Copy Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Datalinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DC Bus Voltage / Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Decel Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DPI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Drive Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Drive Ratings (kW, Amps, Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Economizer (Auto-Economizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fan Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Flux Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Flux Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Grounding, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
HIM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
HIM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Input Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Input Power Conditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Linking Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
MOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Motor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Motor Start/Stop Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Output Current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Output Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Overspeed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Owners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
PET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Preset Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Process PI Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Reflected Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Regen Power Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Reset Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Reset Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
RFI Filter Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
S Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Scale Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Shear Pin Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Skip Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Speed Control, Mode, Regulation & Vector Speed Feedback. . . . . . . . . . . . . . . . 162
Speed Feedback Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Speed Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Speed Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Speed/Torque Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Speed Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
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Start Inhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Performance Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unbalanced or Ungrounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . .
User Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
176
176
177
197
200
200
200
201
204
205
205
206
207
207
207
Index
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Chapter
1
Preface
The purpose of this manual is to provide detailed drive information including
operation, parameter descriptions and programming.
Manual Conventions
To help differentiate parameter names and LCD display text from other text, the
following conventions will be used:
• Parameter Names will appear in [brackets]. For example: [DC Bus Voltage].
• Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an action:
Word
Can
Cannot
May
Must
Shall
Should
Should Not
Meaning
Possible, able to do something
Not possible, not able to do something
Permitted, allowed
Unavoidable, you must do this
Required and necessary
Recommended
Not recommended
• The following symbols are used throughout the manual to indicate specific
drive imformation.
Symbol
Description
Standard
Indicates that the information presented is specific to the Standard Control Option
Vector
This information only applies to PowerFlex 700 drives with the Vector Control option
Vector
EC
FV Applies to PowerFlex 700 drives with [Motor Cntl Sel] set to “FVC Vector.”
Indicates that the information presented is specific to the PowerFlex 70 Enhanced Control
Option.
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Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource
Description
PowerFlex 700 Standard Control User Manual,
publication 20B-UM001
Provides detailed information on:
• Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex 70 AC Drive Technical Data, publication
20A-TD001
This publication provides detailed drive specifications,
option specifications and input protection device ratings.
PowerFlex 700 AC Drive Technical Data, publication
20B-TD001
PowerFlex Comm Adapter Manuals, publication
20COMM-UM…
These publications provide information on configuring,
using, and troubleshooting PowerFlex communication
adapters.
PowerFlex 70 Enhanced Control and PowerFlex 700
Vector Control Reference Manual, publication
PFLEX-RM004
These publications provide detailed application specific
information for programming and configuring the
PowerFlex 700 drive.
Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives, publication DRIVES-IN001
Provides basic information needed to properly wire and
ground PWM AC drives.
Safety Guidelines for the Application, Installation and
Maintenance of Solid State Control, publication SGI-1.1
Provides general guidelines for the application,
installation, and maintenance of solid-state control.
Guarding Against Electrostatic Damage, publication
8000-4.5.2
Provides practices for guarding against Electrostatic
damage (ESD)
You can view or download publications at
http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
General Precautions
!
!
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as,
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
!
ATTENTION: Only qualified personnel familiar with adjustable frequency AC
drives and associated machinery should plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply may
result in personal injury and/or equipment damage.
!
10
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before performing any work on the drive.
Measure the DC bus voltage at the +DC & –DC terminals of the Power Terminal
Block (refer to the Installation Instructions for location). The voltage must be
zero.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Chapter
2
Detailed Drive Operation
This chapter explains PowerFlex drive functions in detail. Explanations are
organized alphabetically by topic. Refer to the Table of Contents for a listing of
topics.
[Accel Time 1, 2]
The Accel Time parameters set the rate at which the drive ramps up its output
frequency after a Start command or during an increase in command frequency
(speed change). The rate established is the result of the programmed Accel Time
and the Minimum and Maximum Frequency, as follows:
Maximum Speed
Accel Time
= Accel Rate (Hz./sec.)
(1)
(1)
(1)
Two accel times exist to allow the user to change acceleration rates “on the fly” via
PLC command or digital input. The selection is made by programming [Accel
Time 1] & [Accel Time 2] and then using one of the digital inputs ([Digital Inx
Sel]) programmed as “Accel 2” (see Table 9 for further information). However, if
a PLC is used, manipulate the bits of the command word as shown below.
MO
P
Sp Dec
d
Sp Ref I
d
D
Sp Ref 2
d ID
De Ref 1
ce ID
De l 2 0
ce
Ac l 1
ce
Ac l 2
c
Mo el 1
p
Lo Inc
ca
Re l Co
ve n
Fo rse trl
rw
Cle ard
a
Jo r Fa
g ult
Sta
r
Sto t
p
Accel Time
0 0 0 0 1 1 1 0 1 0 0 0 1 1 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
0
0
0
1
0
0
1
0
0
1
0
0
1
0
0
0
1 = Condition True
0 = Condition False
x = Reserved
Accel 1
Accel 2
Decel 1
Decel 2
The effectiveness of these bits or digital inputs can be affected by [Accel Mask].
See Masks on page 113 for more information.
Times are adjustable in 0.1 second increments from 0.0 seconds to 3600.0
seconds.
In its factory default condition, when no accel select inputs are closed and no
accel time bits are “1,” the default acceleration time is Accel Time 1 and the rate is
determined as above.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
11
Advanced Tuning
Advanced Tuning
Advanced Tuning Parameters – PF700 Vector Control Only
!
ATTENTION: To guard against unstable or unpredictable operation,
the following parameters must only be changed by qualified service
personnel.
Parameter Name & Description
500 [KI Current Limit]
Values
Default:
Related
No.
File
Group
The following parameters can only be viewed when “2, Unused” is selected in
parameter 196, [Param Access Lvl].
1500
Min/Max: 0/10000
Current Limit Integral gain. This gain is applied to the
1
current limit error signal to eliminate steady state current Units:
limit error. A larger value increases overshoot during a
step of motor current/load.
Default: 500
501 [KD Current Limit]
Current Limit Derivative gain. This gain is applied to the Min/Max: 0/10000
1
Units:
sensed motor current to anticipate a current limit
condition. A larger value reduces overshoot of the current
relative to the current limit value.
Default: 450
502 [Bus Reg ACR Kp]
UTILITY
Diag-Motor Cntl
This proportional gain, in conjunction with P160, adjusts Min/Max: 0/10000
1
the output frequency of the drive during a bus limit or Units:
inertia ride through condition. The output frequency is
adjusted in response to an error in the active, or torque
producing, current to maintain the active bus limit, or
inertia ride through bus reference. A larger value of gain
reduces the dynamic error of the active current.
Default: 900
503 [Jerk]
Min/Max: 2/30000
This parameter allows you to adjust the amount of
S-Curve, or “Jerk” applied to the Acc/Dec rate. To enable Units:
1
the Jerk feature, bit 1 of P56 must be set high.
Default: 500
504 [Kp Ln Ls Bus Reg]
Min/Max: 0/10000
This proportional gain adjusts the active current
1
command during an inertia-ride through condition, in Units:
response to a bus error. A larger value of gain reduces the
dynamic error of the bus voltage as compared to the bus
voltage reference.
505 [Kd Ln Ls Bus Reg]
Default: 500
Line Loss Bus Reg Kd is a derivative gain, which is applied Min/Max: 0/10000
to the sensed bus voltage to anticipate dynamic changes Units:
1
and minimize them. A larger value reduces overshoot of
the bus voltage relative to the inertia-ride through bus
voltage reference.
Default: 51
506 [Angl Stblty Gain]
Angle Stability Gain adjusts the electrical angle to
maintain stable motor operation. An increase in the
value increases the angle adjustment.
507 [Volt Stblty Gain]
Min/Max: 0/32767
1
Units:
Default:
93
Adjusts the output voltage to maintain stable motor
Min/Max: 0/32767
operation. An increase in the value increases the output Units:
1
voltage adjustment.
508 [Stability Filter]
Default: 3250
The Stability Filter coefficient is used to adjust the
bandwidth of a low pass filter. The smaller the value of
this coefficient, the lower the bandwidth of the filter.
12
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Min/Max: 0/32767
1
Units:
Parameter Name & Description
509 [Lo Freq Reg KpId]
Values
Default:
Related
No.
File
Group
Advanced Tuning
64
This proportional gain adjusts the output voltage at very Min/Max: 0/32767
1
Units:
low frequency in response to the reactive, or d-axis,
motor current. A larger value increases the output
voltage change.
Default: 64
510 [Lo Freq Reg KpIq]
The proportional gain adjusts the output voltage at very Min/Max: 0/32767
1
low frequency in response to the active, or q-axis, motor Units:
current. A larger value increases the output voltage
change.
Default: 44
511 [Ki Cur Reg]
Diag-Motor Cntl
This integral gain adjusts the output voltage in response Min/Max: 0/32767
1
Units:
to the q and d axis motor currents. A larger value
increases the output voltage change.
512 [Kp Cur Reg]
Default: 1600
This proportional gain adjusts the output voltage in
response to the q and d axis motor currents. A larger
value increases the output voltage change.
523 [Bus Utilization]
Min/Max: 0/32767
Units:
1
Default:
95.0%
Min/Max: 85.0/100.0%
This value sets the drive output voltage limit as a
0.1%
Units:
percentage of the fundamental output voltage when
operating in 6 step mode. Values above 95% increase
harmonic content and jeopardize control stability. This
output voltage limit is strictly a function of input line and
resulting bus voltage.
Default: 0
524 [PWM Type Sel]
UTILITY
Allows selection of the active PWM type. A value of 0 is Min/Max: 0/1
1
Units:
default, and results in a change of PWM method at
approximately 2/3 of rated motor frequency. If this is
unacceptable for harmonic or audible reasons, a value of
1 disables the change.
536 [Ki Flux Braking]
Default: 100
Proportional gain for the Flux Regulator
537 [Kp Flux Braking]
Integral gain for the Flux Regulator
538 [Rec Delay Time]
TBD
513 [PWM DAC Enable]
Diag-DACs
Reserved. Do Not Adjust
514
515
516
517
[DAC47-A]
[DAC47-B]
[DAC47-C]
[DAC47-D]
Reserved. Do Not Adjust
518 [Host DAC Enable]
Reserved. Do Not Adjust
519
520
521
522
[DAC55-A]
[DAC55-B]
[DAC55-C]
[DAC55-D]
Min/Max: 0/32767
1
Units:
Default: 500
Min/Max: 0/32767
Units:
1
Default: 1000
Min/Max: 1/30000
1
Units:
Default: 0
Min/Max: 0/1
1
Units:
Default: 0
Min/Max: 0/7432
Units:
1
Default:
0
Min/Max: 0/1
1
Units:
Default: 0
Min/Max: 0/7432
Units:
1
Reserved. Do Not Adjust
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
13
Related
No.
File
Group
Advanced Tuning
Parameter Name & Description
525 [Torq Adapt Speed]
Values
Default:
Selects the operating frequency/speed at which the
adaptive torque control regulators become active as a
percent of motor nameplate frequency.
526 [Torq Reg Enable]
Min/Max: 0.0/100.0%
0.1%
Units:
Enables or disables the torque regulator
527 [Kp Torq Reg]
Proportional gain for the torque regulator
528 [Ki Torq Reg]
Integral gain for the torque regulator
529 [Torq Reg Trim]
Default:
10.0%
1
Min/Max: 0/1
Units:
1
Default: 32
Min/Max: 0/32767
1
Units:
Default: 128
Min/Max: 0/32767
1
Units:
Default: 1.0
Torque Regulator trim gain. A larger value increases the Min/Max: 0.5/1.5
developed torque. Typically used to compensate for
Units:
0.1
losses between developed and shaft torque.
530 [Slip Reg Enable]
Default: 1
Enables or disables the slip frequency regulator.
531 [Kp Slip Reg]
UTILITY
Diag-Vector Cnt
Proportional gain for the slip frequency regulator.
532 [Ki Slip Reg]
Integral gain for the slip frequency regulator.
533 [Flux Reg Enable]
Enables or disables the flux regulator.
534 [Kp Flux Reg]
Proportional gain for the flux regulator.
535 [Ki Flux Reg]
Integral gain for the flux regulator.
539 [Freq Reg Ki]
Integral gain for the Frequency Regulator
540 [Freq Reg Kp]
Proportional gain for the Frequency Regulator.
541 [Encdlss Ang Comp]
TBD
542 [Encdlss Vlt Comp]
TBD
544 [Excitation Kp]
TBD
14
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Min/Max: 0/1
1
Units:
Default: 256
Min/Max: 0/32767
Units:
1
Default: 64
Min/Max: 0/32767
1
Units:
Default: 1
Min/Max: 0/1
1
Units:
Default: 64
Min/Max: 0/32767
Units:
1
Default: 32
Min/Max: 0/32767
Units:
1
Default: 450
Min/Max: 0/32767
1
Units:
Default: 2000
Min/Max: 0/32767
Units:
1
Default: 0
Min/Max: –1023/1023
1
Units:
Default: 6.1
Min/Max: 0/115
1
Units:
Default: 1800
Min/Max: 0/32767
1
Units:
Alarms
Alarms
Alarms are indications of situations that are occurring within the drive or
application that should be annunciated to the user. These situations may affect
the drive operation or application performance. Conditions such as Power Loss
or Analog input signal loss can be detected and displayed to the user for drive or
operator action.
There are two types of alarms:
• Type 1 Alarms are conditions that occur in the drive or application that may
require alerting the operator. These conditions, by themselves, do not cause
the drive to “trip” or shut down, but they may be an indication that, if the
condition persists, it may lead to a drive fault.
• Type 2 Alarms are conditions that are caused by improper programming and
they prevent the user from Starting the drive until the improper programming
is corrected. An example would be programming one digital input for a 2-wire
type control (Run Forward) and another digital input for a 3-wire type
control (Start). These are mutually exclusive operations, since the drive could
not determine how to properly issue a “Run” command. Because the
programming conflicts, the drive will issue a type 2 alarm and prevent Starting
until the conflict is resolved.
Alarm Status Indication
[Drive Alarm 1]
[Drive Alarm 2]
Two 16 bit Drive Alarm parameters are available to indicate the status of any
alarm conditions. Both Type 1 and Type 2 alarms are indicated.
A “1” in the bit indicates the presence of the alarm and a “0” indicates no alarm is
present
Configuration
In order for a drive alarm to be annunciated to the “outside” world, it must first
be “configured” or activated. Configuration parameters contain a configuration
bit for each Type 1 alarm. Type 2 alarms are permanently configured to
annunciate. The configuration word is a mirror image of the Drive Alarm word;
that is, the same bits in both the Drive Alarm Word and the Alarm Configuration
Word represent the same alarm.
Drive Alarm
1
1
1
1
0
X
0
X
Alarm Config
Active
Alarm
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Inactive Inactive
Alarm Alarm
15
Alarms
The configuration bits act as a mask to block or pass through the alarm condition
to the active condition. An active alarm will be indicated on the LCD HIM and
will cause the drive alarm status bit to go high (“1”) in the Drive Status word (Bit
6, parameter 209). This bit can then be linked to a digital output for external
annunciation. As default, all configuration bits are high (“1”). Note that setting a
configuration bit to “0” to “mask” an alarm does not affect the status bit in the
Drive Alarm parameter, only its ability to annunciate the condition.
Application
A process is being controlled by a PowerFlex drive. The speed reference to the
drive is a 4-20 mA analog signal from a sensor wired to Analog Input 1.
The input is configured for mA by setting the corresponding bit in [Anlg In
Config] to “1”
320 [Anlg In Config]
322
325
323
326
An
2
An 0=V
1 0 1=
=V mA
1=
mA
Selects the mode for the analog inputs.
x x x x x x x x x x x x x x 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Current
0 =Voltage
x =Reserved
Bit #
Factory Default Bit Values
Analog In Config
0
1
The input is scaled for 4-20 mA by setting [Analog In 1 Lo] to “4” mA and
[Analog In 1 Hi] to “20” mA.
The signal is designated as the active speed reference by setting [Speed Ref A Sel]
to its factory default value of “1”
090 [Speed Ref A Sel]
Selects the source of the speed reference to the drive
unless [Speed Ref B Sel] or [Preset Speed 1-7] is
selected.
Speed References
(1) See User Manual for DPI port locations.
16
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Default:
2
“Analog In 2”
Options:
1
2
3-6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
“Analog In 1”
“Analog In 2”
“Reserved”
“Pulse In”
“Encoder”
“MOP Level”
“Reserved”
“Preset Spd1”
“Preset Spd2”
“Preset Spd3”
“Preset Spd4”
“Preset Spd5”
“Preset Spd6”
“Preset Spd7”
“DPI Port 1”(1)
“DPI Port 2”(1)
“DPI Port 3”(1)
“DPI Port 4”(1)
“DPI Port 5”(1)
002
091
thru
093
101
thru
107
117
thru
120
192
thru
194
213
272
273
320
361
thru
366
Alarms
By setting Speed Ref A Hi to 60 Hz and Speed ref A Lo to 0 Hz, the speed
reference is scaled to the application needs. Because of the Input scaling and link
to the speed reference, 4 mA represents minimum frequency (0 Hz.) and 20 mA
represents Maximum Frequency (60 Hz.)
Scale Block
P322
20mA
P323
4mA
P091
60 Hz
P092
0 HZ
The input is configured to recognize a loss of signal and react accordingly to the
programming.
324 [Analog In 1 Loss]
327 [Analog In 2 Loss]
Default:
0
0
“Disabled”
“Disabled”
Selects drive action when an analog signal loss is
Options:
detected. Signal loss is defined as an analog signal less
than 1V or 2mA. The signal loss event ends and normal
operation resumes when the input signal level is greater
than or equal to 1.5V or 3mA.
0
1
2
3
4
5
6
“Disabled”
“Fault”
“Hold Input”
“Set Input Lo”
“Set Input Hi”
“Goto Preset1”
“Hold OutFreq”
091
092
The loss action is chosen as Hold Input, meaning that the last received signal will
be maintained as the speed reference.
Finally, a Digital Output relay is configured to annunciate an alarm by turning on
a flashing yellow light mounted on the operator panel of the process control area.
380 [Digital Out1 Sel]
384 [Digital Out2 Sel]
388
[Digital Out3 Sel]
Vector
Default:
Selects the drive status that will energize a (CRx) output Options:
relay.
(1)Contacts shown in User Manual are in drive powered
Digital Outputs
INPUTS & OUTPUTS
state with condition present. Refer to “Fault” and
“Alarm” information.
(2)Vector Control Option Only.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
1
4
4
“Fault”
“Run”
“Run”
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2126
27
28
29
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed”
“At Freq”
“At Current”
“At Torque”
“At Temp”
“At Bus Volts”
“At PI Error”
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1-6 Link”
381
385
382
386
383
002
001
003
004
218
012
137
157
147
053
048
184
“PI Enable”(2)
“PI Hold”(2)
“PI Reset”(2)
17
Analog Inputs
While the process is normal and running from the analog input, everything
proceeds normally. However, if the wire for the analog input should be severed or
the sensor malfunction so that the 4-20mA signal is lost, the following sequence
occurs:
1. The drive will sense the signal loss.
2. An active Type 1 Alarm is created and the last signal value is maintained as the
speed reference.
3. The alarm activates the digital output relay to light the alarm light for the
operator.
4. The operator uses the HIM to switch the drive to Manual Control (see Auto/
Manual).
5. The operator manually brings the process to a controlled stop until the signal
loss is repaired.
Alarm Queue (PowerFlex 700 Only)
Alarms
UTILITY
A queue of 8 parameters exists that capture the drive alarms as they occur. A
sequential record of the alarm occurrences allows the user to view the history of
the eight most recent events.
262
263
264
265
266
267
268
269
[Alarm 1 Code]
[Alarm 2 Code]
[Alarm 3 Code]
[Alarm 4 Code]
[Alarm 5 Code]
[Alarm 6 Code]
[Alarm 7 Code]
[Alarm 8 Code]
Default:
Read Only
261
Min/Max: 0/256
Display: 1
A code that represents a drive alarm. The codes will
appear in the order they occur (first 4 alarms in – first 4
out alarm queue). A time stamp is not available with
alarms.
Analog Inputs
Possible Uses of Analog Inputs
The analog inputs provide data that can be used for the following purposes:
• Provide a value to [Speed Ref A] or [Speed Ref B].
• Provide a trim signal to [Speed Ref A] or [Speed Ref B].
• Provide a reference when the terminal block has assumed manual control of
the reference
• Provide the reference and feedback for the PI loop. See Process PI Loop on
page 135.
• Provide an external and adjustable value for the current limit and DC braking
level
• Enter and exit sleep mode.
Vector FV Provide a value to [Torque Ref A] or [Torque Ref B].
•
18
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Analog Inputs
Analog Input Configuration
[Anlg In Config]
[Current Lmt Sel] allows an analog input to control the set point while [DC Brk
Levl Sel] allows an analog input to define the DC hold level used when
Ramp-to-Stop, Ramp-to-Hold, or Brake-to-Stop is active.
To provide local adjustment of a master command signal or to provide improved
resolution the input to analog channel 1 or 2 can be defined as a trim input.
Setting [Trim In Select] allows the selected channel to modify the commanded
frequency by ±10%. The speed command will be reduced by 10% when the input
level is at [Anlg In x Lo] with it linearly increasing to 10% above command at
[Anlg In xHi].
Feedback can be used to control an operation using the “Process PI”
(proportional-integral) feature of the control. In this case one signal, defined
using [PI Reference Sel], provides a reference command and a second, defined
using [PI Feedback Sel], provides a feedback signal for frequency compensation.
Please refer to the Process PI Loop on page 135 for details on this mode of
operation.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
19
20
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Hz
Reference A
+
Ref A
Scale/Limit
Hz
Trim Out Sel
Reference B
+
Trim Hi
Trim Lo
Trim In Select
Hz
Trim
Scale/Limit
Speed Ref B Hi
Ref B
Scale/Limit
Speed Ref A Hi
Speed Ref B Lo
Speed Ref B Sel
Speed Ref A Lo
Speed Ref A Sel
TB Manual
Hz
TB Manual
Scale/Limit
TB Man Ref Sel
Volts or mA
PI Reference
%
PI
Reference
Scale/Limit
PI Reference Sel
Cal Analog 2
PI Feedback Sel
Current Lmt Sel
DC Brk Levl Sel
Parameter
PI Feedback
%
PI Feedback
Scale/Limit
Current Limit
% Rated
Current
Current Limit
Scale/Limit
DC Brake
% Rated
Current
Brake Level
Scale/Limit
Sleep/Wake
Sleep/
Wake
Sleep Level
Compare
Torque Ref A
%
Torque Ref B Hi
Torque Ref B Lo
Torque Ref B Sel
Torque Ref B
%
Torque Ref B
Mult
Torque Ref A Hi
Torque Ref A Lo
Torque Ref A Sel
Torque Ref A
Div
Wake Level
Sleep Level
Sleep-Wake Ref
Selection/Control
Analog Input
2 Scale
Cal Analog 1
Analog In 2 Hi
Volts or mA
Processing
Analog Input
1 Scale
Input/Output
Analog In 2 Lo
Analog In 1 Hi
Analog In 1 Lo
Analog Inputs
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Analog 2
Current
Analog 2
Bipolar
Analog 2
Unipolar
Analog 1
Current
Analog 1
Voltage
ADC
ADC
(current)
(voltage)
Anlg In Config
Anlg In Config
Selection/Control
Processing
Parameter
Input/Output
0-20mA
-10v - +10v
0-10v
Analog In 2 Hi
Analog In 2 Lo
0-20mA
0-10v
Current
Cal 2
Bipolar
Cal 2
Unipolar
Cal 2
Note: If either of these
parameters is < 0, input will go
into bipolar mode, otherwise
unipolar.
Current
Cal 1
Unipolar
Cal 1
Limit
4-20mA
Limit
0-10V
Limit
0-10V
Limit
4-20mA
Limit
-10V to
10V
Analog In2 Value
Loss
Detect
Loss
Detect
Anlg In 2 Loss
Analog In1 Value
Loss
Detect
Loss
Detect
Anlg In 1 Loss
Square
Root
Anlg In Sqr Root
Square
Root
Anlg In Sqr Root
Cal Analog 2
Cal Analog 1
Analog Inputs
21
Analog Inputs
Analog Scaling
[Analog In Hi]
[Analog In Lo]
A scaling operation is performed on the value read from an analog input in order
to convert it to units usable for some particular purpose. The user controls the
scaling by setting parameters that associate a low and high point in the input
range (i.e. in volts or mA) with a low and high point in the target range (e.g.
reference frequency).
Two sets of numbers may be used to specify the analog input scaling. One set
(called the “input scaling points”) defines low and high points in terms of the
units read by the input hardware, i.e. volts or mA.
The second set of numbers (called the “output scaling points”) used in the analog
input scaling defines the same low and high points in units appropriate for the
desired use of the input. For instance, if the input is to be used as a frequency
reference, this second set of numbers would be entered in terms of Hz. For many
features the second set of numbers is fixed. The user sets the second set for speed
and reference trim.
An analog input or output signal can represent a number of different commands.
Typically an analog input is used to control output frequency, but it could control
frequency trim, current limit or act as a PI loop input. An analog output typically
is a frequency indication, but it could represent output current, voltage, or power.
For this reason this document defines an analog signal level as providing a
“command” value rather than a “frequency.” However when viewing a command
value it is presented as a frequency based on the [Minimum Speed] and
[Maximum Freq] settings.
The 0-10 volt input scaling can be adjusted using the following parameters:
• [Analog In x Lo]
• [Analog In x Hi]
Configuration #1:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (Voltage)
[Speed Ref A Sel] = “Analog In 1”
[Speed Ref A Hi] = 60 Hz
[Speed Ref A Lo] = 0 Hz
[Analog In 1 Hi] = 10V
[Analog In 1 Lo] = 0V
This is the default setting, where minimum input (0 volts) represents 0 Hz and
maximum input (10 volts) represents 60 Hz (it provides 6 Hz change per input
volt).
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Analog Inputs
12
10
Input Volts
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Analog Scaling
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
10V
60 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
0V
0 Hz
Configuration #2:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (Voltage)
[Speed Ref A Sel] = “Analog In 1”
[Speed Ref A Hi] = 30 Hz
[Speed Ref A Lo] = 0 Hz
[Analog In 1 Hi] = 10V
[Analog In 1 Lo] = 0V
This is an application that only requires 30 Hz as a maximum output frequency,
but is still configured for full 10 volt input. The result is that the resolution of the
input has been doubled, providing only 3 Hz change per input volt
(Configuration #1 is 6 Hz/Volt).
12
Input Volts
10
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Analog Scaling
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
10V
30 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
0V
0 Hz
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Analog Inputs
Configuration #3:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “1” (Current)
[Speed Ref A Sel] = “Analog In 1”
[Speed Ref A Hi] = 60 Hz
[Speed Ref A Lo] = 0 Hz
[Analog In 1 Hi] = 20 mA
[Analog In 1 Lo] = 4 mA
This configuration is referred to as offset. In this case, a 4-20 mA input signal
provides 0-60 Hz output, providing a 4 mA offset in the speed command.
Analog Scaling
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
20 mA
60 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
4 mA
0 Hz
20
Input mA
16
12
8
4
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Configuration #4:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (Voltage)
[Speed Ref A Sel] = “Analog In 1”
[Speed Ref A Hi] = 0 Hz
[Speed Ref A Lo] = 60 Hz
[Analog In 1 Hi] = 10V
[Analog In 1 Lo] = 0V
This configuration is used to invert the operation of the input signal. Here,
maximum input (10 Volts) represents 0 Hz and minimum input (0 Volts)
represents 60 Hz.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Analog Inputs
10
Input Volts
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Analog Scaling
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
10V
0 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
0V
60 Hz
Configuration #5:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (Voltage)
[Speed Ref A Sel] = “Analog In 1”
[Speed Ref A Hi] = 60 Hz
[Speed Ref A Lo] = 0 Hz
[Analog In 1 Hi] = 5V
[Analog In 1 Lo] = 0V
This configuration is used when the input signal is 0-5 volts. Here, minimum
input (0 Volts) represents 0 Hz and maximum input (5 Volts) represents 60 Hz.
This allows full scale operation from a 0-5 volt source.
6
Input Volts
5
4
3
2
1
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Analog Scaling
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
5V
60 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
0V
0Hz
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Analog Inputs
FV
Vector
•
•
•
•
•
Configuration #6 – Torque Ref:
[Anlg In Config], bit 0 = “0” (Voltage)
[Torque Ref A Sel] = “Analog In 1”
[Torque Ref A Hi] = 200%
[Torque Ref A Lo] = 0%
[Torque Ref A Div] = 1
This configuration is used when the input signal is 0-10 volts. The minimum
input of 0 volts represents a torque reference of 0% and maximum input of 10
volts represents a torque reference of 200%.
12
Input Volts
10
8
6
4
2
0
20
40
60
80
100
120
140
160
180
200
Torque Ref %
Analog Scaling
[Torque Ref A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Torque Ref A Hi]
10V
200%
[Analog In 1 Lo]
[Torque Ref A Lo]
0V
0%
Square Root
[Anlg In Sqr Root]
For both analog inputs, the user can enable a square root function for an analog
input through the use of [Analog In Sq Root]. The function should be set to
enabled if the input signal varies with the square of the quantity (i.e. drive speed)
being monitored.
If the mode of the input is bipolar voltage (–10v to 10v), then the square root
function will return 0 for all negative voltages.
The square root function is scaled such that the input range is the same as the
output range. For example, if the input is set up as a unipolar voltage input, then
the input and output ranges of the square root function will be 0 to 10 volts, as
shown in figure below.
Output (Volts)
10
8
6
4
2
0
2
4
6
8
10
Input (Volts)
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Analog Inputs
Signal Loss
[Analog In 1, 2 Loss]
Signal loss detection can be enabled for each analog input. The [Analog In x
Loss] parameters control whether signal loss detection is enabled for each input
and defines what action the drive will take when loss of any analog input signal
occurs.
One of the selections for reaction to signal loss is a drive fault, which will stop the
drive. All other choices make it possible for the input signal to return to a usable
level while the drive is still running.
•
•
•
•
•
Hold input
Set input Lo
Set input Hi
Goto Preset 1
Hold Output Frequency
Value
0
1
2
3
4
5
6
Action on Signal Loss
Disabled (default)
Fault
Hold input (continue to use last frequency command.)
Set Input Hi - use [Minimum Speed] as frequency command.
Set Input Lo - use [Maximum Speed] as frequency command.
use [Preset 1] as frequency command.
Hold Out Freq (maintain last output frequency)
If the input is in current mode, 4 mA is the normal minimum usable input value.
Any value below 3.2 mA will be interpreted by the drive as a signal loss, and a
value of 3.8 mA will be required on the input in order for the signal loss
condition to end.
4 mA
3.8 mA
3.2 mA
Signal Loss
Condition
End Signal Loss
Condition
If the input is in unipolar voltage mode, 2V is the normal minimum usable input
value. Any value below 1.6 volts will be interpreted by the drive as a signal loss,
and a value of 1.9 volts will be required on the input in order for the signal loss
condition to end.
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27
Analog Inputs
No signal loss detection is possible while an input is in bipolar voltage mode. The
signal loss condition will never occur even if signal loss detection is enabled.
2V
1.9V
1.6V
Signal Loss
Condition
End Signal Loss
Condition
Trim
An analog input can be used to trim the active speed reference (Speed Reference
A/B). If analog is chosen as a trim input, two scale parameters are provide to scale
the trim reference. The trim is a +/- value which is summed with the current
speed reference. See also Speed Reference on page 167.
•
•
•
•
[Trim In Select]
[Trim Out Select]
[Trim Hi]
[Trim Lo]
Value Display
Parameters are available in the Monitoring Group to view the actual value of an
analog input regardless of its use in the application. Whether it is a current limit
adjustment, speed reference or trim function, the incoming value can be read via
these parameters.
Metering
The value displayed includes the input value plus any factory hardware
calibration value, but does not include scaling information programmed by the
user (i.e. [Analog In 1 Hi/Lo]). The units displayed are determined by the
associated configuration bit (Volts or mA)
016 [Analog In1 Value]
017 [Analog In2 Value]
Value of the signal at the analog inputs.
Default:
Read Only
Min/Max: 0.000/20.000 mA
–/+10.000V
Display: 0.001 mA
0.001 Volt
Cable Selection
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable
Selection.
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Analog Inputs
Terminal Designations & Wiring Examples
Refer to the appropriate PowerFlex User Manual or “Wiring and Grounding
Guidelines for Pulse Width Modulated (PWM) AC Drives,” publication
DRIVES-IN001 for I/O terminal designations and wiring examples.
How [Analog Inx Hi/Lo] & [Speed Ref A Hi/Lo] Scales the Frequency
Command Slope with [Minimum/Maximum Speed]
Example 1:
Consider the following setup:
•
•
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (voltage)
[Speed Ref A Sel] = “Analog In 1”
[Analog In1 Hi] = 10V
[Analog In1 Lo] = 0V
[Speed Ref A Hi] = 60 Hz
[Speed Ref A Lo] = 0 Hz
[Maximum Speed] = 45 Hz
[Minimum Speed] = 15 Hz
This operation is similar to the 0-10 volts creating a 0-60 Hz signal until the
minimum and maximum speeds are added. [Minimum Speed] and [Maximum
Speed] limits will create a command frequency deadband.
[Minimum Speed]
[Analog In1 Hi]
10V
[Maximum Speed]
Motor Operating Range
Frequency Deadband
0-2.5 Volts
Frequency Deadband
7.5-10 Volts
Command Frequency
[Analog In1 Lo]
0V
0 Hz
[Speed Ref A Lo]
15 Hz
Slope defined by (Analog Volts)/(Command Frequency)
45 Hz
60 Hz
[Speed Ref A Hi]
This deadband, as it relates to the analog input, can be calculated as follows:
1. The ratio of analog input volts to frequency (Volts/Hz) needs to be
calculated. The voltage span on the analog input is 10 volts. The frequency
span is 60 Hz.
10 Volts/60 Hz = 0.16667 Volts/Hz
2. Determine the frequency span between the Minimum and Maximum Speed
limits and Speed Ref A Hi and Lo.
[Speed Ref A Hi] – [Maximum Speed] = 60 – 45 = 15 Hz and . . .
[Minimum Speed] – [Speed Ref A Lo] = 15 – 0 = 15 Hz.
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29
Analog Inputs
3. Multiply by the Volts/Hertz ratio
15 Hz x 0.16667 Volts/Hz = 2.5 Volts
Therefore the command frequency from 0 to 2.5 volts on the analog input will be
15 Hz. After 2.5 volts, the frequency will increase at a rate of 0.16667 volts per
hertz to 7.5 volts. After 7.5 volts on the analog input the frequency command will
remain at 45 Hertz.
Example 2:
Consider the following setup:
•
•
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (voltage)
[Speed Ref A Sel] = “Analog In 1”
[Analog In1 Hi] = 10V
[Analog In1 Lo] = 0V
[Speed Ref A Hi] = 50hz
[Speed Ref A Lo] = 0hz
[Maximum Speed] = 45hz
[Minimum Speed] = 15hz
The only change from Example 1 is the [Speed Ref A Hi] is changed to 50 Hz.
[Minimum Speed]
[Maximum Speed]
[Analog In1 Hi]
10V
Motor Operating Range
Frequency Deadband
9-10 Volts
Frequency Deadband
0-3 Volts
Command Frequency
[Analog In1 Lo]
0V
0 Hz
[Speed Ref A Lo]
15 Hz
Slope defined by (Analog Volts)/(Command Frequency)
45 Hz
50 Hz
[Speed Ref A Hi]
The deadband, as it relates to the analog input, can be calculated as follows:
1. The ratio of analog input volts to frequency (Volts/Hertz) needs to be
calculated. The voltage span on the analog input is 10 volts. The frequency
span is 60 Hz.
10 Volts/50 Hz = 0.2 Volts/Hz
2. Determine the frequency span between the minimum and maximum speed
limits and the Speed Ref A Hi and Lo.
[Speed Ref A Hi] – [Maximum Speed] = 50 – 45 = 5 Hz and . . .
[Minimum Speed] – [Speed Ref A Lo] = 15 – 0 = 15 Hz
3. Multiply by the volts/hertz ratio
5 Hz x 0.2 Volts/Hz = 1 Volt
15 Hz x 0.2 Volts/Hz = 3 Volts
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Analog Outputs
Here, the deadband is “shifted” due to the 50 Hz limitation. The command
frequency from 0 to 3 volts on the analog input will be 15 Hz. After 3 volts, the
frequency will increase at a rate of 0.2 volts per hertz up to 9 volts. After 9 volts
on the analog input the frequency command will remain at 45 Hz.
Explanation
Each drive has one or more analog outputs that can be used to annunciate a wide
variety of drive operating conditions and values.
The user selects the analog output source by setting [Analog Out Sel].
342 [Analog Out1 Sel]
345
[Analog Out2 Sel]
Vector
Default:
0 “Output Freq”
Options:
See Table
Selects the source of the value that drives the analog
output.
Analog Outputs
[Analog Out1 Lo] Value
INPUTS & OUTPUTS
Analog Outputs
Options
0
“Output Freq”
1
“Command Freq”
1* “Command Spd”
2
“Output Amps”
3
“Torque Amps”
4
“Flux Amps”
5
“Output Power”
6
“Output Volts”
7
“DC Bus Volts”
8
“PI Reference” (1)
“PI Feedback”
9
10 “PI Error”
11 “PI Output”
12 “%Motor OL”
13 “%Drive OL”
14* “CommandedTrq”
15* “MtrTrqCurRef” (1)
16* “Speed Ref”
17* “Speed Fdbk”
18* “Pulse In Ref” (1)
19* “Torque Est” (1)
20-23** “Scale Block1-4” (1)
24** “Param Cntl” (1)
Param. 341 = Signed
Param. 341 = Absolute [Analog Out1 Hi] Value
–[Maximum Speed]
–[Maximum Speed]
–[Maximum Speed]
0 Amps
–200% Rated
0 Amps
0 kW
0 Volts
0 Volts
–100%
–100%
–100%
–100%
0%
0%
–800% Rated
–200% Rated
–[Maximum Speed]
–[Maximum Speed]
–25200.0 RPM
–800%
0 Hz
0 Hz
0 Hz/RPM
0 Amps
0 Amps
0 Amps
0 kW
0 Volts
0 Volts
0%
0%
0%
0%
0%
0%
0%
0%
0 Hz/RPM
0 Hz/RPM
0 Hz/RPM
0%
+[Maximum Speed]
+[Maximum Speed]
+[Maximum Speed]
200% Rated
200% Rated
200% Rated
200% Rated
120% Rated Input Volts
200% Rated Input Volts
100%
100%
100%
100%
100%
100%
800% Rated
200% Rated
+[Maximum Speed]
+[Maximum Speed]
+[Maximum Speed]
+800%
001
002
003
004
005
007
006
012
135
136
137
138
220
219
377
378
* Vector Control Option Only
**Vector firmware 3.001 & later
(1) Refer to Option Definitions in User Manual.
Configuration
The PowerFlex 70 standard I/O analog output is permanently configured as a
0-10 volt output. The output has 10 bits of resolution yielding 1024 steps. The
analog output circuit has a maximum 1.3% gain error and a maximum 7 mV
offset error. For a step from minimum to maximum value, the output will be
within 0.2% of its final value after 12ms.
The PowerFlex 700 standard I/O analog output is permanently configured as a
0-10 volt output. The output has 10 bits of resolution yielding 1024 steps. The
analog output circuit has a maximum 1.3% gain error and a maximum 100 mV
offset error. For a step from minimum to maximum value, the output will be
within 0.2% of its final value after 12ms.
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31
Analog Outputs
Absolute (default)
Certain quantities used to drive the analog output are signed, i.e. the quantity can
be both positive and negative. The user has the option of having the absolute
value (value without sign) of these quantities taken before the scaling occurs.
Absolute value is enabled separately for each analog output via the bitmapped
parameter [Anlg Out Absolut].
Important: If absolute value is enabled but the quantity selected for output is
not a signed quantity, then the absolute value operation will have no
effect.
Scaling Blocks
The user defines the scaling for the analog output by entering analog output
voltages into two parameters, [Analog Out1 Lo] and [Analog Out1 Hi]. These
two output voltages correspond to the bottom and top of the possible range
covered by the quantity being output. The output voltage will vary linearly with
the quantity being output. The analog output voltage will not go outside the
range defined by [Analog Out1 Lo] and [Analog Out1 Hi].
Analog Output Configuration Examples
This section gives a few examples of valid analog output configurations and
describes the behavior of the output in each case.
Example 1 -- Unsigned Output Quantity
• [Analog Out1 Sel] = “Output Current”
• [Analog Out1 Lo] = 1 volt
• [Analog Out1 Hi] = 9 volts
10V
[Analog Out1 Hi]
Output Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
0%
200%
Output Current
Note that analog output value never goes outside the range defined by [Analog
Out1 Lo] and [Analog Out1 Hi]. This is true in all cases, including all the
following examples.
Example 2 -- Unsigned Output Quantity, Negative Slope
• [Analog Out1 Sel] = “Output Current”
• [Analog Out1 Lo] = 9 volts
• [Analog Out1 Hi] = 1 volts
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Analog Outputs
10V
[Analog Out1 Lo]
Output Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Hi]
0V
0%
200%
Output Current
This example shows that you can have [Analog Out1 Lo] greater than [Analog
Out1 Hi]. The result is a negative slope on the scaling from original quantity to
analog output voltage. Negative slope could also be applied to any of the other
examples in this section.
Example 3 – Signed Output Quantity, Absolute Value Enabled
• [Analog Out1 Sel] = “Output Torque Current”
• [Analog Out1 Lo] = 1 volt
• [Analog Out1 Hi] = 9 volts
• [Anlg Out Absolut] set so that absolute value is enabled for output 1.
10V
[Analog Out1 Hi]
Output Torque Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
– 200%
0%
200%
Output Torque Current
Example 4 – Signed Output Quantity, Absolute Value Disabled
• [Analog Out1 Sel] = “Output Torque Current”
• [Analog Out1 Lo] = 1 volt
• [Analog Out1 Hi] set to 9 volts
• [Anlg Out Absolut] set so that absolute value is disabled for output 1.
10V
[Analog Out1 Hi]
Output Torque Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
– 200%
0%
200%
Output Torque Current
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33
Analog Outputs
Filtering
Software filtering will be performed on the analog outputs for certain signal
sources, as specified in Table 1. “Filter A” is one possible such filter, and it is
described later in this section. Any software filtering is in addition to any
hardware filtering and sampling delays.
Table 1 Software Filters
Quantity
Output Frequency
Commanded Frequency
Output Current
Output Torque Current
Output Flux Current
Output Power
Output Voltage
DC Bus Voltage
PI Reference
PI Feedback
PI Error
PI Output
Filter
No extra filtering
No extra filtering
Filter A
Filter A
Filter A
Filter A
No extra filtering
Filter A
No extra filtering
No extra filtering
No extra filtering
No extra filtering
Analog output software filters are specified in terms of the time it will take the
output of the filter to move from 0% to various higher levels, given an
instantaneous step in the filter input from 0% to 100%. The numbers describing
filters in this document should be considered approximate; the actual values will
depend on implementation.
Filter A is a single pole digital filter with a 162ms time constant. Given a 0% to
100% step input from a steady state, the output of Filter A will take 500ms to get
to 95% of maximum, 810 ms to get to 99%, and 910 ms to get to 100%.
PowerFlex 700 Firmware 3.001 (& later) Enhancements
Certain analog output enhancements have been included in firmware version
3.001 (and later) for the PowerFlex 700 Vector Control drive. These include:
• Ability to scale the analog outputs
• Connect scale blocks to the analog outputs
• Analog Output controlled via Datalink
Output Scaling
A new scaling feature has been added to allow scaling. Prior to this feature,
[Analog Outx Lo] and [Analog Outx Hi] limited only the voltage. This voltage
range was scaled to the selected option range listed in [Analog Outx Sel]. With
the new feature, [Analog Outx Lo] and [Analog Outx Hi] still set the voltage
range, but the scaling parameter now scales the range of the [Analog Outx Sel]
selection. See the following example.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Analog Outputs
INPUTS & OUTPUTS
Analog Outputs
354
355
Vector v3
Vector v3
[Anlg Out1 Scale]
[Anlg Out2 Scale]
Default:
Sets the high value for the range of analog out scale.
Entering 0.0 will disable this scale and max scale will be
used. Example: If [Analog Out Sel] = “Commanded Trq,”
a value of 150 = 150% scale in place of the default
800%.
0.0
Min/Max: [Analog Out1 Sel]
0.01
Units:
Example
Analog Output 1 set for 0-10V DC at 0-100% Commanded Torque.
Setup
• [Analog Out1 Sel], parameter 342 = 14 “Commanded Torque”
• [Analog Out1 Hi], parameter 343 = 10.000 Volts
• [Analog Out1 Lo], parameter 344 = 0.000 Volts
• [Anlg Out1 Scale], parameter 354 = 100.0
If [Analog Out1 Lo] = –10.000 Volts the output will be –10.0 to +10.0V DC for
–100% to +100% Commanded Torque.
If [Anlg Out1 Scale] = 0.0, the default scaling listed in [Analog Out1 Sel] will be
used. This would be 0-1.25V DC for 0-100% Torque or 0-800% for 0-10V DC.
Scale Block Analog Output
Selects scaled analog output relative to the Scale Block value. Values not in the
[Analog OutX Sel] parameter list can be used to drive the analog outputs. When
using the Scale Block select, the Scale block Out Hi and Out Lo parameters are
not used.
Link
Testpoint 1 Data
477
In Hi
235
476
In Hi
478
In Lo
Scale 1
Out Hi
479
Out
481
Out Lo
480
Example
Analog Output 2 set for 0-10V DC for Heat Sink Temp 0-100 Degrees C. using
Scale Block 1.
Setup
• Link [Scale1 In Value], parameter 476 to [Testpoint 1 Data], param. 235
• [Testpoint 1 Sel], parameter 234 = 2 “Heat Sink Temp”
• [Analog Out2 Sel], parameter 345 = 20 “Scale Block 1”
• [Analog Out2 Hi], parameter 346 = 10.000 Volts
• [Analog Out2 Lo], parameter 347 = 0.000 Volts
• [Scale1 In Hi], parameter 477 = 100
• [Scale1 In Lo], parameter 478 = 0
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
35
Auto/Manual
Parameter Controlled Analog Output
Enables the analog outputs to be controlled by Datalinks to the drive.
377
378
Vector v3
Vector v3
[Anlg1 Out Setpt]
[Anlg2 Out Setpt]
Sets the analog output value from a communication
device. Example: Set [Data In Ax] to “377” (value from
communication device). Then set [Analog Outx Sel] to
“Param Cntl.”
Default:
20.000 mA, 10.000 Volts
Min/Max: 0.000/20.000mA
–/+10.000V
Units:
0.001 mA
0.001 Volt
Example
Analog Output 1 controlled by DataLink C1. Output 0-10V DC with DataLink
values of 0-10000.
Setup
• [Data In C1], parameter = 304 “Analog Output 1 Setpoint”
• [Analog Out1 Sel], parameter 342 = 24 “Parameter Control”
• [Analog Out1 Hi], parameter 343 = 10.000 Volts
• [Analog Out1 Lo], parameter 344= 0.000 Volts
The device that writes to DataLink C1 now controls the voltage output of
Analog Out1. For example: 2500 = 2.5V DC, 5000 = 5.0V DC, 7500 = 7.5V
DC.
Auto/Manual
The intent of Auto/Manual is to allow the user to override the selected reference
(referred to as the “auto” reference) by either toggling a button on the
programming terminal (HIM), or continuously asserting a digital input that is
configured for Auto/Manual.
• “Alt” Function on the HIM
By toggling the “Alt” and “Auto/Man” function on the HIM, the user can
switch the speed reference back and forth between the active “Auto” source
(per drive programming and inputs) and the HIM requesting the manual
control. “Manual” switches the Reference Source to the HIM, “Auto” switches
it back to drive programming.
The HIM manual reference can be preloaded from the auto source by
enabling the [Man Ref Preload] parameter. With the preload function
enabled, when the HIM requests Manual control, the current value of the
auto source is loaded into the HIM reference before manual control is
granted. This allows the manual control to begin at the same speed as the auto
source, creating a smooth transition. If the preload function is disabled, the
speed will ramp to whatever manual reference was present in the HIM at the
time manual control was granted.
• Digital Input
By toggling the digital input programmed as Auto/Manual, the user can
switch the speed reference back and forth between the active “Auto” source
(per drive programming and inputs) and the designated Terminal Block
manual reference. When this digital input is asserted, the TB will attempt to
36
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Auto/Manual
gain exclusive control (Manual) of the reference. If granted control of the
reference, the specific source for the reference is determined by the parameter
TB manual reference select.
The TB manual reference is selected in [TB Man Ref Sel]. The choices for
this parameter are:
– Analog Input 1
– Analog Input 2
– MOP Level
– Analog Input 3 (PF700 Only)
– Pulse Input (PF700 Only)
– Encoder input (PF700 Only)
– Releasing this input sends the control back to the Auto source.
General Rules
The following rules apply to the granting and releasing of Manual control:
1. Manual control is requested through a one-time request (Auto/Man toggle,
not continuously asserted). Once granted, the terminal holds Manual control
until the Auto/Man button is pressed again, which releases Manual control
(i.e. back to Auto mode).
2. Manual control can only be granted to the TB or to a programming terminal
(e.g. HIM) if Manual control is not already being exercised by the TB or
another programming terminal at the time.
3. Manual control can only be granted to a terminal if no other device has Local
control already asserted (i.e. no other device has ownership of the Local
control function).
4. A HIM (or TB) with Manual control active can have it taken away if another
DPI port requests, and is granted Local control. In this case when Local
control is released the drive will not go back to Manual control, Manual
control must be again requested (edge based request, see 1. above). This is true
for both the HIM and the TB (i.e. if the TB switch was in the Manual
position it must be switched to Auto and back to Manual to get Manual
control again).
5. The status indicator (point LED on LED HIM & Text on LCD HIM) will
indicate when that particular terminal has been granted Manual control, not
the fact any terminal connected has Manual control and not the fact that the
particular terminal has simply asked for Manual control.
6. When Manual control is granted, the drive will latch and save the current
reference value prior to entering Manual. When Manual control is then
released the drive will use that latched reference for the drive until another
DPI device arbitrates ownership and changes the reference to a different
value.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
37
Auto Restart (Reset/Run)
7. If a terminal has Manual control and clears its DPI reference mask (disallows
reference ownership), then Manual control will be released. By extension, if
the drive is configured such that the HIM can not select the reference (via
reference mask setting), then the drive will not allow the terminal to acquire
Manual control.
8. If a terminal has Manual control and clears its DPI logic mask (allowing
disconnect of the terminal), then Manual control will be released. By
extension if the drive is configured such that the HIM can be unplugged (via
logic mask setting), then the drive will not allow the terminal to acquire
Manual control. The disconnect also applies to a DPI HIM that executes a
soft “Logout.”
9. If a com loss fault occurs on a DPI that has Manual control, then Manual
control will be released as a consequence of the fault (on that port which had
Manual control).
10.There will be no way to request and hence no support of the Auto/Manual
feature on old SCANport based HIMs.
11.You can not acquire Manual control if you are already an assigned source for
the DPI port requesting Manual.
12.When a restore factory defaults is performed Manual control is aborted.
Auto Restart (Reset/Run)
The Auto Restart feature provides the ability for the drive to automatically
perform a fault reset followed by a start attempt without user or application
intervention. This allows remote or “unattended” operation. Only certain faults
are allowed to be reset. Certain faults (Type 2) that indicate possible drive
component malfunction are not resettable.
Caution should be used when enabling this feature, since the drive will attempt to
issue its own start command based on user selected programming.
Configuration
This feature is configured through two user parameters
174 [Auto Rstrt Tries]
Default:
0
175
Sets the maximum number of times the drive attempts Min/Max: 0/9
Display: 1
to reset a fault and restart.
!
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.
175 [Auto Rstrt Delay]
Sets the time between restart attempts when [Auto
Rstrt Tries] is set to a value other than zero.
Default:
1.0 Secs
174
Min/Max: 0.5/30.0 Secs
Display: 0.1 Secs
Setting [Auto Rstrt Tries] to a value greater than zero will enable the Auto Restart
feature. Setting the number of tries equal to zero will disable the feature.
The [Auto Rstrt Delay] parameter sets the time, in seconds, between each reset/
run attempt.
38
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Auto Restart (Reset/Run)
The auto-reset/run feature provides 2 status bits in [Drive Status 2] – an active
status, and a countdown status.
210 [Drive Status 2]
Read Only
209
DP
I
Mo at 50
to 0
Bu r Ov k
s F er
Cu req ld
rr
R
Au Lim eg
to it
Au Rst
to A
DB Rst ct
A C
Au ctiv tdn
to T e *
DC u n
B in
Sto raki g
p n
Jo ping g
gg
Ru ing
nn
Ac ing
tiv
Re e
ad
y
UTILITY
Diagnostics
Present operating condition of the drive.
x x 0 0 0 0 0 0 0 0 0 0 0 0 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
1 =Condition True
0 =Condition False
x =Reserved
* Vector firmware 3.001 & later
The typical steps performed in an Auto-Reset/Run cycle are as follows:
1. The drive is running and an auto-resettable fault occurs, tripping the drive.
2. After the number of seconds in [Auto Rstrt Delay], the drive will
automatically perform an internal Fault Reset, resetting the faulted condition.
3. The drive will then issue an internal Start command to start the drive.
4. If another auto-resettable fault occurs the cycle will repeat itself up to the
number of attempts set in [Auto Rstrt Tries].
5. If the drive faults repeatedly for more than the number of attempts set in
[Auto Rstrt Tries] with less than five minutes between each fault, the
auto-reset/run is considered unsuccessful and the drive remains in the faulted
state.
6. Aborting an Auto-Reset/Run Cycle (see Aborting an Auto-Reset/Run Cycle
for details).
7. If the drive remains running for five minutes or more since the last reset/run
without a fault, or is otherwise stopped or reset, the auto-reset/run is
considered successful. The entire process is reset to the beginning and will
repeat on the next fault.
Beginning an Auto-Reset/Run Cycle
The following conditions must be met when a fault occurs for the drive to begin
an auto-reset/run cycle.
• The fault must be defined as an auto-resettable fault
• [Auto Rstrt Tries] setting must be greater than zero.
• The drive must have been running, not jogging, not autotuning, and not
stopping, when the fault occurred. (Note that a DC Hold state is part of a
stop sequence and therefore is considered stopping.)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
39
Autotune
Aborting an Auto-Reset/Run Cycle
During an auto-reset/run cycle the following actions/conditions will abort the
reset/run attempt process.
• Issuing a stop command from any source. (Note: Removal of a 2-wire run-fwd
or run-rev command is considered a stop assertion).
• Issuing a fault reset command from any source.
• Removal of the enable input signal.
• Setting [Auto Rstrt Tries] to zero.
• The occurrence of a fault which is not auto-resettable.
• Removing power from the drive.
• Exhausting an Auto-Reset/Run Cycle
After all [Auto Rstrt Tries] have been made and the drive has not successfully
restarted and remained running for five minutes or more, the auto-reset/run
cycle will be considered exhausted and therefore unsuccessful. In this case the
auto-reset/run cycle will terminate and an additional fault, “Auto Rstrt Tries”
(Auto Restart Tries) will be issued if bit 5 of [Fault Config 1] = “1.”
Autotune
Description of parameters determined by the autotune tests.
Flux Current Test
[Flux Current Ref ] is set by the flux current test. Flux current is the reactive
portion of the motor current (portion of the current that is out of phase with the
motor voltage) and is used to magnetize the motor. The flux current test is used
to identify the value of motor flux current required to produce rated motor
torque at rated current. When the flux test is performed, the motor will rotate.
The drive accelerates the motor to approximately two-thirds of base speed and
then coasts for several seconds.
IR Voltage Drop Test
[IR Voltage Drop] is set by the IR voltage drop test. [IR Voltage Drop] is used by
the IR Compensation procedure to provide additional voltage at all frequencies
to offset the voltage drop developed across the stator resistance. An accurate
calculation of the [IR Voltage Drop] will ensure higher starting torque and better
performance at low speed operation. The motor should not rotate during this
test.
Vector
FV
Leakage Inductance Test
[Ixo Voltage Drop] is set by the leakage inductance test. This test measures the
inductance characteristics of the motor. A measurement of the motor inductance
is required to determine references for the regulators that control torque. The
motor should not rotate during this test.
40
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Autotune
Vector
FV
Inertia Test
[Total Inertia] is set by the inertia test. [Total Inertia] represents the time in
seconds, for the motor coupled to a load to accelerate from zero to base speed at
rated motor torque. During this test, the motor is accelerated to about 2/3 of base
motor speed. This test is performed during the Start-up mode, but can be
manually performed by setting [Inertia Autotune] to “Inertia Tune”. The [Total
Inertia] and [Speed Desired BW] automatically determine the [Ki Speed Loop]
and [Kp Speed Loop] gains for the speed regulator.
Autotune Procedure for Sensorless Vector and Economizer
The purpose of Autotune is to identify the motor flux current and stator
resistance for use in Sensorless Vector Control and Economizer modes.
The user must enter motor nameplate data into the following parameters for the
Autotune procedure to obtain accurate results:
• [Motor NP Volts]
• [Motor NP Hertz]
• [Motor NP Power]
Next, the Dynamic or Static Autotune should be performed:
• Dynamic - the motor shaft will rotate during this test. The dynamic autotune
procedure determines both the stator resistance and motor flux current. The
test to identify the motor flux current requires the load to be uncoupled from
the motor to find an accurate value. If this is not possible then the static test
can be performed.
• Static - the motor shaft will not rotate during this test. The static test
determines only [IR Voltage Drop]. This test does not require the load to be
uncoupled from the motor.
The static and dynamic tests can be performed during the Start-up routine on the
LCD HIM. The tests can also be run manually by setting the value of the
[Autotune] parameter to 1 “Static Tune” or 2 “Rotate Tune”.
Alternate Methods to Determine [IR Voltage Drop] & [Flux Current Ref]
If it is not possible or desirable to run the Autotune tests, there are three other
methods for the drive to determine the [IR Voltage Drop] and [Flux Current]
parameters:
• The first method is used when the motor nameplate parameters are left at
default. When the drive is initially powered up, the [Autotune] parameter is
defaulted to a value of 3 “Calculate”. The values for [IR Voltage Drop] and
[Flux Current] are calculated based on the default motor nameplate data.
This is the least preferred method.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
41
Autotune
• The second method calculates them from the user-entered motor nameplate
data parameters. When [Autotune] is set to 3 “Calculate”, any changes made
by the user to motor nameplate HP, Voltage, or Frequency activates a new
calculation. This calculation is based on a typical motor with those nameplate
values.
• Finally, if the stator resistance and flux current of the motor are known, the
user can calculate the voltage drop across the stator resistance. Then set
[Autotune] to 0 “Ready” and directly enter these values into the [Flux
Current] and [IR Voltage Drop] parameters.
Autotune Procedure for Flux Vector
Vector FV For FVC vector control an accurate model of the motor must be
used. For this reason, the motor data must be entered and the autotune tests
should be performed with the connected motor.
Motor nameplate data must be entered into the following parameters for the
Autotune procedure to obtain accurate results:
•
•
•
•
•
•
[Motor NP Volts]
[Motor NP FLA]
[Motor NP Hertz]
[Motor NP RPM]
[Motor NP Power]
[Motor Poles]
Next the Dynamic or Static Autotune should be performed:
• Dynamic - the motor shaft will rotate during this test. The dynamic autotune
procedure determines the stator resistance, motor flux current, and leakage
inductance. The test to identify the motor flux current requires the load to be
uncoupled from the motor to find an accurate value. If this is not possible
then the static test can be performed.
• Static - the motor shaft will not rotate during this test. The static test
determines only [IR Voltage Drop] and [Ixo Voltage Drop]. This test does not
require the load to be uncoupled from the motor.
The static and dynamic tests can be performed during the Start-up routine on the
LCD HIM. The tests can also be run manually by setting the value of [Autotune]
to “1,” (Static Tune) or “2” (Rotate Tune), respectively, and then starting the
drive.
After the Static or Dynamic Autotune the Inertia test should be performed. The
motor shaft will rotate during the inertia test. During the inertia test the motor
should be coupled to the load to find an accurate value. The inertia test can be
performed during the Start-up routine on the LCD HIM. The inertia test can
also be run manually by setting [Inertia Autotune] to 1 “Inertia Tune”, and then
starting the drive.
42
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Autotune
Troubleshooting the Autotune Procedure
If any errors are encountered during the Autotune process drive parameters are
not changed, the appropriate fault code will be displayed in the fault queue, and
the [Autotune] parameter is reset to 0. If the Autotune procedure is aborted by
the user, the drive parameters are not changed and the [Autotune] parameter is
reset to 0.
The following conditions will generate a fault during an Autotune procedure:
•
•
•
•
•
Incorrect stator resistance measurement
Incorrect motor flux current measurement
Load too large
Autotune aborted by user
Vector FV Incorrect leakage inductance measurement
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
43
44
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
PI Regulator
Logic
10
01
108
100
138
10
01
Logic
PI Output Meter
Limit
Speed Ref Selection
+
+
Jog Speed 2
Jog Speed 1
2
Logic
10
01
272
PI Excl
Mode
Linear
Ramp &
S Curve
Drive Ref Rslt
Commanded Freq
Commanded Speed
PI Speed
Trim
+
273
22
Kf Speed Loop
Ki Speed Loop
161
162
Bus Reg Mode B
Logic
Bus Reg Mode A
Torque Trim
*, /, +
88
449
447
445
446
Notch
Control
Lead Lag
Provides additional information
Read Testpoint with Data Select Value
Read / Write Parameter with Bit Enumeration
Read Only Parameter with Bit Enumeration
Drive
& Motor
Protection
1
Flux
Mtr Tor Cur Ref
Read / Write Parameter
Read Only Parameter
Bus Volt
& Power
Regulator
Torque
Selection
Speed Desired BW
Speed/Torque Mod
10
01
Lead Lag
Kp Speed Loop
Speed
Feedback
(From Encoder)
25
23
PI Regulator
Speed Control - Regulator (1.0ms)
Speed Reference
Torque Control (0.25ms)
Spd Reg In
Min/Max
Limits
Drive Ramp Rslt
Ramped Speed
Vector Control Mode with Speed Control
PI Feedback
PI Reference
Trim
Spd Ref B
Process Control (2ms)
DPI Port 1-6
Presets 1-7
MOP
Enc/Pulse
Spd Ref A
93
Speed Ref B Sel
S
O
U
R
C
E
S
90
Speed Ref A Sel
2
Limit
441
Motor
Current
Processing
Vector
Control
Block Diagrams
Analog 1/2
117
Trim In Select
Speed Control - Reference (2.0ms)
Block Diagrams
PowerFlex 700VC
Block Diagrams
The following pages contain the block diagrams for the PowerFlex 700 Vector
Control drive.
Figure 1 PowerFlex 700VC Block Diagrams (1)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
PI Regulator
Logic
10
01
108
100
138
10
01
Logic
PI Output Meter
Limit
Speed Ref Selection
+
+
Jog Speed 2
Jog Speed 1
Logic
10
01
PI Excl
Mode
Linear
Ramp &
S Curve
Drive Ref Rslt
Commanded Freq
2
272
Commanded Speed
2
V/Hz Mode with Speed Control
PI Feedback
PI Reference
Trim
Spd Ref B
Process Control (2ms)
DPI Port 1-6
Presets 1-7
MOP
Enc/Pulse
Spd Ref A
93
Speed Ref B Sel
S
O
U
R
C
E
S
90
Speed Ref A Sel
Analog 1/2
117
Trim In Select
Speed Control - Reference (2.0ms)
+
273
22
Min/Max
Limits
Drive Ramp Rslt
Ramped Speed
23
Speed Reference
80
Feedback Select
Encoder
3
+
1
Output Freq
1.5*Rated Slip
Limit
Provides additional information
Read Testpoint with Data Select Value
Read / Write Parameter with Bit Enumeration
Read Only Parameter with Bit Enumeration
Read / Write Parameter
0
Open Loop
Read Only Parameter
1
Slip Comp
449
447
Speed Desired BW
Kf Speed Loop
446
445
Ki Speed Loop
Kp Speed Loop
Speed Feedback
(From Encoder)
25
23
PI Regulator
Speed Control - Regulator (1.0ms)
Speed Reference
Motor
Current
Processing
V/Hz
Block Diagrams
PowerFlex 700VC
Block Diagrams
Figure 2 PowerFlex 700VC Block Diagrams (2)
45
46
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
DPI Port 6
DPI Port 6
(NVS)
(0)
DPI Port 5
DPI Port 5
Saved
Not Saved
192
1
0
0
Save HIM Ref
(At Powr Down)
DPI Port 4
DPI Port 4
DPI Port 3
Power Up
Preload
Preset Spd7
DPI Port 3
107
Preset Speed 7
Preset Spd6
DPI Port 2
106
Preset Speed 6
Preset Spd5
DPI Port 2
105
Preset Speed 5
Preset Spd4
DPI Port 1
104
Preset Speed 4
Preset Spd3
Preset Spd2
Preset Spd1
MOP Level
Encoder
DPI Port 1
103
102
Preset Speed 2
Preset Speed 3
101
Preset Speed 1
From MOP Output Ref
(8F3)
From Encoder Output Ref
Pulse
Analog In 2
From Analog In 2 Ref
(10D5)
From Pulse Output Ref
Analog In 1
1
(0)
1
0
(0)
1
0
23
22
21
193
14
13
12
11
10
9
Command Ref
Port 6 Manual
DPI Port 6
Man Ref Preload
Port 5 Manual
DPI Port 5
Port 3 Manual
Port 2 Manual
Port 1 Manual
TB Manual
8
7
6
5
4
3
2
1
0
271
14
Drive Logic Rslt
(Spd Ref ID)
From Internal
DPI Command
Port 4 Manual
HIM
Preload
9
2
1
96
Preset 7 Auto
Preset 6 Auto
Preset 5 Auto
Preset 4 Auto
Preset 3 Auto
Preset 2 Auto
Ref B Auto
Ref A Auto
DPI Port 4
DPI Port 3
DPI Port 2
DPI Port 1
MOP Level
From MOP Output Ref
(8F3)
19
20
Analog In 2
From Analog In2 Ref
(10D5)
107
106
105
104
103
102
TB Man Ref Sel
Preset Speed 7
Preset Speed 6
Preset Speed 5
Preset Speed 4
Preset Speed 3
Preset Speed 2
18
+
+
Analog In 1
1
0
From Analog In1 Ref
(10D2)
Speed Ref B
Trim
118
Trim Out Select
(Trim Ref B)
Speed Ref A
Trim
118
Trim Out Select
(Trim Ref A)
17
16
15
14
13
12
11
9
8
7
2
90
93
Speed Ref A Sel
Speed Ref B Sel
From Analog In 1 Ref
(10D2)
117
Trim In Select
1
0
13 12
Jog Speed 2
108
Jog Speed 1
100
From Internal
Selectable Ref(s)
OR
Fault
Preset1
Hold Ref
1
0
1
0
TB Jog 2
1
0
271
02
Drive Logic Rslt
(Jog)
Jog Ref
Selector
327
324
Analog In 1/2 Loss
From PI Output
[ 7H4]
Analog Loss Detection
Internal HIM/TB
Auto/Manual
124
1
0
211
4
Drive Alarm 1
(Anlg In Loss)
To Reference
(4A2)
00
PI Configuration
(Excl Mode)
Speed Control - Reference
(2.0 ms)
Block Diagrams
Figure 3 PowerFlex 700VC Block Diagrams (3)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
85
86
87
Skip Frequency 2
Skip Frequency 3
Skip Freq Band
0
1
209
84
Unipol Rev
(-1)
(0)
2
Drive Status 1
(Command Dir)
Skip Frequency 1
Unipol Fwd
0
1
(+1)
Internal
Autotune
From Reference
(3H2)
Skip Bands
Max
0
1
209
Max Speed
0
2
1
2
454
82
(0)
X
1
0
210
4
Drive Status 2
(Stopping)
(-1)
Stopping or Not Active
Not Stopping and Active
Rev Speed Limit
Drive Logic Rslt
(Jog)
X
Unipolar
Reverse Dis
Bipolar
190
Direction Mode
(0)
0
1
1
Drive Status 2
(Active)
210
≠0
0
81
(-1)
141
140
Decel Time 2
143
142
Ramp
Decel Time 1
Accel Time 2
Accel Time 1
Minimum Speed
Rev Spd Limit Non-Zero
Rev Spd Limit Zero
454
Rev Speed Limit
Limit
Drive Ramp Rslt
273
22
Ramped Speed
S Curve %
S Curve
Min Spd Limit
146
From PI Speed Trim
[7H5]
X
Limit
Jog Ref
02
79
Speed Units
0
1
271
Drive Logic Rslt
(Jog)
+
Convert
Hz/RPM
to
Internal
79
Speed Units
Convert
To Speed Cntrl Ref
[5A4]
Drive Ref Rslt (+/-32767)
272
Hz/Rpm
to
Internal
Commanded Freq (Hz)
Commanded Speed (RPM)
23
2
Speed Control - Reference
(2.0 ms)
Block Diagrams
Figure 4 PowerFlex 700VC Block Diagrams (4)
47
48
Fdbk Filter Sel
416
25
Speed Feedback
from Speed Cntrl Ref
[4H4]
Lead Lag
s +ω
ks + ω
23
Speed Reference
-
+
Kf Speed Loop
ω2
s2 + 2 s + ω 2
FeedFwd
2 nd Order LPass
Filter
447
kf
-
-
+
+
Ki Speed Loop
445
ki
s
I Gain
Kp Speed Loop
446
kp
P Gain
121
152
Testpoint 621
Droop RPM @FLA
621
Slip RPM @ FLA
+
Droop
Limit
620
416
Testpoint 620
Fdbk Filter Sel
Lead Lag
ks + ω
s+ω
To Torque Control Ref
[6A1]
Speed Control - Regulator
(1.0 ms)
Block Diagrams
Figure 5 PowerFlex 700VC Block Diagrams (5)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
431
434
Torque Ref B
Torque Ref B Mult
5
Flux Current
41
42
43
44
45
49
62
63
64
529
Motor NP Amps
Motor NP Hertz
Motor NP RPM
Motor NP Power
Motor Poles
IR Voltage Drop
Flux Current Ref
Ixo Voltage Drop
Torque Ref Trim
235/7
234/6
Motor NP Volts
Vqs Cmd
235/7
234/6
4
Torque Current
Vds Cmd
1
Current
Output Frequency
Calc
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Motor NP
Torque,
Flux,Rs,
Lo,Ls
Calc
X
/
>0
0
124
+
235/7
234/6
Torque Est.
08
Iqs Rated
Lo Gain
Ls Gain
Motor NP Flux
Motor NP Torque
Rs Gain
Torque
Estimator
Motor NP
and Tuning
Data
509
506
430
Torq Ref A Div
Torque
427
0
Process PI Config
Torque Ref A
From Torque Trim
[7H5]
From Speed Regulator
[5H4]
518
161
162
12
Bus Reg Mode A
Bus Reg Mode B
DC Bus Voltage
528
Torque Reg Ki
-
527
+
148
3
150
151
1
12
NTC
Mi
0
0
1
124
Observe Sts
Limit
526
0
1
IT-openloop
235/7
234/6
Power
Limit Calc
04
+
Min
Flux Current
235/7
234/6
235/7
234/6
5
03
Active Cur Limit
(Amps RMS x 10)
Peak Torq Current Limit
235/7
234/6
Iq
521
Calc
Is
437
Iq Rated
28
Rated Amps
517
Torque Ref Out
Neg Torque Limit
-1
436
419
>0
0
Max
Min
Min
Iq Scale
521
X
Limit
Limit
Iq Actual Lim
235/7
234/6
(-1)
*Iq Rated
Drive Rated
Notch Filt Freq
Pos Torque Limit
Notch
IIR
Iq Actual Lim
Active PWM Freq
Torque Reg Enable
0
25
420
419
Regen Power Lim
Thermal Manager
14
Limit
153
Speed Feedback
Notch Filter K
Notch Filter Freq
Bus Volt
Regulator
Power Unit Data
Current Lim Val
Output Current
Drive OL Mode
PWM Frequency
Output Freq
DC Bus Voltage
I Gain
ki
s
kp
P Gain
13
DC Bus Memory
Torque Reg Kp
27
6
5
4
3
2
1
0
88
Rated Volts
Abs
Min
+
Max
Min
0
Spd/Torq ModeSel
440
4-7
1
0
154
Current Rate Limit
PosTrqCurLim
440
440
NegTrqCurLim
Control Status
24
Commanded Torque
Rate Lim
441
to
Motor
Control
Mtr Tor Cur Ref
Torque Control
(0.25ms)
Block Diagrams
Figure 6 PowerFlex 700VC Block Diagrams (6)
49
50
From Feedback
Selectable Source(s)
From Reference
Selectable Source(s)
462
463
PI Feedback Lo
128
Enable
Scale
PI Configuration
(Feedback SqRt)
SqRt
05
Scale
Out - Lo
Hi - Lo
Out - Lo
Hi - Lo
124
461
PI Feedback Sel
460
PI Reference Hi
PI Reference Lo
PI Feedback Hi
Selector
Selector
126
PI Reference Sel
0
PI Fdback Meter
136
135
PI Ref Meter
133
-1
1
0
1
0
124
02
PI Configuration
(Preload Mode)
PI Preload
-
+
0
00
PI Integral Time
134
PI Status
(PI Enabled)
129
I Gain
ki
s
kp
125
04
Limit
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
0
124
00
PI Configuration
(Excl Mode)
PI Control
(Zero Clamp)
125
1
0
131
(0)
132
PI Lower Limit
+
PI Upper Limit
01
PI Control
(PI Hold)
1
P Gain
PI Prop Gain
137
PI Error Meter
PI BW Filter
BW
Error
Filter
130
01
139
124
PI Configuration
(Invert Error)
03
To Torque Trim
[6A2]
To PI Speed Trim
[ 4G2]
0
08
To PI Output
[4D3]
1
124
PI Configuration
(Torque Trim)
PI Status
(In Limit)
134
138
PI Output Meter
Process Trim
(2.0 ms)
Block Diagrams
Figure 7 PowerFlex 700VC Block Diagrams (7)
Block Diagrams
Figure 8 PowerFlex 700VC Block Diagrams (8)
Save MOP Ref
(At Stop)
Drive Logic Rslt
(Stop)
271
194
0
0
Clear
1
0
(0)
MOP Control
(2.0 ms)
1
1
Drive Logic Rslt
(Mop Inc)
271
(0)
(1)
MOP Rate
7
0
Add Rate
1
To MOP Output
[3B2] [3D4]
195
Ramp
Drive Logic Rslt
(Mop Dec)
11
271
15
MOP Frequency
Scale
(0)
(-1)
0
Subtract Rate
Speed Units
1
79
Save MOP Ref
(At Powr Down)
194
(0)
(NVS)
Not Saved
Saved
0
0
Power Up
Preload
1
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
51
52
24 VDC Common
TB1-26
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
TB2-32
TB2-31
TB2-30
TB2-29
TB2-28
TB1-27
TB1-25
{Logic Common}
24 VDC
TB1-24
Debounce
Debounce
Debounce
Debounce
Debounce
Debounce
00
01
02
03
From Internal
Selectable Source(s)
Selector
Selector
388
Digital Out3 Sel
384
Digital Out2 Sel
Logic
10
01
Logic
10
01
05
Dig In Status
(DigIn 6)
216
Digital In6 Sel
216
366
Selector
Terminal Block
Configuration
Setting [11A1]
Logic
Terminal Block
Configuration
Setting [11A1]
Terminal Block
Configuration
Setting [11A1]
From Internal
Selectable Source(s)
Selector
380
Digital Out1 Sel
Dig In Status
(DigIn 5)
Selector
Selector
Selector
Terminal Block
Configuration
Setting [11A1]
Terminal Block
Configuration
Setting [11A1]
From Internal
Selectable Source(s)
10
01
365
364
363
Selector
Selector
Terminal Block
Configuration
Setting [11A1]
04
Digital In5 Sel
Dig In Status
(DigIn 4)
216
Digital In4 Sel
361
362
Dig In Status
(DigIn 3)
216
Digital In3 Sel
Dig In Status
(DigIn 2)
216
Digital In2 Sel
Dig In Status
(DigIn 1)
216
Digital In1 Sel
02
03
Dig Out3 OnTime
Dig Out3 OffTime
391
Dig Out3 Level
Dig Out Status
(DigOut 3)
217
Dig Out2 OffTime
Dig Out2 OnTime
Dig Out2 Level
Dig Out Status
(DigOut 2)
217
Dig Out1 OffTime
Dig Out1 OnTime
Dig Out1 Level
390
389
387
386
385
383
382
381
01
Dig Out Status
(DigOut 1)
217
NC
NC
TB1-16
TB1-15
TB1-14
TB1-11
TB1-12
TB1-13
Inputs & Outputs - Digital
(0.5ms)
Block Diagrams
Figure 9 PowerFlex 700VC Block Diagrams (9)
TB1-20
TB1-19
TB1-4
TB1-3
TB1-18
TB1-17
TB1-2
TB1-1
+
-
+
-
00
Current
Jumper
ma/V
Scale
320
01
Anlg In Config
Current
Jumper
ma/V
Scale
320
Anlg In Config
A/D
12bit
A/D
12bit
00
01
Anlg In Sqr Root
321
17
Analog In2 Value
Anlg In Sqr Root
321
16
Analog In1 Value
Enable
SqRt
Enable
SqRt
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Analog In 1 Loss
Speed Ref B Lo
TB Man Ref Lo
Trim Lo
98
120
Speed Ref A Lo
Analog In 2 Loss
Selector
95
92
324
TB Man Ref Hi
Speed Ref B Hi
94
Trim Hi
Speed Ref A Hi
91
97
Trim Lo
120
119
Speed Ref B Lo
TB Man Ref Lo
95
Speed Ref A Lo
98
92
Out - Lo
Hi - Lo
Scale
Analog In2 Lo
347
In - Lo
Hi - Lo
346
Trim Hi
324
TB Man Ref Hi
97
119
Selector
Speed Ref B Hi
94
Out - Lo
Hi - Lo
Scale
Analog In2 Hi
Analog In1 Lo
323
In - Lo
Hi - Lo
322
Analog In1 Hi
Speed Ref A Hi
91
4
4
Drive Alarm 1
211
342
Selector
Analog Out2 Sel
345
Selector
Analog Out1 Sel
From Internal
Selectable Source(s)
To Analog In 2
Output Ref
(3B2)
Drive Alarm 1
211
To Analog In 1
Output Ref
(3B2)
From Internal
Selectable Source(s)
00
Abs
341
01
Anlg Out Absolut
Abs
341
Anlg Out Absolut
344
Analog In1 Lo
Scale
Out - Lo
Hi - Lo
In - Lo
Hi - Lo
347
Analog Out2 Lo
Scale
Out - Lo
Hi - Lo
346
Analog Out2 Hi
In - Lo
Hi - Lo
343
Analog Out1 Hi
D/A
12bit
D/A
12bit
00
ma/V
Scale
340
01
Anlg Out Config
ma/V
Scale
340
Anlg Out Config
+
-
+
-
TB1-9
TB1-8
TB1-7
TB1-6
Inputs & Outputs - Analog
(2.0ms)
Block Diagrams
Figure 10 PowerFlex 700VC Block Diagrams (10)
53
54
DPI Port 5
DPI Port 4
DPI Port 3
DPI Port 2
DPI Port 1 (HIM)
Terminal Block
Configuration
Settings
[9Dx]
AND
276
Logic Mask
6
/
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Ref
Owner
Logic
Dir
Owner
Logic
297
Local
Owner
Logic
Single
Owner
Eval
Single
Owner
Eval
Local Owner
Single
Owner
Eval
Local
Mask
Evaluation
Jog
Owner
Logic
285
AND
AND
AND
AND
AND
AND
AND
AND
Start
Owner
Logic
Local Mask
MOP Mask
284
Fault Clr Mask
283
Decel Mask
282
Accel Mask
281
Reference Mask
280
Direction Mask
279
Jog Mask
278
Start Mask
277
AND
Stop
Owner
Logic
MOP
Owner
Logic
Fault
Clear
Owner
Logic
Decel
Owner
Logic
Accel
Owner
Logic
292
294
Decel Owner
293
Accel Owner
2-Wire
Stop
Control
296
MOP Owner
295
Fault Clr Owner
Reference Owner
291
Dir Owner
290
Jog Owner
289
Start Owner
288
Stop Owner
Transition
Detection
Transition
Detection
Drive
Sequencer
State
Logic
Evaluation
271
Drive Logic Rslt
Control Logic
(2.0ms)
Block Diagrams
Figure 11 PowerFlex 700VC Block Diagrams (11)
148
Current Limit
Value
162
3
Output Current
161
151
PWM Frequency
Bus Reg Mode B
150
Drive OL Mode
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
257
255
253
251
249
247
245
243
Active PWM Freq
Active Cur Limit
Heatsink Temp
257
253
257
257
255
253
251
249
247
245
(DB Resistance)
255
251
243
253
255
251
249
247
245
243
Fault x Code
249
Fault x Code
(Inv OL Level 1)
(Inv OL Level 2)
04
03
02
247
245
243
Alarm x Code
235/7
234/6
235/7
234/6
235/7
234/6
(IntDBRes OvrHeat)
Alarm x Code
dc bus
DB resistor
(see torque block)
Heat sink and
Junction degree
Calculator
Inverter Over Load (IT)
Bus Reg Mode A
12
DC Bus Voltage
Duty Cycle
Pwr EE Data
NTC
Power Device
Characteristics
42
Motor NP FLA
Motor OL Hertz
48
Motor OL Factor
(Drive Overload)
(Heatsink OvrTemp)
47
X
50%
Motor
Current
60 (Hot)
180 (Cold)
1.0 - 2.0
(1.025 Typ)
102%
150%
Motor
Current
Mtr Over Load (I2T)
Motor
Speed (Hz)
time (sec)
right of curve
257
255
253
251
249
247
245
243
(Motor Overload)
Motor OL Count
Fault x Code
220
Inverter Overload IT
Block Diagrams
Figure 12 PowerFlex 700VC Block Diagrams (12)
55
Bus Regulation
Bus Regulation
[Bus Reg Gain]
[Bus Reg Mode A, B]
Some applications, such as the hide tanning shown here, create an intermittent
regeneration condition. 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 a nuisance
overvoltage trip.
When an AC motor regenerates energy from the load, the drive DC bus voltage
increases unless there is another means (dynamic braking chopper/resistor, etc.)
of dissipating the energy.
Motoring
Regenerating
Without bus regulation, if the bus voltage exceeds the operating limit established
by the power components of the drive, the drive will fault, shutting off the output
devices to protect itself from excess voltage.
Single Seq 500 S/s
0V Fault @Vbus Max
3
Drive Output Shut Off
2
1
Ch1 100mV
Ch3 500mV
Ch2 100mV
M 1.00s Ch3
1.47 V
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.
Since the same integrator is used for bus regulation as for normal frequency ramp
operation, a smooth transition between normal frequency ramp operation and
bus regulation is accomplished.
The regulator senses a rapid rise in the bus voltage and activates prior to actually
reaching the internal bus voltage regulation set point Vreg. This is important
since it minimizes overshoot in the bus voltage when bus regulation begins
thereby attempting to avoid an over-voltage fault.
56
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Bus Regulation
The bus voltage regulation set point (Vreg) in the drive is fixed for each voltage
class of drive. The bus voltage regulation set points are identical to the internal
dynamic brake regulation set points VDB's.
DB Bus
Motor Speed
Output Frequency
To avoid over-voltage faults, a bus voltage regulator is incorporated as part of the
acceleration/deceleration control. As the bus voltage begins to approach the bus
voltage regulation point (Vreg), the bus voltage regulator increases the
magnitude of the output frequency and voltage to reduce the bus voltage. The
bus voltage regulator function takes precedence over the other two functions. See
Figure 13.
The bus voltage regulator is shown in the lower one-third of Figure 13. The
inputs to the bus voltage regulator are the bus voltage, the bus voltage regulation
set point Vreg, proportional gain, integral gain, and derivative gain. The gains are
intended to be internal values and not parameters. These will be test points that
are not visible to the user. Bus voltage regulation is selected by the user in the Bus
Reg Mode parameter.
Operation
Bus voltage regulation begins when the bus voltage exceeds the bus voltage
regulation set point Vreg and the switches shown in Figure 13 move to the
positions shown in Table 2.
Table 2 Switch Positions for Bus Regulator Active
Bus Regulation
SW 1
Limit
SW 2
Bus Reg
SW 3
Open
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
SW 4
Closed
SW 5
Don’t Care
57
Bus Regulation
Figure 13 Bus Voltage Regulator, Current Limit and Frequency Ramp.
Current Limit
U Phase Motor Current
Derivative Gain
Block
Magnitude
Calculator
W Phase Motor Current
SW 3
Current Limit Level
PI Gain Block
Integral Channel
Proportional Channel
I Limit,
No Bus Reg
Limit
0
SW 1
No Limit
I Limit,
No Bus Reg
Acc/Dec Rate
Jerk
Ramp
Frequency
Ramp
(Integrator)
No Limit
Jerk
Clamp
SW 2
+
Frequency
Reference
+
Bus Reg
Frequency
Limits
+
+
+
SW 5
Frequency Set Point
Output Frequency
Speed
Control
Mode
Maximum Frequency, Minimum Speed, Maximum Speed, Overspeed Limit
Frequency Reference (to Ramp Control, Speed Ref, etc.)
Proportional Channel
Integral Channel
Speed Control (Slip Comp, Process PI, etc)
SW 4
Bus Voltage Regulation Point, Vreg
PI Gain Block
Bus Reg On
Derivative
Gain Block
Bus Voltage (Vbus)
Bus Voltage Regulator
The derivative term senses a rapid rise in the bus voltage and activates the bus
regulator prior to actually reaching the bus voltage regulation set point Vreg. The
derivative term is important since it minimizes overshoot in the bus voltage when
bus regulation begins thereby attempting to avoid an over-voltage fault. The
integral channel acts as the acceleration or deceleration rate and is fed to the
frequency ramp integrator. The proportional term is added directly to the output
of the frequency ramp integrator to form the output frequency. The output
frequency is then limited to a maximum output frequency.
Bus voltage regulation is the highest priority of the three components of this
controller because minimal drive current will result when limiting the bus voltage
and therefore, current limit will not occur.
58
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Bus Regulation
!
ATTENTION: The “adjust freq” portion of the bus regulator
function is extremely useful for preventing nuisance overvoltage faults
resulting from aggressive decelerations, overhauling loads, and eccentric
loads. It forces the output frequency to be greater than commanded
frequency while the drive's bus voltage is increasing towards levels that
would otherwise cause a fault; however, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in input voltage (more than a 10% increase
within 6 minutes) can cause uncommanded positive speed changes;
however an “OverSpeed Limit” fault will occur if the speed reaches
[Max Speed] + [Overspeed Limit]. If this condition is unacceptable,
action should be taken to 1) limit supply voltages within the
specification of the drive and, 2) limit fast positive input voltage
changes to less than 10%. Without taking such actions, if this operation
is unacceptable, the “adjust freq” portion of the bus regulator function
must be disabled (see parameters 161 and 162).
2. Actual deceleration times can be longer than commanded
deceleration times; however, a “Decel Inhibit” fault is generated if the
drive stops decelerating altogether. If this condition is unacceptable, the
“adjust freq” portion of the bus regulator must be disabled (see
parameters 161 and 162). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.
Note: These faults are not instantaneous and have shown test results
that take between 2 and 12 seconds to occur.
PowerFlex 70/700
The user selects the bus voltage regulator using the Bus Reg Mode parameters.
The available modes include:
•
•
•
•
off
frequency regulation
dynamic braking
frequency regulation as the primary regulation means with dynamic braking
as a secondary means
• dynamic braking as the primary regulation means with frequency regulation
as a secondary means
The bus voltage regulation setpoint is determined off of bus memory (a means to
average DC bus over a period of time). The following graph and tables describe
the operation.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
59
Bus Regulation
Table 3
Voltage Class
240
DC Bus Memory
< 342V DC
> 342V DC
480
< 685V DC
> 685V DC
600
< 856V DC
> 856V DC
600/690V
< 983V DC
PowerFlex 700 Frames > 983V DC
5 & 6 Only
DB On Setpoint
375V DC
Memory + 33V DC
750V DC
Memory + 65V DC
937V DC
Memory + 81V DC
1076V DC
Memory + 93V DC
DB Off Setpoint
On – 4V DC
On – 8V DC
On – 10V DC
On – 11V DC
880
815
DB Turn On
750
DC Volts
DB Turn Off
685
1
e#
urv
650
C
eg
sR
Bu
2
e#
urv
C
eg
sR
ory
Bu
em
M
us
B
509
453
320
360
460 484
AC Volts
528
576
If [Bus Reg Mode A], parameter 161 is set to “Dynamic Brak”
The Dynamic Brake Regulator is enabled. In “Dynamic Brak” mode the Bus
Voltage Regulator is turned off. The “DB Turn On” and turn off curves apply
(Table 3). For example, with a DC Bus Memory at 684V DC, the Dynamic Brake
Regulator will turn on at 750V DC and turn back off at 742V DC.
If [Bus Reg Mode A], parameter 161 is set to “Both-Frq 1st”
Both regulators are enabled, and the operating point of the Bus Voltage Regulator
is lower than that of the Dynamic Brake Regulator. The Bus Voltage Regulator
setpoint follows the “Bus Reg Curve 2” below a DC Bus Memory of 650V DC
and follows the “DB Turn Off ” curve above a DC Bus Memory of 650V DC
(Table 4). The Dynamic Brake Regulator follows the “DB Turn On” and turn off
curves (Table 3). For example, with a DC Bus Memory at 684V DC, the Bus
Voltage Regulator setpoint is 742V DC and the Dynamic Brake Regulator will
turn on at 750V DC and back off at 742V DC.
If [Bus Reg Mode A], parameter 161 is set to “Adjust Freq”
The Bus Voltage Regulator is enabled. The Bus Voltage Regulator setpoint
follows “Bus Reg Curve 1” below a DC Bus Memory of 650V DC and follows
the “DB Turn On” above a DC Bus Memory of 650V DC (Table 4). For
example, with a DC Bus Memory at 684V DC, the adjust frequency setpoint is
750V DC.
60
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Cable, Control
If [Bus Reg Mode A], parameter 161 is set to “Both-DB 1st”
Both regulators are enabled, and the operating point of the Dynamic Brake
Regulator is lower than that of the Bus Voltage Regulator. The Bus Voltage
Regulator setpoint follows the “DB Turn On” curve (Table 3). The Dynamic
Brake Regulator follows the “DB Turn On” and turn off curves (Table 3). For
example, with a DC Bus Memory at 684V DC, the Bus Voltage Regulator
setpoint is 750V DC and the Dynamic Brake Regulator will turn on at 750V DC
and back off at 742V DC.
Table 4
Voltage Class
240
DC Bus Memory
< 325V DC
325V DC ≤ DC Bus Memory ≤ 342V DC
> 342V DC
480
< 650V DC
650V DC ≤ DC Bus Memory ≤ 685V DC
> 685V DC
600
< 813V DC
813V DC ≤ DC Bus Memory ≤ 856V DC
> 856V DC
< 933V DC
600/690V
PowerFlex 700
933V DC ≤ DC Bus Memory ≤ 983V DC
Frames 5 & 6 Only > 983V DC
Bus Reg Curve #1
Memory + 50V DC
375V DC
Memory + 33V DC
Memory + 100V DC
750V DC
Memory + 65V DC
Memory + 125V DC
937V DC
Memory + 81V DC
Memory + 143V DC
1076V DC
Memory + 93V DC
Bus Reg Curve #2
Curve 1 – 4V DC
Curve 1 – 8V DC
Curve 1 – 10V DC
Curve 1 – 11V DC
Cable, Control
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable,
Control.
Cable, Motor Lengths
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable,
Motor Lengths.
Cable, Power
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable,
Power.
Cable Trays and Conduit
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable
Trays and Conduit.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
61
Carrier (PWM) Frequency
Carrier (PWM) Frequency
In general, the lowest possible switching frequency that is acceptable for any
particular application is the one that should be used. There are several benefits to
increasing the switching frequency. Refer to Figure 14 and Figure 15. Note the
output current at 2 kHz and 4 kHz. The “smoothing” of the current waveform
continues all the way to 10 kHz.
Figure 14 Current at 2 kHz PWM Frequency
Figure 15 Current at 4 kHz PWM Frequency
The benefits of increased carrier frequency include less motor heating and lower
audible noise. An increase in motor heating is considered negligible and motor
failure at lower switching frequencies is very remote. The higher switching
frequency creates less vibration in the motor windings and laminations thus,
lower audible noise. This may be desirable in some applications.
Some undesirable effects of higher switching frequencies include derating
ambient temperature vs. load characteristics of the drive, higher cable charging
currents and higher potential for common mode noise.
A very large majority of all drive applications will perform adequately at 2-4 kHz.
62
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
CE Conformity
CE Conformity
EMC Instructions
CE Conformity
Conformity with the Low Voltage (LV) Directive and Electromagnetic
Compatibility (EMC) Directive has been demonstrated using harmonized
European Norm (EN) standards published in the Official Journal of the
European Communities. PowerFlex Drives comply with the EN standards listed
below when installed according to the User and Reference Manuals.
CE Declarations of Conformity are available online at:
http://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)
• EN50178 Electronic equipment for use in power installations.
EMC Directive (89/336/EEC)
• EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC
product standard including specific test methods.
General Notes
• If the adhesive label is removed from the top of the drive, the drive must be
installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and
top openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV
Directive.
• The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
• Use of line filters in ungrounded systems is not recommended.
• PowerFlex drives may cause radio frequency interference if used in a
residential or domestic environment. The user is required to take measures to
prevent interference, in addition to the essential requirements for CE
compliance listed below, if necessary.
• Conformity of the drive with CE EMC requirements does not guarantee an
entire machine or installation complies with CE EMC requirements. Many
factors can influence total machine/installation compliance.
• PowerFlex drives can generate conducted low frequency disturbances
(harmonic emissions) on the AC supply system.
Essential Requirements for CE Compliance
Conditions 1-6 listed below must be satisfied for PowerFlex drives to meet the
requirements of EN61800-3.
1. Standard PowerFlex CE compatible Drive.
2. Review important precautions/attention statements throughout the User
Manual before installing the drive.
3. Grounding as described on page 107.
4. Output power, control (I/O) and signal wiring must be braided, shielded
cable with a coverage of 75% or better, metal conduit or equivalent
attenuation.
5. All shielded cables should terminate with the proper shielded connector.
6. Conditions in the appropriate table (5, 6 or 7).
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
63
CE Conformity
Frame
Table 5 PowerFlex 70 – EN61800-3 EMC Compatibility
A
B
C
D
E
Drive Description
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Second Environment
Restrict Motor Cable
to 40 m (131 ft.)
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Internal Filter
Option
–
–
–
✔
✔
✔
–
–
–
–
–
–
–
–
–
External
Filter (1)
✔
✔
✔
–
–
–
–
–
–
–
–
–
–
–
–
Input
Ferrite (2)
–
–
✔
–
–
✔
–
–
✔
–
–
✔
–
–
✔
Frame
Table 6 PowerFlex 70 – EN61800-3 First Environment Restricted Distribution )
A
B
C
D
E
Drive Description
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
Drive Only
Drive with any Comm Option
Drive with Remote I/O
First Environment Restricted Distribution
Restrict Motor Internal
External
Cable to:
Filter Option Filter (1)
40 m (131 ft.) –
✔
40 m (131 ft.) –
✔
40 m (131 ft.) –
✔
12 m (40 ft.)
✔
–
12 m (40 ft.)
✔
–
12 m (40 ft.)
✔
–
12 m (40 ft.)
–
–
12 m (40 ft.)
–
–
12 m (40 ft.)
–
–
12 m (40 ft.)
–
–
12 m (40 ft.)
–
–
12 m (40 ft.)
–
–
30 m (98 ft.)
–
✔
30 m (98 ft.)
–
✔
30 m (98 ft.)
–
✔
Comm Cable
Ferrite (2)
–
–
✔
–
–
✔
–
–
✔
–
–
✔
–
–
✔
Common Mode
Core (3)
–
–
–
–
–
–
✔
✔
✔
–
–
–
–
–
–
Frame
Table 7 PowerFlex 700 EN61800-3 EMC Compatibility (1)
Second Environment
First Environment Restricted Distribution
Restrict Motor Cable to 30 m (98 ft.)
Restrict Motor Cable to 150 m (492 ft.)
Any Drive and Option
0-6 ✔
Any Drive and Option
✔
External Filter Required
✔
(1) External filters for First Environment installations and increasing motor cable lengths in Second Environment
installations are available. Roxburgh models KMFA (RF3 for UL installations) and MIF or Schaffner FN3258
and FN258 models are recommended. Refer to Table 8 and http://www.deltron-emcon.com and http://
www.mtecorp.com (USA) or http://www.schaffner.com, respectively.
(2) Two turns of the blue comm option cable through a Ferrite Core (Frames A, B, C Fair-Rite #2643102002, Frame
D Fair-Rite #2643251002 or equivalent).
(3) Refer to the 1321 Reactor and Isolation Transformer Technical Data publication, 1321-TD001x for 1321-Mxxx
selection information.
64
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Copy Cat
Table 8 Recommended Filters (1)
Manufacturer
Deltron
Drive Type
PowerFlex 70
PowerFlex 700
Schaffner
PowerFlex 70
PowerFlex 700
Frame
A
B w/o Filter
B w/Filter
C
D
D w/o DC CM Capacitor
E
0
1
2
2 w/o DC CM Capacitor
3
3 w/o DC CM Capacitor
A
B w/o Filter
B w/Filter
C
D
D w/o DC CM Capacitor
0
1
2
2 w/o DC CM Capacitor
3
3 w/o DC CM Capacitor
Manufacturer
Part Number
KMF306A
KMF310A
KMF306A
KMF318A
KMF336A
KMF336A
–
KMF318A
KMF325A
KMF350A
KMF350A
KMF370A
KMF370A
FN3258-7-45
FN3258-7-45
FN3258-7-45
FN3258-16-45
FN3258-30-47
FN3258-30-47
FN3258-16-45
FN3258-30-47
FN3258-42-47
FN3258-42-47
FN3258-75-52
FN3258-75-52
Class
A
(Meters)
25
50
100
–
150
–
–
–
–
200
176
150
150
–
100
–
–
0
–
–
–
50
150
100
150
B
(Meters)
25
25
50
150
5
50
–
100
150
150
150
100
100
50
50
100
150
0
150
150
150
50
150
100
150
Manufacturer
Part Number
–
–
MIF306
–
MIF330
–
MIF3100
MIF316
–
–
–
–
–
–
–
–
–
FN258-30-07
–
–
–
–
–
–
–
Class
A
(Meters)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
B
(Meters)
–
–
100
–
150
–
30
150
–
–
–
–
–
–
–
–
–
150
–
–
–
–
–
–
–
(1) Use of these filters assumes that the drive is mounted in an EMC enclosure.
Copy Cat
Some PowerFlex drives have a feature called Copy Cat, which allows the user to
upload a complete set of parameters to the LCD HIM. This information can
then be used as backup or can be transferred to another drive by downloading the
memory.
Generally, the transfer process manages all conflicts. If a parameter from HIM
memory does not exist in the target drive, if the value stored is out of range for
the drive or the parameter cannot be downloaded because the drive is running,
the download will stop and a text message will be issued. The user than has the
option of completely stopping the download or continuing after noting the
discrepancy for the parameter that could not be downloaded. These parameters
can then be adjusted manually.
The LCD HIM will store a number of parameter sets (memory dependant) and
each individual set can be named for clarity.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
65
Current Limit
Current Limit
[Current Lmt Sel]
[Current Lmt Val]
[Current Lmt Gain]
There are 6 ways that the drive can protect itself from overcurrent or overload
situations:
•
•
•
•
•
•
Instantaneous Overcurrent trip
Software Instantaneous Trip
Software Current Limit
Overload Protection IT
Heatsink temperature protection
Thermal Manager
1. Instantaneous Overcurrent - This is a feature that instantaneously trips or
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.
2. Software Instantaneous Trip - There could be situations where peak currents
do not reach the F12 “HW Overcurrent” value and are sustained long enough
and high enough to damage certain drive components. If this situation occurs,
the drives protection scheme will cause an F36 “SW Overcurrent” fault. The
point at which this fault occurs is fixed and stored in drive memory.
3. Software Current Limit - This is a software feature that selectively faults the
drive or attempts to reduce current by folding back output voltage and
frequency if the output current exceeds this value. The [Current Lmt Val]
parameter is programmable between approximately 25% and 150% of drive
rating. The reaction to exceeding this value is programmable with [Shear Pin
Fault]. Enabling this parameter creates an F63 “Shear Pin Fault.” Disabling
this parameter causes the drive to use Volts/Hz fold back to try and reduce
load.
The frequency adjust or fold back operation consists of two modes. In the
primary mode of current limit operation, motor phase current is sampled and
compared to the Current Limit setting in the [Current Lmt Val]. If a current
“error” exists, error is scaled by an integral gain and fed to the integrator. The
output of this integrator is summed with the proportional term and the active
speed mode component to adjust the output frequency and the commanded
voltage. The second mode of current limit operation is invoked when a
frequency limit has been reached and current limit continues to be active. At
this point, a current regulator is activated to adjust the output voltage to limit
the current. When the current limit condition ceases or the output voltage of
the current regulator attempts to exceed the open loop voltage commands,
control is transferred to the primary current limit mode or normal ramp
operation.
66
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Datalinks
4. Overload Protection I2T - This is a software feature that monitors the output
current over time and integrates per IT. The base protection is 110% for 1
minute or the equivalent I2T value (i.e. 150% for 3 seconds, etc.). If the IT
integrates to maximum, an F64 “Drive Overload” fault will occur. The
approximate integrated value can be monitored via the [Drive OL Count]
parameter.
5. Heatsink Temperature Protection - The drive constantly monitors the
heatsink temperature. If the temperature exceeds the drive maximum, a
“Heatsink OvrTemp” fault will occur. The value is fixed by hardware at a
nominal value of 100 degrees C. This fault is generally not used for
overcurrent protection due to the thermal time constant of the heatsink. It is
an overload protection.
6. Thermal manager (see Drive Overload on page 94).
Datalinks
A Datalink is one of the mechanisms used by PowerFlex drives to transfer data to
and from a programmable controller. Datalinks allow a parameter value to be
changed without using an Explicit Message or Block Transfer. Datalinks consist
of a pair of parameters that can be used independently for 16 bit transfers or in
conjunction for 32 bit transfers. Because each Datalink consists of a pair of
parameters, when enabled, each Datalink occupies two 16 or 32-bit words in
both the input and output image tables, depending on configuration. A user
enters a parameter number into the Datalink parameter. The value that is in the
corresponding output data table word in the controller is then transferred to the
parameter whose number has been placed in the Datalink parameter. The
following example demonstrates this concept. The object of the example is to
change Accel and Decel times “on the fly” under PLC control.
The user makes the following PowerFlex drive parameter settings:
Parameter 300 [Data In A1] = 140 (the parameter number of [Accel Time 1]
Parameter 301 [Data In A2] = 142 (the parameter number of [Decel Time 1]
Programmable
Controller
I/O Image Table
Remote I/O
Communication
Module
Adjustable Frequency
AC Drive
Output Image
Block Transfer
Logic Command
Analog Reference
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
Datalink A
Parameter/Number
Data In A1
Data In A2
300
301
Datalink A
Data Out A1 310
Data Out A2 311
Input Image
Block Transfer
Logic Status
Analog Feedback
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
67
Datalinks
In the PLC data Table, the user enters Word 3 as a value of 100 (10.0 Secs) and
word 4 as a value of 133 (13.3 seconds). On each I/O scan, the parameters in the
PowerFlex drive are updated with the value from the data table:
Accel Time P140 = 10.0 seconds (value from output image table Word 3) Decel
Time P142 = 13.3 seconds (value from output image table Word 4).
Any time these values need to be changed, the new values are entered into the
data table, and the parameters are updated on the next PLC I/O scan.
Rules for Using Datalinks
1. 1. A Datalink consists of 4 words, 2 for Datalink x IN and 2 for Datalink x
Out. They cannot be separated or turned on individually.
2. Only one communications adapter can use each set of Datalink parameters in
a PowerFlex drive. If more than one communications adapter is connected to a
single drive, multiple adapters must not try to use the same Datalink.
3. Parameter settings in the drive determine the data passed through the
Datalink mechanism
4. When you use a Datalink to change a value, the value is not written to the
Non-Volatile Storage (EEprom memory). The value is stored in volatile
memory (RAM) and lost when the drive loses power.
32-Bit Parameters using 16-Bit Datalinks
To read (and/or write) a 32-bit parameter using 16-bit Datalinks, typically both
Datalinks (A,B,C,D) are set to the 32-bit parameter. For example, to read
Parameter 09 - [Elapsed MWh], both Datalink A1 and A2 are set to “9.”
Datalink A1 will contain the least significant word (LSW) and Datalink A2 the
most significant word (MSW). In this example, the parameter 9 value of
5.8MWh is read as a “58” in Datalink A1
Datalink
A1
A2
Most/Least Significant Word
LSW
MSW
Parameter
9
9
Data (decimal)
58
0
Regardless of the Datalink combination, x1 will always contain the LSW and x2
will always contain the MSW.
In the following examples Parameter 242 - [Power Up Marker] contains a value of
88.4541 hours.
68
Datalink
A1
A2
Most/Least Significant Word
LSW
-Not Used-
Parameter
242
0
Data (decimal)
32573
0
Datalink
A1
A2
Most/Least Significant Word
-Not UsedMSW
Parameter
0
242
Data (decimal)
0
13
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
DC Bus Voltage / Memory
Even if non-consecutive Datalinks are used (in the next example, Datalinks A1
and B2 would not be used), data is still returned in the same way.
Datalink
A2
B1
Most/Least Significant Word
MSW
LSW
Parameter
242
242
Data (decimal)
13
32573
32-bit data is stored in binary as follows:
231 through 216
215 through 20
MSW
LSW
Example
Parameter 242 - [Power Up Marker] = 88.4541 hours
MSW = 13decimal = 1101binary = 216 + 218 + 219 = 851968
LSW = 32573
851968 + 32573 = 884541
DC Bus Voltage / Memory
[DC Bus Voltage] is a measurement of the instantaneous value. [DC Bus
Memory] is a heavily filtered value or “nominal” bus voltage. Just after the
pre-charge relay is closed during initial power-up bus pre-charge, bus memory is
set equal to bus voltage. Thereafter it is updated by ramping at a very slow rate
toward Vbus. The filtered value ramps at approximately 2.4V DC per minute
(for a 480V AC drive).
Bus memory is used as the base line to sense a power loss condition. If the drive
enters a power loss state, the bus memory will also be used for recovery (i.e.
pre-charge control or inertia ride through upon return of the power source) upon
return of the power source. Update of the bus memory is blocked during
deceleration to prevent a false high value caused by a regenerative condition.
Decel Time
[Decel Time 1, 2]
Sets the rate at which the drive ramps down its output frequency after a Stop
command or during a decrease in command frequency (speed change). The rate
established is the result of the programmed Decel Time and the Minimum and
Maximum Frequency, as follows:
Maximum Speed
= Decel Rate (Hz/sec)
Decel Time
Two decel times exist to allow the user to change rates “on the fly” via PLC
command or digital input. The selection is made by programming [Decel Time
1] & [Decel Time 2] and then using one of the digital inputs ([Digital Inx Sel])
programmed as “Decel 2” (see Table 9 for further information). However, if a
PLC is used, manipulate the bits of the command word as shown below.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
69
(1 )
(1 )
MO
P
Sp Dec
d
Sp Ref I
d
D
Sp Ref 2
d R ID
De ef 1
ce ID
De l 2 0
ce
Ac l 1
ce
Ac l 2
c
Mo el 1
p
Lo Inc
ca
Re l Co
ve n
Fo rse trl
rw
Cle ard
a
Jo r Fa
g ult
Sta
r
Sto t
p
(1 )
Digital Inputs
0 0 0 0 1 1 1 0 1 0 0 0 1 1 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
0
0
0
1
0
0
1
0
0
1
0
0
1
0
0
0
1 = Condition True
0 = Condition False
x = Reserved
Accel 1
Accel 2
Decel 1
Decel 2
The effectiveness of these bits or digital inputs can be affected by [Decel Mask].
See Masks on page 113 for more information.
Times are adjustable in 0.1 second increments from 0.0 seconds to 3600.0
seconds.
In its factory default condition, when no decel select inputs are closed and no
time bits are “1,” the default deceleration time is [Decel Time 1] and the rate is
determined as above.
Digital Inputs
Cable Selection
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on Cable
Selection for Digital Inputs.
Wiring Examples
Refer to the appropriate PowerFlex user manual for wiring diagrams.
PowerFlex 70
Each digital input has a maximum response/pass through/function execution
time of 25ms. For example, no more than 25ms should elapse from the time the
level changes at the Start input to the time voltage is applied to the motor.
There is both hardware and software filtering on these inputs. The hardware
provides an average delay of 12ms from the time the level changes at the input to
the earliest time that the software can detect the change. The actual time can vary
between boards from 7 to 17ms, but any particular board should be consistent to
within 1% of its average value. The amount of software filtering is not alterable by
the user.
PowerFlex 700
Each digital input has a maximum response/pass through/function execution
time of 25ms. This means that, for example, no more than 25ms should elapse
from the time the level changes at the Start input to the time voltage is applied to
the motor.
70
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Digital Inputs
Digital Input Configuration
Inputs are configured for the required function by setting a [Digital Inx Sel]
parameter (one for each input). These parameters cannot be changed while the
drive is running.
PowerFlex 700 Digital Input Selection
361
362
363
364
365
366
[Digital In1 Sel]
[Digital In2 Sel]
[Digital In3 Sel]
[Digital In4 Sel]
[Digital In5 Sel]
[Digital In6 Sel] (11)
Default:
Default:
Default:
Default:
Default:
Default:
4
5
18
15
16
17
“Stop – CF”
“Start”
“Auto/ Manual”
“Speed Sel 1”
“Speed Sel 2”
“Speed Sel 3”
Selects the function for the digital inputs.
Options:
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15-17
18
19
20
21
22
23
24
25
26
27
28
29
30
31-33
34
“Not Used”
“Enable” (8)(10)
“Clear Faults”(CF) (4)
“Aux Fault”
“Stop – CF” (10)
“Start” (5)(9)
“Fwd/ Reverse” (5)
“Run” (6)(10)
“Run Forward” (6)
“Run Reverse” (6)
“Jog”(5) “Jog1” (2)(5)
“Jog Forward” (6)
“Jog Reverse” (6)
“Stop Mode B”
“Bus Reg Md B”
“Speed Sel 1-3” (1)
“Auto/ Manual” (7)
“Local”
“Acc2 & Dec2”
“Accel 2”
“Decel 2”
“MOP Inc”
“MOP Dec”
“Excl Link”
“PI Enable”
“PI Hold”
“PI Reset”
“Pwr Loss Lvl”
“Precharge En”
“Spd/Trq Sel1-3” (2,3)
“Jog 2” (2)
(1) Speed Select Inputs.
Digital Inputs
INPUTS & OUTPUTS
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Auto Reference Source
Reference A
Reference B
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
To access Preset Speed 1, set [Speed
Ref x Sel] to “Preset Speed 1”.
Type 2 Alarms - Some digital input
programming may cause conflicts
that will result in a Type 2 alarm.
Example: [Digital In1 Sel] set to “5,
Start” in 3-wire control and [Digital
In2 Sel] set to 7 “Run” in2-wire.
Refer to User Manual for information
on resolving this type of conflict.
(2) Vector Control Option Only.
(3)
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Spd/Trq Mode
Zero Torque
Spd Reg
Torque Reg
Min Spd/Trq
Max Spd/Trq
Sum Spd/Trq
Absolute
Zero Trq
100
156
162
096
140
194
380
384
388
124
(4) When [Digital Inx Sel] is set to option 2 “Clear Faults” the Stop button cannot be
used to clear a fault condition.
(5) Typical 3-Wire Inputs - Requires that only 3-wire functions are chosen.
Including 2-wire selections will cause a type 2 alarm.
(6) Typical 2-Wire Inputs - Requires that only 2-wire functions are chosen. Includ-
ing 3-wire selections will cause a type 2 alarm. See User Manual for conflicts.
(7) Auto/Manual - Refer to User Manual for details.
(8) Opening an “Enable” input will cause the motor to coast-to-stop, ignoring any
programmed Stop modes.
(9) A “Dig In ConflictB” alarm will occur if a “Start” input is programmed without a
“Stop” input.
(10) Refer to the Sleep-Wake Mode Attention statement on User Manual.
(11) A dedicated hardware enable input is available via a jumper selection. Refer to
User Manual for further information.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
71
Digital Inputs
PowerFlex 70 Digital Input Selection
361 [Digital In1 Sel]
Default:
4
[Digital In2 Sel]
362 [Digital In3 Sel]
363 [Digital In4 Sel]
[Digital In5 Sel]
364 [Digital In6 Sel]
365 Selects the function for the digital inputs.
Default:
Default:
Default:
Default:
Default:
5
18
15
16
17
“Stop – CF”
(CF = Clear Fault)
“Start”
“Auto/ Manual”
“Speed Sel 1”
“Speed Sel 2”
“Speed Sel 3”
Options:
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
“Not Used”
“Enable”(6)
“Clear Faults”(1)
“Aux Fault”
“Stop – CF”(2)
“Start”(2)(7)
“Fwd/ Reverse”(2)
“Run”(3)
“Run Forward”(3)
“Run Reverse”(3)
“Jog”(2)
“Jog Forward”
“Jog Reverse”
“Stop Mode B”
“Bus Reg Md B”
“Speed Sel 1”(4)
“Speed Sel 2”(4)
“Speed Sel 3”(4)
“Auto/ Manual”(5)
“Local”
“Acc2 & Dec2”
“Accel 2”
“Decel 2”
“MOP Inc”
“MOP Dec”
“Excl Link”
“PI Enable”
“PI Hold”
“PI Reset”
Digital Inputs
INPUTS & OUTPUTS (File J)
366
(1) When [Digital Inx Sel] is set to option 2 “Clear
Faults” the Stop button cannot be used to clear a
fault condition.
(2) Typical 3-Wire Inputs.
Requires that only 3-wire functions are chosen.
Including 2-wire selections will cause a type 2
alarm.
(3) Typical 2-Wire Inputs.
Requires that only 2-wire functions are chosen.
Including 3-wire selections will cause a type 2
alarm.
(4) Speed Select Inputs.
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Auto Reference Source
Reference A
Reference B
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
To access Preset Speed 1, set [Speed Ref A Sel]
or [Speed Ref B Sel] to “Preset Speed 1”.
Type 2 Alarms
Some digital input programming may cause
conflicts that will result in a Type 2 alarm. Example:
[Digital In1 Sel] set to 5 “Start” in 3-wire control and
[Digital In2 Sel] set to 7 “Run” in 2-wire.
Refer to Alarm Descriptions in the User Manual for
information on resolving this type of conflict.
(5) Auto/Manual - Refer to User Manual for details.
(6) Opening an “Enable” input will cause the motor to
coast-to-stop, ignoring any programmed Stop
modes.
(7) A “Dig In ConflictB” alarm will occur if a “Start”
input is programmed without a “Stop” input.
100
156
162
096
140
194
380
384
388
124
The available functions are defined in Table 9.
Table 9 Digital Input Function List
Input Function Name
Stop - CF
Run Forward
Run Reverse
Run
Start
Forward/Reverse
Jog
Jog Forward
Jog Reverse
Speed Select 3
Speed Select 2
Speed Select 1
Auto/Manual
72
Purpose
Stop drive
Clear Faults (open to closed transition)
Run in forward direction (2-wire start mode)
Run in reverse direction (2-wire start mode)
Run in current direction (2-wire start mode)
Start drive (3-wire start mode)
Set drive direction (3-wire mode only)
Jog drive
Jog in forward direction
Jog in reverse direction
Select which Speed reference the drive uses.
Allows terminal block to assume complete control of Speed Reference.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Digital Inputs
Accel 2
Decel 2
Accel 2 & Decel 2
Select acceleration rate 1 or 2.
Select deceleration rate 1 or 2.
Select acceleration rate 1 and deceleration rate 1 or acceleration rate 2
and deceleration rate 2.
Increment MOP (Motor Operated Pot Function Speed ref)
Decrement MOP (Motor Operated Pot Function Speed ref)
Select Stop Mode A (open) or B (closed)
Select which bus regulation mode to use
Enable Process PI loop.
Hold integrator for Process PI loop at current value.
Clamp integrator for Process PI loop to 0.
Open to cause “auxiliary fault” (external string).
Allows terminal block to assume complete control of drive logic.
Clear faults and return drive to ready status.
Open input causes drive to coast to stop, disallows start.
Exclusive Link – digital input is routed through to digital output, no
other use.
Selects between using fixed value for power loss level and getting the
level from a parameter
If common bus configuration, denotes whether drive is disconnected
from DC bus or not. Controls precharge sequence on reconnection to
bus.
MOP Increment
MOP Decrement
Stop Mode B
Bus Regulation Mode B
PI Enable
PI Hold
PI Reset
Auxiliary Fault
Local Control
Clear Faults
Enable
Exclusive Link
Power Loss Level (PowerFlex 700 only)
Precharge Enable (PowerFlex 700 only)
Input Function Detailed Descriptions
• Stop - Clear Faults
An open input will cause the drive to stop and become “not ready”. A closed
input will allow the drive to run.
If “Start” is configured, then “Stop - Clear Faults” must also be configured.
Otherwise, a digital input configuration alarm will occur. “Stop - Clear Faults”
is optional in all other circumstances.
An open to closed transition is interpreted as a Clear Faults request. The drive
will clear any existing faults. The terminal block bit must be set in the [Fault
Mask] and [Logic Mask] parameters in order for the terminal block to clear
faults using this input function.
If the “Clear Faults” input function is configured at the same time as “Stop Clear Faults”, then it will not be possible to reset faults with the “Stop - Clear
Faults” input.
• Run Forward, Run Reverse
An open to closed transition on one input or both inputs while drive is
stopped will cause the drive to run unless the “Stop - Clear Faults” input
function is configured and open.
The table below describes the basic action taken by the drive in response to
particular states of these input functions.
Run Forward
Open
Run Reverse
Open
Action
Drive stops, terminal block relinquishes direction ownership.
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Open
Closed
Closed
Closed
Open
Closed
Drive runs in reverse direction, terminal block takes direction ownership.
Drive runs in forward direction, terminal block takes direction ownership.
Drive continues to run in current direction, but terminal block maintains
direction ownership.
If one of these input functions is configured and the other one isn’t, the above
description still applies, but the unconfigured input function should be
considered permanently open.
The terminal block bit must be set in the [Start Mask], [Direction Mask], and
[Logic Mask] parameters in order for the terminal block to start or change the
direction of the drive using these inputs.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) 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
[Direction Owner]), it will not be possible to start the drive or
change direction by using the terminal block digital inputs
programmed for both Run and Direction control (i.e. Run/
Fwd).
If one or both of these input functions is configured, it will not be possible to
start or jog the drive from any other control device. This is true irrespective of
the state of the [Start Mask], [Direction Mask], and [Logic Mask] parameters.
• Run
An open to closed transition on this input while drive is stopped will cause the
drive to run in the currently selected direction unless the “Stop - Clear Faults”
input function is configured and open.
If this input is open, then the drive will stop.
The purpose of this input function is to allow a 2-wire start while the
direction is being controlled by some other means.
The terminal block bit must be set in the [Start Mask] and [Logic Mask]
parameters in order for the terminal block to start the drive using this input.
If the “Run” input function is configured, it will not be possible to start or jog
the drive from any other control device. This is true irrespective of the state of
the [Start Mask], [Direction Mask], and [Logic Mask] parameters.
The Effects of 2-Wire Start Modes on Other DPI Devices
The “Run/Stop” and “Run Fwd/Rev” start modes are also called “2-wire”
start modes, because they allow the drive to be started and stopped with only a
single input and two wires. When a “2-wire” terminal block start mode is put
into effect by the user, the drive can no longer be started or jogged from any
other control device (i.e. HIM, network card, etc.). This restriction persists as
long as one or more of “Run”, “Run Forward”, and “Run Reverse” are
configured. This is true even if the configuration is otherwise illegal and
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causes a configuration alarm. See page 109 for typical 2 and 3-wire
configurations.
• Start
An open to closed transition while the drive is stopped will cause the drive to
run in the current direction, unless the “Stop – Clear Faults” input function is
open.
The terminal block bit must be set in the [Start Mask] and [Logic Mask]
parameters in order for the terminal block to start or change the direction of
the drive using these inputs.
If “Start” is configured, then “Stop - Clear Faults” must also be configured.
• Forward/Reverse
This function is one of the ways to provide direction control when the Start /
Stop / Run functions of the drive are configured as 3 – wire control.
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, drive will
change direction.
The terminal block bit must be set in the [Direction Mask] and [Logic Mask]
parameters in order for the terminal block to select the direction of the drive
using this input function.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) 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
[Direction Owner]), it will not be possible to start the drive or
change direction by using the terminal block digital inputs
programmed for both Run and Direction control (i.e. Run/
Fwd).
Important: Because an open condition (or unwired condition) commands
Forward, the terminal block seeks direction ownership as soon as
this input function is configured, which may happen at power-up.
In order for the terminal block to actually gain ownership, the masks
must be set up correctly (see above) and no other device can
currently have direction ownership. Once the terminal block gains
direction ownership, it will retain it until shutdown, until the
[Direction Mask] or [Logic Mask] bits for the terminal block are
cleared, or until this input function is no longer configured
• Jog
Jog is essentially a non-latched “run/start” command. An open to closed
transition while drive is stopped causes drive to start (jog) in the current
direction. When the input opens while drive is running (jogging), the drive
will stop.
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The drive will not jog while running or while the “Stop - Clear Faults” input is
open. Start has precedence.
!
ATTENTION: If a normal drive start command is received while the
drive is jogging, the drive will switch from jog mode to run mode. The
drive will not stop, but may change speed and/or change direction.
The terminal block bit must be set in the [ Jog Mask] and [Logic Mask]
parameters in order for the terminal block to cause the drive to jog using this
input function.
• Jog Forward, Jog Reverse
An open to closed transition on one input or both inputs while drive is
stopped will cause the drive to jog unless the “Stop - Clear Faults” 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
Open
Jog Reverse
Open
Open
Closed
Closed
Closed
Open
Closed
Action
Drive will stop if already jogging, but can be started by other means. Terminal
block relinquishes direction ownership.
Drive jogs in reverse direction. Terminal block takes direction ownership.
Drive jogs in forward direction. Terminal block takes direction ownership.
Drive continues to jog in current direction, but terminal block maintains
direction ownership.
If one of these input functions is configured and the other one isn’t, the above
description still applies, but the unconfigured input function should be
considered permanently open.
The drive will not jog while drive is running or while “Stop - Clear Faults”
input is open. Start has precedence.
!
ATTENTION: If a normal drive start command is received while the
drive is jogging, the drive will switch from jog mode to run mode. The
drive will not stop, but may change speed and/or change direction.
The terminal block bit must be set in the [ Jog Mask], [Direction Mask], and
[Logic Mask] parameters in order for the terminal block to cause the drive to
jog using these input functions.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) 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
[Direction Owner]), it will not be possible to jog the drive or
change direction by using the terminal block digital inputs
programmed for both Run and Direction control (i.e. Run/
Fwd).
If another device is not currently the direction owner (as indicated by
[Direction Owner]) and the terminal block bit is set in the [Direction Mask]
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and [Logic Mask] parameters, the terminal block becomes direction owner as
soon as one (or both) of the “Jog Forward” or “Jog Reverse” input functions is
closed.
• Speed select 1, 2, and 3
One, two, or three digital input functions can be used to select the speed
reference used by the drive, and they are called the Speed Select input
functions. The current open/closed state of all Speed Select input functions
combine to select which source is the current speed reference. There are 8
possible combinations of open/closed states for the three input functions, and
thus 8 possible parameters can be selected. The 8 parameters are: [Speed Ref
A Sel], [Speed Ref B Sel], and [Preset Speed 2] through [Preset Speed 7].
If the Speed Select input functions select [Speed Ref A Sel] or [Speed Ref B
Sel], then the value of that parameter further selects a reference source. There
are a large number of possible selections, including all 7 presets.
If the input functions directly select one of the preset speed parameters, then
the parameter contains a frequency that is to be used as the reference.
The terminal block bit must be set in the [Reference Mask] and [Logic Mask]
parameters in order for the reference selection to be controlled from the
terminal block using the Speed Select inputs functions.
Important: Reference Control is an “Exclusive Ownership” function (see
Owners on page 125). This means that only one control device
(terminal block, DPI device, HIM, etc.) at a time is allowed to
select the reference source. The terminal block must become
direction “owner” before it can be used to control direction. If
another device is currently the reference owner (as indicated by
[Reference Owner]), it will not be possible to select the reference
by using the terminal block digital inputs, and the Speed Select
Inputs will have no effect on which reference the drive is
currently using.
Because any combination of open/closed conditions (or unwired condition)
commands a reference source, terminal block seeks ownership of reference
selection as soon as any of these input functions are configured, which may
happen at power-up. In order for the terminal block to actually gain
ownership, the masks must be set up correctly (see above) and no other device
can currently have reference ownership. Once the terminal block gains
reference ownership, it will retain it until shutdown, until the [Reference
Mask] or [Logic Mask] bits for the terminal block are cleared, or until none of
the digital inputs are configured as Speed Select input functions.
The Speed Select input function configuration process involves assigning the
functionality of the three possible Speed Select input functions to physical
digital inputs. The three Speed Select inputs functions are called “Speed
Select 1”, “Speed Select 2”, and “Speed Select 3”, and they are assigned to
physical inputs using the [Digital Inx Sel] parameters.
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The table below describes the various reference sources that can be selected
using all three of the Speed Select input functions.
Speed Select 3
Open
Open
Open
Open
Closed
Closed
Closed
Closed
Speed Select 2
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Speed Select 1
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Parameter that determines Reference
[Speed Ref A Sel]
[Speed Ref B Sel]
[Preset Speed 2]
[Preset Speed 3]
[Preset Speed 4]
[Preset Speed 5]
[Preset Speed 6]
[Preset Speed 7]
If any of the three Reference Select input functions are not configured, then
the software will still follow the table, but will treat the unconfigured inputs as
if they are permanently open.
As an example, the table below describes what reference selections can be
made if “Speed Select 1” is the only configured input function. This
configuration allows a single input to choose between [Speed Ref A Sel] and
[Speed Ref B Sel].
Speed Select 1
Open
Closed
Selected Parameter that determines Reference
[Speed Ref A Sel]
[Speed Ref B Sel]
As another example, describes what reference selections can be made if the
“Speed Select 3” and “Speed Select 2” input functions are configured, but
“Speed Select 1” is not.
Speed Select 3
Open
Open
Closed
Closed
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Speed Select 2
Open
Closed
Open
Closed
Selected Parameter that determines reference
[Speed Ref A Sel]
[Preset Speed 2]
[Preset Speed 4]
[Preset Speed 6]
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• Auto/Manual
The Auto/Manual facility is essentially a higher priority reference select. It
allows a single control device to assume exclusive control of reference select,
irrespective of the reference select digital inputs, reference select DPI
commands, the reference mask, and the reference owner.
If the “Auto/Manual” input function is closed, then the drive will use one of
the analog inputs (defined by [TB Man Ref Sel]) as the reference, ignoring the
normal reference selection mechanisms. This mode of reference selection is
called “Terminal Block Manual Reference Selection Mode”.
If this input function is open, then the terminal block does not request
manual control of the reference. If no control device (including the terminal
block) is currently requesting manual control of the reference, then the drive
will use the normal reference selection mechanisms. This is called “Automatic
Reference Selection” mode.
The drive arbitrates among manual reference requests from different control
devices, including the terminal block.
• Accel 2 / Decel 2
The Acceleration/Deceleration Rate Control input functions (Acc/Dec
input functions for short) allow the rate of acceleration and deceleration for
the drive to be selected from the terminal block. The rates themselves are
contained in [Accel Time 1], [Decel Time 1], [Accel Time 2], and [Decel
Time 2]. The Acc/Dec input functions are used to determine which of these
acceleration and deceleration rates are in effect at a particular time.
The terminal block bit must be set in the [Accel Mask] and [Logic Mask]
parameters in order for the acceleration rate selection to be controlled from
the terminal block. The terminal block bit must be set in the [Decel Mask]
and [Logic Mask] parameters in order for the deceleration rate selection to be
controlled from the terminal block.
There are two different schemes for using the Acc/Dec input functions. Each
one will be described in its own section.
• Accel 2, Decel 2
In the first scheme, one input function (called “Accel 2”) selects between
[Accel Time 1] and [Accel Time 2], and another input function (called
“Decel 2”) selects between [Decel Time 1] and [Decel Time 2]. The open
state of the function selects [Accel Time 1] or [Decel Time 1], and the closed
state selects [Accel Time 2] or [Decel Time 2].
Important: Acc/Dec Control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed to select the
Acc/Dec rates. The terminal block must become Acc/Dec
“owner” before it can be used to control ramp rates. If another
device is currently the reference owner (as indicated by
[Reference Owner]), it will not be possible to select the reference
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by using the terminal block digital inputs, and the Speed Select
Inputs will have no effect on which reference the drive is
currently using.
Because any combination of open / closed conditions (or unwired condition)
commands a reference source, the terminal block seeks accel ownership as
soon as the “Accel 2” input function is configured, which may happen at
power-up. In order for the terminal block to actually gain ownership, the
masks must be set up correctly (see above) and no other device can currently
have accel ownership. Once the terminal block gains accel ownership, it will
retain it until shutdown, until the [Accel Mask] or [Logic Mask] bits for the
terminal block are cleared, or until “Accel 2” is unconfigured.
For the “Decel 2” input function, deceleration rate selection ownership is
handled in a similar fashion to acceleration rate selection ownership.
• Acc2 & Dec2
In the second scheme, the “1” rates are combined (Acc and Dec) and the “2”
rates are combined. A single input function is used to select between [Accel
Time 1]/[Decel Time 1] and [Accel Time 2]/[Decel Time 2]. This input
function is called “Acc 2 & Dec 2”.
If function is open, then drive will use [Accel Time 1] as the acceleration rate
and [Decel Time 1] as the deceleration rate. If function is closed, then drive
will use [Accel Time 2] as the acceleration rate and [Decel Time 2] as the
deceleration rate.
The same ownership rules as above apply.
• MOP Increment, MOP Decrement
These inputs are used to increment and decrement the Motor Operated
Potentiometer (MOP) value inside the drive. The MOP is a reference setpoint
(called the “MOP Value”) that can be incremented and decremented by
external devices. The MOP value will be retained through a power cycle.
While the “MOP Increment” input is closed, MOP value will increase at rate
contained in [MOP Rate]. Units for rate are Hz per second.
While the “MOP Decrement” input is closed, MOP value will decrease at rate
contained in [MOP Rate]. Units for rate are Hz per second.
If both the “MOP Increment” and “MOP Decrement” inputs are closed,
MOP value will stay the same.
The terminal block bit must be set in the [MOP Mask] and [Logic Mask]
parameters in order for the MOP to be controlled from the terminal block.
In order for the drive to use the MOP value as the current speed reference,
either [Speed Ref A Sel] or [Speed Ref B Sel] must be set to “MOP.”
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• Stop Mode B
This digital input function selects between two different drive stop modes.
See also Stop Modes on page 197.
If the input is open, then [Stop Mode A] selects which stop mode to use. If the
input is closed, then [Stop Mode B] selects which stop mode to use. If this
input function is not configured, then [Stop Mode A] always selects which
stop mode to use.
• Bus Regulation Mode B
This digital input function selects how the drive will regulate excess voltage
on the DC bus. See also Bus Regulation.
If the input is open, then [Bus Reg Mode A] selects which bus regulation
mode to use. If the input is closed, then [Bus Reg Mode B] selects which bus
regulation mode to use. If this input function is not configured, then [Bus Reg
Mode A] always selects which bus regulation mode to use.
• PI Enable
If this input function is closed, the operation of the Process PI loop will be
enabled.
If this input function is open, the operation of the Process PI loop will be
disabled. See Process PI Loop on page 135.
• PI Hold
If this input function is closed, the integrator for the Process PI loop will be
held at the current value, which is to say that it will not increase.
If this input function is open, the integrator for the Process PI loop will be
allowed to increase. See Process PI Loop on page 135.
• PI Reset
If this input function is closed, the integrator for the Process PI loop will be
reset to 0.
If this input function is open, the integrator for the Process PI loop will
integrate normally. See Process PI Loop on page 135.
• Auxiliary Fault
The “Aux Fault” input function allows external equipment to fault the drive.
Typically, one or more machine inputs (limit switches, pushbuttons, etc.) will
be connected in series and then connected to this input. If the input function
is open, the software detects the change of state then the drive will fault with
the “Auxiliary Input” (F2) fault code.
If the “Aux Fault” input function is assigned to a physical digital input, that
input will be active regardless of any drive control masks. Also, the input will
be active even if a device other than the terminal block gains complete local
control of drive logic. See Local Control.
If this input function is not configured, then the fault will not occur.
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• Local Control
The “Local Control” input function allows exclusive control of all drive logic
functions from the terminal block. If this input function is closed, the
terminal block has exclusive control (disabling all the DPI devices) of drive
logic, including start, reference selection, acceleration rate selection, etc. The
exception is the stop condition, which can always be asserted from any
connected control device.
The drive must be stopped in order for the terminal block to gain complete
local control.
Important: Local Control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed take local
control. If another device is not currently the local owner (as
indicated by [Local Owner]) and the terminal block bit is set in
the [Local Mask] and [Logic Mask] parameters, the terminal
block becomes local owner as soon as the “Local Control” input
function is closed.
• Clear Faults
The “Clear Faults” digital input function allows an external device to reset
drive faults through the terminal block. An open to closed transition on this
input will cause the current fault (if any) to be reset.
If this input is configured at the same time as “Stop - Clear Faults”, then only
the “Clear Faults” input can actually cause faults to be reset.
The terminal block bit must be set in the [Fault Mask] and [Logic Mask]
parameters in order for faults to be reset from the terminal block.
• Enable
If this input is closed, then the drive can run (start permissive). If open, the
drive will not start.
If the drive is already running when this input is opened, the drive will coast
and indicate “not enabled” on the HIM (if present). This is not considered a
fault condition, and no fault will be generated.
This input is not used for a fast output power removal. The drive will not stop
running until the software detects the open state of this input function.
If multiple “Enable” inputs are configured, then the drive will not run if any of
the inputs are open.
• Exclusive Link
This input function is used to activate the state of the input to control one of
the drive’s digital outputs. See Digital Outputs.
If an Input is so configured, no function exists for the input until
complementary Digital Output programming is done. If no outputs are
programmed (linked), the input has no function.
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This choice is made when the user wishes to link the input to the output, but
desires that no other functionality be assigned to the input.
The state of any digital input can be “passed through” to a digital output by
setting the value of a digital output configuration parameter ([Digital Outx
Sel]) to “Input n Link”. The output will then be controlled by the state of the
input, even if the input is being used for a second function. If the input is
configured as “Not used” input function, the link to the input is considered
non-functional.
• Power Loss Level (PowerFlex 700 only)
When the DC bus level in the drive falls below a certain level, a “power loss”
condition is created in the drive logic. This input allows the user to select
between two different “power loss” detection levels dynamically.
If the physical input is closed, then the drive will take its power loss level from
[Power Loss Level]. If the physical input is open (de-energized), then the drive
will use a power loss level designated by internal drive memory, typically 82%
of nominal.
If the input function is not configured, then the drive always uses the internal
power loss level. This input function is used in PowerFlex 700 drives only. In
PowerFlex 70 drives, the power loss level is always internal and not selectable.
• Precharge Enable (PowerFlex 700 only)
This input function is used to manage disconnection from a common DC
bus.
If the physical 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 thus the drive
should enter the precharge state (precharge relay open) and initiate a coast
stop immediately in order 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 will be done.
This input function is used in PowerFlex 700 drive only. In PowerFlex 70
drives, the drive assumes it is always connected to the DC bus.
Digital Input Conflict Alarms
If the user configures the digital inputs so that one or more selections conflict
with each other, one of the digital input configuration alarms will be asserted. As
long as the Digital Input Conflict exists, the drive will not start. These alarms
will be automatically cleared by the drive as soon as the user changes the
parameters so that there is an internally consistent digital input configuration.
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Examples of configurations that cause an alarm are:
• User tries to configure both the “Start” input function and the “Run Forward”
input function at the same time. “Start” is only used in “3-wire” start mode,
and “Run Forward” is only used in “2-wire” run mode, so they should never be
configured at the same time
• User tries to assign a toggle input function (for instance “Forward/Reverse”)
to more than one physical digital input simultaneously.
• These alarms, called Type 2 Alarms, are different from other alarms in that it
will not be possible to start the drive while the alarm is active. It should not be
possible for any of these alarms to occur while drive is running, because all
configuration parameters are only changeable while drive is stopped.
Whenever one or more of these alarms is asserted, the drive ready status will
become “not ready” and the HIM will reflect a message signaling the conflict.
In addition, the drive status light will be flashing yellow.
There are three different digital input configuration alarms. They appear to the
user (in [Drive Alarm 2]) as “DigIn CflctA”, “DigIn CflctB”, and “DigIn CflctC”.
“DigIn CflctA” indicates a conflict between different input functions that are
not specifically associated with particular start modes.
The table below defines which pairs of input functions are in conflict.
Combinations marked with a “ ” will cause an alarm.
Important: There are combinations of input functions in Table 10 that will
produce other digital input configuration alarms. “DigIn CflctA”
alarm will also be produced if “Start” is configured and “Stop –
Clear Faults” is not.
Table 10 Input function combinations that produce “DigIn CflctA” alarm
Acc2/Dec2
Accel 2
Decel 2
Jog
Jog Fwd
Jog Rev
Fwd/Rev
Acc2 / Dec2
Accel 2
Decel 2
Jog
Jog Fwd
Jog Rev
Fwd / Rev
“DigIn CflctB” indicates a digital Start input has been configured without a
Stop input or other functions are in conflict. Combinations that conflict are
marked with a “ ” and will cause an alarm.
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Table 11 Input function combinations that produce “DigIn CflctB” alarm
Start
Stop–CF
Run
Run Fwd
Run Rev
Jog
Jog Fwd
Jog Rev
Fwd/
Rev
Start
Stop–CF
Run
Run Fwd
Run Rev
Jog
Jog Fwd
Jog Rev
Fwd / Rev
“Digin CflctC” indicates that more than one physical input has been configured
to the same input function, and this kind of multiple configuration isn’t allowed
for that function. Multiple configuration is allowed for some input functions and
not allowed for others.
The input functions for which multiple configuration is not allowed are:
Forward/Reverse
Speed Select 1
Speed Select 2
Speed Select 3
Run Forward
Run Reverse
Jog Forward
Jog Reverse
Run
Stop Mode B
Bus Regulation Mode B
Accel2 & Decel2
Accel 2
Decel 2
There is one additional alarm that is related to digital inputs: the “Bipolar Cflct”
alarm occurs when there is a conflict between determining motor direction using
digital inputs on the terminal block and determining it by the polarity of an
analog speed reference signal.
Note that the drive will assert an alarm when the user sets up a illegal
configuration rather than refusing the first parameter value that results in such a
configuration. This is necessary because the user may have to change several
parameters one at a time in order to get to a new desired configuration, and some
of the intermediate configurations may actually be illegal. Using this scheme, the
user or a network device can send parameter updates in any order when setting up
the digital input configuration.
The “Bipolar Cflct” alarm occurs when there is a conflict between determining
motor direction using digital inputs on the terminal block and determining it by
some other means.
When [Direction Mode] is “Bipolar”, the drive uses the sign of the reference to
determine drive direction; when [Direction Mode] is “Reverse Dis”, then the
drive never permits the motor to run in the reverse direction. In both of these
cases, the terminal block inputs cannot be used to set direction, so this alarm is
asserted if any digital input function that can set motor direction is configured.
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Digital Inputs
The “Bipolar Cflct” alarm will be asserted if both of the following are true:
• One or more of the following digital input functions are configured:
“Forward/Reverse”, “Run Forward”, “Run Reverse”, “Jog Forward”, “Jog
Reverse”.
• [Direction Mode] is set to “Bipolar” or “Reverse Dis”.
Digital In Status
This parameter represents the current state of the digital inputs. It contains one
bit for each input. The bits are “1” when the input is closed and “0” when the
input is open.
Digital In Examples
PowerFlex 70
Figure 16 shows a typical digital input configuration that includes “3-wire” start.
The digital input configuration parameters should be set as shown.
Figure 16 Typical digital input configuration with “3-wire” start
Internal Power Source
Digital In1 = Stop
Digital In2 = Start
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Speed Select 1
Digital In6 = Enable
24V Common
Digital In Common
24V
External Power Source
+24V Common
Digital In1 = Stop
Digital In2 = Start
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Speed Select 1
Digital In6 = Enable
24V Common
Digital In Common
24V
Figure 17 represents a typical digital input configuration that includes “2-wire”
start. The digital input configuration parameters should be set up as shown
Figure 17 Typical digital input configuration with “Run Fwd/Rev” start
Internal Power Source
Digital In1 = Run
Digital In2 = Clear Faults
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Auxiliary Fault
Digital In6 = Enable
24V Common
Digital In Common
24V
86
External Power Source
+24V Common
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Digital In1 = Run
Digital In2 = Clear Faults
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Auxiliary Fault
Digital In6 = Enable
24V Common
Digital In Common
24V
Digital Outputs
Digital Outputs
Each drive provides digital (relay) outputs for external annunciation of a variety
of drive conditions. Each relay is a Form C (1 N.O. – 1 N.C. with shared
common) device whose contacts and associated terminals are rated for a
maximum of 250V AC or 220V DC. The table below shows specifications and
limits for each relay/contact.
Rated Voltage
Maximum Current
Maximum Power
Minimum DC Current
Switching Time
Initial State
Number of relays
(Standard I/O)
PowerFlex 70
Resistive Load
250V AC
220V DC
3A
AC - 50 VA
DC - 60 W
10 μA
8 ms
De-energized
2
Inductive Load
250V AC
220V DC
1.5 A
AC - 25 VA
DC - 30 W
PowerFlex 700
Resistive Load
Inductive Load
240V AC
240V AC
30V DC
30V DC
5A
3.5 A
1200 VA
840 VA
150W
105W
10 mA
10 ms
De-energized
2 - Standard Control
3 - Vector Control
Configuration
The outputs may be independently configured via the following parameters to
switch for various states of the drive.
PowerFlex 700 Digital Output Selection
380 [Digital Out1 Sel] (5)
384 [Digital Out2 Sel]
388
[Digital Out3 Sel]
Vector
Selects the drive status that will energize a (CRx)
output relay.
(1 ) Any relay programmed as Fault or Alarm will
(2)
(3)
(4)
(5)
energize (pick up) when power is applied to
drive and deenergize (drop out) when a fault
or alarm exists. Relays selected for other
functions will energize only when that
condition exists and will deenergize when
condition is removed.
Vector Control Option Only.
Activation level is defined in [Dig Outx Level]
below.
Vector firmware 3.001 and later.
When [TorqProve Cnfg] is set to “Enable,”
[Digital Out1 Sel] becomes the brake control
and any other selection will be ignored.
(6) Refer to Option Definitions in User Manual.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Default:
1
4
4
“Fault”
“Run”
“Run”
Options:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21-26
27
28
29
30
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed” (6)
“At Freq” (3)
“At Current” (3)
“At Torque” (3)
“At Temp” (3)
“At Bus Volts” (3)
“At PI Error” (3)
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1-6 Link” (6)
“PI Enable”(2)
“PI Hold”(2)
“Drive Overload”(2)
“Param Cntl”(4, 6)
381
385
389
382
386
390
383
002
001
003
004
218
012
137
157
147
053
048
184
379
87
Digital Outputs
PowerFlex 70 Digital Output Selection
380 [Digital Out1 Sel]
384 [Digital Out2 Sel]
Selects the drive status that will energize a (CRx)
output relay.
are in drive powered state with condition not
present. For functions such as “Fault” and
“Alarm” the normal relay state is energized and
N.O. / N.C. contact wiring may have to be
reversed.
Digital Outputs
INPUTS & OUTPUTS (File J)
(1) Contacts shown in the Installation Instructions
Default:
1
4
“Fault”
“Run”
Options:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed”
“At Freq”
“At Current”
“At Torque”
“At Temp”
“At Bus Volts”
“At PI Error”
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1 Link”
“Input 2 Link”
“Input 3 Link”
“Input 4 Link”
“Input 5 Link”
“Input 6 Link”
381
385
389
382
386
390
383
002
001
003
004
218
012
137
157
147
053
048
184
The selections can be divided into three types of annunciation.
1. The relay changes state due to a particular status condition in the drive.
The following drive conditions or status can be selected to cause the relay
activation:
Condition
Fault
Alarm
Ready
Run
Forward Run
Reverse Run
Reset/Run
Powerup Run
DC Braking
Current Limit
Economize
Mtr Overload
Power Loss
88
Description
A drive Fault has occurred and stopped the drive
A Drive Type 1 or Type 2 Alarm condition exists
The drive is powered, Enabled and no Start Inhibits exist. It is “ready” to run
The drive is outputting Voltage and frequency to the motor (indicates 3–wire control, either
direction)
The drive is outputting Voltage and frequency to the motor (indicates 2–wire control in
Forward)
The drive is outputting Voltage and frequency to the motor (indicates 2–wire control in Reverse)
The drive is currently attempting the routine to clear a fault and restart the drive
The drive is currently executing the Auto Restart or “Run at Power Up” function
The drive is currently executing either a “DC Brake” or a “Ramp to Hold” Stop command and the
DC braking voltage is still being applied to the motor.
The drive is currently limiting output current
The drive is currently reducing the output voltage to the motor to attempt to reduce energy costs
during a lightly loaded situation.
The drive output current has exceeded the programmed [Motor NP FLA] and the electronic
motor overload function is accumulating towards an eventual trip.
The drive has monitored DC bus voltage and sensed a loss of input AC power that caused the DC
bus voltage to fall below the fixed monitoring value (82% of [DC bus Memory]
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Digital Outputs
2. The relay changes state because a particular value in the drive has exceeded a
preset limit.
The following drive values can be selected to cause the relay activation:
Condition
At Speed
Description
The drive Output Frequency has equalled the commanded frequency
The balance of these functions require that the user set a limit for the specified
value. The limit is set into one of two parameters: [Dig Out1 Level] and [Dig
Out2 Level] depending on the output being used. If the value for the specified
function (frequency, current, etc.) exceeds the user programmed limit, the
relay will activate. If the value falls back below the limit, the relay will
deactivate.
381 [Dig Out1 Level]
385 [Dig Out2 Level]
[Dig Out3 Level]
389
Vector
Default:
0.0
0.0
Min/Max: 0.0/819.2
0.1
Sets the relay activation level for options 10 – 15 Units:
in [Digital Outx Sel]. Units are assumed to match
the above selection (i.e. “At Freq” = Hz, “At
Torque” = Amps).
380
384
388
Notice that the [Dig Outx Level] parameters do not have units. The drive
assumes the units from the selection for the annunciated value. For example, if
the chosen “driver” is current, the drive assumes that the entered value for the
limit [Dig Outx Level] is% rated Amps. If the chosen “driver” is Temperature,
the drive assumes that the entered value for the limit [Dig Outx Level] is
degrees C. No units will be reported to LCD HIM users, offline tools, devices
communicating over a network, PLC’s, etc.
The online and offline limits for the digital output threshold parameters will
be the minimum and maximum threshold value required for any output
condition.
If the user changes the currently selected output condition for a digital output,
then the implied units of the corresponding threshold parameter will change
with it, although the value of the parameter itself will not. For example, if the
output is set for “At Current” and the threshold for 100, drive current over
100% will activate the relay. If the user changes the output to “At Temp”, the
relay will deactivate (even if current > 100%) because the drive is cooler than
100 degrees C.
The following values can be annunciated
Value
At Freq
At Current
At Torque
At Temp
At Bus Volts
At PI Error
Description
The drive output frequency equals or exceeds the programmed Limit
The drive total output current exceeds the programmed Limit
The drive output torque current component exceeds the programmed Limit
The drive operating temperature exceeds the programmed Limit
The drive bus voltage exceeds the programmed Limit
The drive Process PI Loop error exceeds the programmed Limit
3. The relay changes state because a Digital Input link has been established and
the Input is closed.
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89
Digital Outputs
An Output can be “linked” directly to an Digital Input so that the output
“tracks” the input. When the input is closed, the Output will be energized,
and when the input is open, the output will be de-energized. This “tracking
will occur if two conditions exist:
– The Input is configured for any choice other than “Unused”
– The Output is configured for the appropriate “Input x Link”
Note that the output will continue to track or be controlled by the state of the
input, even if the input has been assigned a function (i.e. Start, Jog)
Output Time Delay
Each digital output has two user-controlled timers associated with it.
One timer (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 second timer (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.
382 [Dig Out1 OnTime]
386 [Dig Out2 OnTime]
390
[Dig Out3 OnTime]
Vector
Default:
Min/Max:
Sets the “ON Delay” time for the digital outputs. This is Units:
the time between the occurrence of a condition and
activation of the relay.
Default:
383 [Dig Out1 OffTime]
387 [Dig Out2 OffTime]
391
[Dig Out3 OffTime]
Vector
Min/Max:
Sets the “OFF Delay” time for the digital outputs. This is Units:
the time between the disappearance of a condition and
de-activation of the relay.
0.00 Secs
0.00 Secs
0.00/600.00 Secs
0.01 Secs
0.00 Secs
0.00 Secs
0.00/600.00 Secs
0.01 Secs
380
384
388
380
384
388
Either timer can be disabled by setting the corresponding delay time to “0.”
Important: Whether a particular type of transition (False-True or True-False)
on an output condition results in an energized or de-energized
output depends on the output condition.
If a transition on an output condition occurs and starts a timer, and the output
condition goes back to its original state before the timer runs out, then the timer
will be aborted and the corresponding digital output will not change state.
Relay Activates
CR1 On Delay = 2 Seconds
Current Limit Occurs
0
5
10
Relay Does Not Activate
CR1 On Delay = 2 Seconds
Cyclic Current Limit
(every other second)
0
90
5
10
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Direction Control
PowerFlex 700 Firmware 3.001 (& later) Enhancements
Certain digital output enhancements have been included in firmware version
3.001 (and later) for the PowerFlex 700 Vector Control drive. These include:
• Digital output control via Datalink
Parameter Controlled Digital Outputs
Enables control of the digital outputs through the Data In parameters.
Vector v3
380
[Dig Out Setpt]
Sets the digital output value from a communication device.
Example
Set [Data In B1] to “379.” The first three bits of this value will determine the setting of [Digital
Outx Sel] which should be set to “24, Param Cntl.”
Ne
tD
Ne igO
ut
t
Ne DigO 3
t D ut2
igO
ut1
Digital Outputs
INPUTS & OUTPUTS
379
x x x x x x x x x x x x x 0 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Output Energized
0 =Output De-energized
x =Reserved
Bit #
Example
Digital Output 2 controlled by Data In B1
Setup
• [Data In B1], parameter 302 = 379 ([Dig Out Setpt] as the Data In target)
• [Digital Out2 Sel], parameter 384 = 30 "Param Cntl"
When Bit 1 of Data In B1 =1 Digital Out 2 will be energized.
Direction Control
Direction control of the drive is an exclusive ownership function. Thus only one
device can be commanding/controlling direction at a time and that device can
only command one direction or the other, not both. Direction is defined as the
forward (+) or reverse (–) control of the drive output frequency, not motor
rotation. Motor wiring and phasing determines its CW or CCW rotation.
Direction of the drive is controlled in one of four ways:
1. 2-Wire digital input selection such as Run Forward or Run Reverse (Figure
17 on page 86).
2. 3-Wire digital input selection such as Forward/Reverse, Forward or Reverse
(Figure 16 on page 86).
3. Control Word bit manipulation from a DPI device such as a communications
interface. Bits 4 & 5 control direction. Refer to the Logic Command Word
information in Appendix A of the PowerFlex 70 or 700 User Manual.
4. The sign (+/-) of a bipolar analog input.
Direction commands by various devices can be controlled using the [Direction
Mask]. See page 113 for details on masks.
Refer to Digital Inputs on page 70 and Analog Inputs on page 18 for more detail
on the configuration and operating rules for direction control.
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91
DPI
DPI
Drive Peripheral Interface (DPI) is an enhancement to SCANport that provides
more functions and better performance. SCANport was a CAN based,
Master-Slave protocol, created to provide a standard way of connecting motor
control products and optional peripheral devices together. It allows multiple (up
to 6) devices to communicate with a motor control product without requiring
configuration of the peripheral. SCANport and DPI both provide two basic
message types called Client/Server (C/S) and Producer/Consumer (P/C).
Client/Server messages are used to transfer parameter and configuration
information in the background (relative to other message types). Producer/
Consumer messages are used for control and status information. DPI adds a
higher baud rate, brand specific enabling, Peer-to-Peer (P/P) communication,
and Flash Memory programming support. PowerFlex 70 & 700 support the
existing SCANport and DPI communication protocols. Multiple devices of each
type (SCANport or DPI) can be attached to and communicate with PowerFlex
70 & 700 drives at the same time. This communication interface is the primary
way to interact with, and control the drive.
Important: The PowerFlex 700 Vector Control option only supports the DPI
communication protocol. It will not communicate with SCANport
peripheral devices.
Client/Server
Client/Server messages operate in the background (relative to other message
types) and are used for non-control purposes. The Client/Server messages are
based on a 10ms “ping” event that allows peripherals to perform a single
transaction (i.e. one C/S transaction per peripheral per time period). Message
fragmentation (because the message transaction is larger than the standard CAN
message of eight data bytes) is automatically handled by Client/Server operation.
The following types of messaging are covered:
•
•
•
•
•
•
•
Logging in peripheral devices
Read/Write of parameter values
Access to all parameter information (limits, scaling, default, etc.)
User set access
Fault/Alarm queue access
Event notification (fault, alarm, etc.)
Access to all drive classes/objects (e.g. Device, Peripheral, Parameter, etc.)
Producer/Consumer operation overview
Producer/Consumer messages operate at a higher priority than Client/Server
messages and are used to control/report the operation of the drive (e.g. start, stop,
etc.). A P/C status message is transmitted every 5ms (by the drive) and a
command message is received from every change of state in any attached DPI
peripheral. Change of state is a button being pressed or error detected by a DPI
peripheral. SCANport devices are slightly different in that those peripherals
transmit command messages upon reception of a drive status message rather than
on detection of a change of state. Producer/Consumer messages are of fixed size,
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DPI
so support of message fragmentation is not required. The following types of
messaging are covered:
•
•
•
•
•
Drive status (running, faulted, etc.)
Drive commands (start, stop, etc.)
Control logic parsing operations (e.g., mask and owner parameters)
Entering Flash programming mode
“Soft” login and logout of peripheral devices (enabling/disabling of peripheral
control)
Peer-to-Peer operation
Peer-to-Peer messaging allows two devices to communicate directly rather than
through the master or host (i.e. drive). They are the same priority as C/S
messages and will occur in the background. In the PowerFlex 70 drive, the only
Peer-to-Peer functionality supports proxy operations for the LED HIM. Since
the PowerFlex 700 drive does not support an LED HIM, it will not support
Peer-to-Peer proxy operations. The Peer-to-Peer proxy operation is only used so
that the LED HIM can access parameters that are not directly part of the
regulator board (e.g. DeviceNet baud rate, etc.). The LED HIM is not attached
to a drive through a CAN connection (as normal DPI or SCANport devices are),
so a proxy function is needed to create a DPI message to access information in an
off-board peripheral. If an LCD HIM is attached to the PowerFlex 70 or 700
drive, it will be able to directly request off-board parameters using Peer-to-Peer
messages (i.e. no proxy support needed in the drive). Because the PowerFlex 70
supports the LED HIM, only 4 communication ports can be used. PowerFlex
700 drives can use all 6 communication ports because Peer-to-Peer proxy
operations are not needed. All Peer-to-Peer operations occur without any
intervention from the user (regardless whether proxy or normal P/P operation),
no setup is required. No Peer-to-Peer proxy operations are required while the
drive is in Flash mode.
All the timing requirements specified in the DPI and SCANport System,
Control, and Messaging specifications are supported. Peripheral devices will be
scanned (“pinged”) at a 10ms rate. Drive status messages will be produced at a
5ms rate, while peripheral command messages will be accepted (by the drive) as
they occur (i.e. change of state). Based on these timings, the following worst case
conditions can occur (independent of the baud rate and protocol):
•
•
•
•
Change of peripheral state (e.g. Start, Stop, etc.) to change in the drive – 10ms
Change in reference value to change in drive operation – 10ms
Change in Datalink data value to change in the drive – 10ms
Change of parameter value into drive – 20ms times the number of attached
peripherals
The maximum time to detect the loss of communication from a peripheral device
is 500ms.
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93
Drive Overload
Table 12 Timing specifications contained in DPI and SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
Host status messages only go out to peripherals once they log in and at least every 125ms (to all
attached peripherals). Peripherals time out if >250ms. Actual time dependent on number of
peripherals attached. Minimum time goal of 5ms (may have to be dependent on Port Baud Rate). DPI
allows minimum 5ms status at 125k and 1ms status at 500k.
Host status messages only go out to peripherals once they log in. Peripherals time out if >500ms. If
Peripheral receives incorrect status message type, Peripheral generates an error. Actual time
dependent on number of peripherals attached. SCANport allows minimum rate of 5ms.
Host determines MUT based on number of attached peripherals. Range of values from 2 to 125ms.
Minimum goal time of 5ms. DPI allows 2ms min at 500k and 5ms min at 125k.
No MUT.
Peripheral command messages (including Datalinks) generated on change-of-state, but not faster
than Host MUT and at least every 250ms. Host will time out if >500ms.
Command messages produced as a result of Host status message. If no command response to Host
status within 3 status scan times, Host will time out on that peripheral.
Peer messages requests cannot be sent any faster than 2x of MUT.
No Peer message support
Host must ping every port at least every 2 sec. Peripherals time out if >3 sec. Host will wait maximum
of 10ms (125k) or 5ms (500k) for peripheral response to ping. Peripherals typical response time is 1ms.
Peripherals only allow one pending explicit message (i.e. ping response or peer request) at a time.
Host waits at least 10ms for response to ping. Host cannot send more than 2 event messages (including
ping) to a peripheral within 5ms. Peripherals typical response time is 1ms.
Response to an explicit request or fragment must occur within 1 sec or device will time out (applies to
Host or Peripheral). Time-out implies retry from beginning. Maximum number of fragments per
transaction is 16. Flash memory is exception with 22 fragments allowed.
Assume same 1 sec time-out. Maximum number of fragments is 16
During Flash mode, host stops ping, but still supports status/command messages at a 1 – 5 sec rate.
Drive will use 1 sec rate. Data transfer occurs via explicit message as fast as possible (i.e. peripheral
request, host response, peripheral request, etc.) but only between two devices.
No Flash mode support
The Minimum Update Time (MUT), is based on the message type only. A
standard command and Datalink command could be transmitted from the same
peripheral faster than the MUT and still be O.K. Two successive Datalink
commands or standard commands will still have to be separated by the MUT,
however.
Drive Overload
The drive thermal overload has two primary functions. The first requirement is
to make sure the drive is not damaged by abuse. The second is to perform the first
in a manor that does not degrade the performance, as long the drive temperature
and current ratings are not exceeded.
The purpose of is to protect the power structure from abuse. Any protection for
the motor and associated wiring is provided by a Motor Thermal Overload
feature.
The drive will monitor the temperature of the power module based on a
measured temperature and a thermal model of the IGBT. As the temperature
rises the drive may lower the PWM frequency to decrease the switching losses in
the IGBT. If the temperature continues to rise, the drive may reduce current limit
to try to decrease the load on the drive. If the drive temperature becomes critical
the drive will generate a fault.
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Drive Overload
If the drive is operated in a low ambient condition the drive may 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 levels, current limit
may be reduced or a fault may be generated.
Operation
The drive thermal overload has two separate protection schemes, an overall RMS
protection based on current over time, and an IGBT junction thermal manager
based on measured power module temperature and operating conditions. The
drive may fold back current limit when either of these methods detects a
problem.
Overall RMS Protection
The overall RMS protection makes sure the current ratings of the drive are not
exceeded. The lower curve in Figure 18 shows the boundary of normal-duty
operation. In normal duty, the drive is rated to produce 110% of rated current for
60 seconds, 150% of rated current for three seconds, and 165% of rated current
for 100 milliseconds. The maximum value for current limit is 150% so the limit
of 165% for 100 milliseconds should never be crossed. If the load on the drive
exceeds the level of current as shown on the upper curve, current limit may fold
back to 100% of the drive rating until the 10/90 or 5/95 duty cycle has been
achieved. For example, 60 seconds at 110% will be followed by 9 minutes at
100%, and 3 seconds at 150% will be followed by 57 seconds at 100%. With the
threshold for where to take action slightly above the rated level the drive will only
fold back when drive ratings are exceeded.
If fold back of current limit is not enabled in [Drive OL Mode], the drive will
generate a fault when operation exceeds the rated levels. This fault can not be
disabled. If current limit fold back is enabled then a fault is generated when
current limit is reduced.
Current Level (Per Normal)
Figure 18 Normal Duty Boundary of Operation
1.80
1.70
1.60
1.50
1.40
1.30
1.20
1.10
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
1.00
10.00
100.00
1,000.00
Time (Seconds)
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95
Drive Overload
The lower curve in Figure 19 shows the boundary of heavy duty operation. In
heavy duty, the drive is rated to produce 150% of rated current for 60 seconds,
200% for three seconds, and 220% for 100 milliseconds. The maximum value for
current limit is 200% so the limit of 220% for 100 milliseconds should never be
crossed. If the load on the drive exceeds the level of current as shown on the upper
curve, current limit may fold back to 100% of the drive rating until the 10/90 or
5/95 duty cycle has been achieved. For example, 60 seconds at 150% will be
followed by 9 minutes at 100%, and 3 seconds at 200% will be followed by 57
seconds at 100%. With the threshold for where to take action slightly above the
rated level the drive will only fold back when drive ratings are exceeded.
Again, if fold back of current limit is not enabled in the [Drive OL Mode], the
drive will generate a fault when operation exceeds the rated levels. This fault can
not be disabled. If current limit fold back is enabled then a fault is generated
when current limit is reduced.
Figure 19 Heavy Duty Boundary of Operation
2.50
2.25
Current Level (Per Normal)
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
1.00
10.00
100.00
Time (Seconds)
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1000.00
10000.00
Drive Overload
Thermal Manager Protection
The thermal manager protection 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.
Figure 20 Thermal Manager Inputs/Outputs
DTO Select
(Off,PWM,ILmt,Both)
DTO Fault
(On,Off)
PWM Frequency
(2 - 12 kHz)
Active PWM Frequency
(2 - 12 kHz)
Current Limit
(0 - 200%)
Active Current Limit
(0 - 200%)
Temperature Analog Input
(Volts)
I_total
(Amps)
Drive
Thermal
Overload
V_dc
(Volts)
Output Frequency
(0-400 Hz)
Drive Temperature
(x deg C)
IGBT Temperature
(x deg C)
KHz Alarm
(On, Off)
ILmt Alarm
(On, Off)
EE Power Board Data
The following is a generalization of the calculations done by the thermal
manager. The IGBT junction temperature TJ is calculated based on the measured
drive temperature TDrive, and a temperature rise that is a function of operating
conditions. When the calculated junction temperature reaches a maximum limit
the drive will generate a fault. This fault can not be disabled. This maximum
junction temperature is stored in EE on the power board along with other
information to define the operation of the drive thermal overload function.
These values are not user adjustable. In addition to the maximum junction
temperature there are thresholds that select the point at which the PWM
frequency begins to fold back, and the point at which current limit begins to fold
back. As TJ increases the thermal manager may reduce the PWM frequency. If TJ
continues to rise current limit may be reduced, and if TJ continues to rise the
drive generates a fault. The calculation of the reduced PWM frequency and
current limit is implemented with an integral control.
PWM Frequency
PWM Frequency as selected by the user can be reduced by the thermal manager.
The resulting Active PWM Frequency may be displayed in a test point parameter.
The active PWM frequency will change in steps of 2 kHz. It will always be less
than or equal to the value selected by the user, and will not be less than the drives
minimum PWM frequency. When drive temperature reaches the level where
PWM frequency would be limited, the Drv OL Lvl 1 Alarm is turned on. This
alarm will be annunciated even if the reduced PWM frequency is not enabled.
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97
Drive Overload
Current Limit
Current Limit as selected by the user can be reduced by the thermal manager. The
resulting active current limit may be displayed as a test point parameter.
The active current limit will always be less than or equal to the value selected by
the user, and will not be less than flux current. When drive temperature reaches
the level where current limit would be clamped, the Drv OL Lvl 2 Alarm is
turned on. This alarm will be annunciated even if reduced current limit is not
enabled.
The active current limit is used during normal operation and during DC
injection braking. Any level of current requested for DC injection braking is
limited by the Active Current Limit.
Configuration
The [Drive OL Mode] allows the user to select the action(s) to perform with
increased current or drive temperature. When this parameter is “Disabled,” the
drive will not modify the PWM frequency or current limit. When set to “Reduce
PWM” the drive will only modify the PWM frequency. “Reduce CLim” will only
modify the current limit. Setting this parameter to “Both-PWM 1st” the drive
will modify the PWM frequency and the current limit.
DTO Fault
For all possible settings of [Drive OL Mode], the drive will always monitor the Tj
and TDrive and generate a fault when either temperature becomes critical. If
TDrive is less than –20° C, a fault is generated. With these provisions, a DTO
fault is generated if the NTC ever malfunctions.
Temperature Display
The Drive’s temperature is measured (NTC in the IGBT module) and displayed
as a percentage of drive thermal capacity in [Drive Temp]. This parameter is
normalized to the thermal capacity of the drive (frame dependent) and displays
thermal usage in % of maximum (100% = drive Trip). A test point, “Heatsink
temperature” is available to read temperature directly in degrees C, but cannot be
related to the trip point since “maximums” are only given in %. The IGBT
temperature shown in Figure 20 is used only for internal development and is not
provided to the user.
Low Speed Operation
When operation is below 4 Hz, the duty cycle is such that a given IGBT will carry
more of the load for a while and more heat will build up in that device. The
thermal manager will increase the calculated IGBT temperature at low output
frequencies and will cause corrective action to take place sooner.
When the 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
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Drive Ratings (kW, Amps, Volts)
torque load reducing the output frequency does not lower the current (load).
Lowering current limit on a CT load will push the drive down to a region where
the thermal issue becomes worse. In this situation the thermal manager will
increase the calculated losses in the power module to track the worst case IGBT.
For example, if the thermal manager normally provides 150% for 3 seconds at
high speeds, it may only provide 150% for one second before generating a fault at
low speeds.
If operating at 60Hz 120%, lowering the current limit may cause a fault sooner
than allowing the drive to continue to operate. In this case the user may want to
disable current limit fold back.
Drive Ratings (kW, Amps,
Volts)
Refer to Fuses and Circuit Breakers on page 106.
Droop
Vector
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 “fight” the master. The input to the droop
block is the commanded motor torque. The output of the droop block reduces
the speed reference. [Droop RPM @ FLA] sets the amount of speed, in RPM,
that the speed reference is reduced when at full load torque. For example, when
[Droop RPM @ FLA] is set to 50 RPM and the drive is running at 100% rated
motor torque, the droop block would subtract 50 RPM from the speed reference.
Economizer
(Auto-Economizer)
Refer to Torque Performance Modes on page 201.
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. The flux current is reduced as long
as the total drive output current does not exceed 75% of motor rated current as
programmed in [Motor NP FLA], parameter 42. The flux current is not allowed
to be less than 50% of the motor flux current as programmed in [Flux Current
Ref ], parameter 63. During acceleration and deceleration, the economizer is
inactive and sensorless vector motor control performs normally.
Maximum Voltage
Motor Nameplate Voltage
Increasing
Load
Rated Flux Current
Vtotal
Reduced Flux Current,
minimum of 50% of Rated Flux Current
Ir Voltage
0
0
Frequency
Motor Nameplate
Frequency
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Maximum
Frequency
99
Efficiency
Efficiency
The following chart shows typical efficiency for PWM variable frequency drives,
regardless of size. Drives are most efficient at full load and full speed.
100
vs. Speed
% Efficiency
95
vs. Load
90
85
80
75
10
Fan Curve
20
30
40 50 60 70
% Speed/% Load
80
90
100
When torque performance (see page 201) is set to Fan/Pump, the relationship
between frequency and voltage is shown in the following figure. The fan/pump
curve generates voltage that is a function of the stator frequency squared up to the
motor nameplate frequency. Above base frequency voltage is a linear function of
frequency. At low speed the fan curve can be offset by the run boost parameter to
provide extra starting torque if needed. No extra parameters are needed for fan/
pump curve.
The pattern matches the speed vs. load characteristics of a centrifugal fan or
pump and optimizes the drive output to those characteristics.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
Base Frequency
(Nameplate)
Fan
100
See Fan Curve above.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Maximum
Frequency
Faults
Faults
Faults are events or conditions occurring within and/or outside of the drive.
Theses events or conditions are (by default) considered to be of such significant
magnitude that drive operation should or must be discontinued. Faults are
annunciated to the user via the HIM, communications and/or contact outputs.
The condition that caused the fault determines the user response.
Once a fault occurs, the fault condition is latched, requiring the user or
application to perform a fault reset action to clear the latched condition. If the
condition that caused fault still exists when the fault is reset, the drive will fault
again and the fault will be latched again.
When a Fault Occurs
1. The drive is set as faulted, causing the drive output to be immediately disabled
and a “coast to stop” sequence to occur
2. The fault code is entered into the first buffer of the fault queue (see “Fault
Queue” below for rules).
3. Additional data on the status of the drive at the time that the fault occurred is
recorded. Note that there is only a single copy of this information which is
always related to the most recent fault queue entry [Fault 1 Code], parameter
243. When another fault occurs, this data is overwritten with the new fault
data. The following data/conditions are captured and latched into
non-volatile drive memory:
– [Status 1 @ Fault] - drive condition at the time of the fault.
– [Status 2 @ Fault] - drive condition at the time of the fault.
– [Alarm 1 @ Fault], - alarm condition at the time of the fault.
– [Alarm 2 @ Fault] - alarm conditions at the time of the fault.
– Fault Motor Amps - motor amps at time of fault.
– [Fault Bus Volts] - unfiltered DC Bus volts at time of fault.
– [Fault Frequency] (Standard Control).
– [Fault Speed] (Vector Control) - drive output frequency (or speed) at time
of 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.” The PowerFlex 70 drive has a four event
queue and the PowerFlex 700 has an eight event queue.
A fault queue will record the occurrence of each fault event that occurs while no
other fault is latched. Each fault queue entry will include a fault code and a time
stamp value. A new fault event will not be 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 will be logged. No fault that occurs while the drive is already faulted will
be logged.
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101
Faults
The fault queue will be a first-in, first-out (FIFO) queue. Fault queue entry #1
will always be the most-recent entry (newest). Entry 4 (8) will always be the
oldest. As a new fault is logged, each existing entry will be shifted up by one (i.e.
previous entry #1 will move to entry #2, previous entry #2 will move to entry #3,
etc.). If the queue is full when a fault occurs, the oldest entry will be discarded.
The fault queue will be saved in nonvolatile storage at power loss, thus retaining
its contents through a power off - on cycle.
Fault Code/Text [Fault Code 1-x]
The fault code for each entry can be read in its respective read-only parameter.
When viewed with a HIM, only the fault code is displayed. If viewed via a DPI
peripheral (communications network), the queue is not accessed through
parameters, and a text string of up to 16 characters is also available.
Fault Time [Fault 1-8 Time]
PowerFlex drives have an internal drive-under-power-timer. The user has no
control over the value of this timer, which will increment in value over the life of
the drive and saved in nonvolatile storage. Each time the drive is powered down
and then repowered, the value of this timer is written to [Power Up Marker],
parameter 242.
The time is presented in xxx.yyyy hours (4 decimal places). Each increment of 1
represents approximately 0.36 seconds. Internally it will be accumulated in a
32-bit unsigned integer with a resolution of 0.35 seconds, resulting in a rollover
to zero every 47.66 years.
The time stamp value recorded in the fault queue at the time of a fault is the value
of internal drive under power timer. By comparing this value to the [PowerUp
Marker], it is possible to determine when the fault occurred relative to the last
drive power-up.
The time stamp for each fault queue entry can be read via the corresponding
parameter. Time comparisons of one fault to the next and/or with [PowerUp
Marker] are only meaningful if they occur less than or equal to the rollover range.
Resetting or Clearing a Fault
A latched fault condition can be cleared by the following:
1. An off to on transition on a digital input configured for fault reset or stop/
reset.
2. Setting [Fault Clear] to “1.”
3. A DPI peripheral (several ways).
4. Performing a reset to factory defaults via parameter write.
5. Cycling power to the drive such that the control board goes through a
power-up sequence.
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Flux Braking
Resetting faults will clear the faulted status indication. If any fault condition still
exists, the fault will relatch and another entry made in the fault queue.
Clearing the Fault Queue
Performing a fault reset does not clear the fault queue. Clearing the fault queue is
a separate action.
Fault Configuration
The drive can be configured such that some fault conditions do not trip the drive.
Configurable faults include those that are user inputs.
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[Fault Config 1] is a bit-mapped 16 bit word enabling or disabling certain fault
conditions (see below). Disabling a fault removes the effect of the fault condition
and makes the event unknown to the user. If the bit is on, the fault is enabled. If
the bit is off, the fault is not enabled.
x x x 0 0 x 0 0 0 1 0 0 1 x 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
Factory Default Bit Values
1 =Enabled
0 =Disabled
x =Reserved
* Vector firmware 3.001 & later
Power Up Marker
Copy of factory “drive under power” timer at the last power-up of the drive. Used
to provide relevance of Fault 'n' Time values with respect to the last power-up of
the drive.
This value will rollover to 0 after the drive has been powered on for more than
the hours shown in the Range field (approximately 47.667 years).
Flux Braking
Vector
You can use flux braking to stop the drive or to shorten the
deceleration time to a lower speed. Other methods of deceleration or stopping
may perform better depending on the motor and the load.
To enable flux braking:
1. [Bus Reg Mode A, B] must be set to “1” Adjust Freq to enable the bus
regulator.
2. [Flux Braking] must be set to 1 “Enabled”.
When enabled, flux braking automatically increases the motor flux resulting in an
increase of motor losses. The flux current is only increased when the bus voltage
regulator is active. When the bus voltage regulator is not active, the flux current is
returned to normal. The maximum flux current is equal to rated motor current
but may be further reduced depending on the load level, IT protection, or current
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103
Flux Up
limits. In general, the flux current is not increased when the motor is at or above
rated speed. At higher speeds, field weakening is active and the motor flux current
cannot be increased. As the speed decreases below base speed, the flux current
increases until there is enough voltage margin to run rated motor current.
Because flux braking increases motor losses, the duty cycle used with this method
must be limited. Check with the motor vendor for flux braking or DC braking
application guidelines. You may also want to consider using external motor
thermal protection.
Flux Up
[Flux Up Mode]
AC induction motors require flux to be established before controlled torque can
be developed. To build flux in these motors, voltage is applied to them. PowerFlex
drives have two methods to flux the motor.
The first method is a normal start. During a normal start, flux is established as the
output voltage and frequency are applied to the motor. While the flux is being
built, the unpredictable nature of the developed torque may cause the rotor to
oscillate even though acceleration of the load may occur. In the motor, the
acceleration profile may not follow the commanded acceleration profile due to
the lack of developed torque.
Figure 21 Accel Profile during Normal Start - No Flux Up
Frequency
Frequency
Reference
Rated Flux
Stator
Rotor
Oscillation due
to flux being
established
0
Time
The second method is Flux Up Mode. In this mode, DC current is applied to the
motor at a level equal to the lesser of the current limit setting, drive rated current,
and drive DC current rating. 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.
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Flying Start
Figure 22 Flux Up Current versus Flux Up Time
Flux Up Current
Flux Up Current = Maximum DC Current
Rated Flux
Current
Rated Motor Flux
Motor Flux
T1
T2
T3
T4
Flux Up Time
[Flux Up Time]
Once rated flux is reached in the motor, normal operation begins and the desired
acceleration profile is achieved.
Figure 23 Rated Flux Reached
Ir Voltage - SVC
Greater of IR Voltage or
Voltage Boost - V/Hz
Stator Voltage
Rotor Speed
Motor Flux
Stator Freq
Flux Up
Voltage
Motor Flux
Flux Up
Flying Start
Normal
Operation
Time
The Flying Start feature is used to start into a rotating motor, as quick as possible,
and resume normal operation with a minimal impact on load or speed.
When a drive is started in its normal mode it initially applies a frequency of 0 Hz
and ramps to the desired frequency. If the drive is started in this mode with the
motor already spinning, large currents will be generated. An overcurrent trip may
result if the current limiter cannot react quickly enough. The likelihood of an
overcurrent trip is further increased if there is a residual flux (back emf ) on the
spinning motor when the drive starts. Even if the current limiter is fast enough to
prevent an overcurrent trip, it will take an unacceptable amount of time for
synchronization to occur and for the motor to reach its desired frequency. In
addition, larger mechanical stress is placed on the application, increasing
downtime and repair costs while decreasing productivity.
In Flying Start mode, the drive’s response to a start command will be to identify
the motor’s speed and apply a voltage that is synchronized in frequency,
amplitude and phase to the back emf of the spinning motor. The motor will then
accelerate to the desired frequency. This process will prevent an overcurrent trip
and significantly reduce the time for the motor to reach its desired frequency.
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105
Fuses and Circuit Breakers
Since the motor is “picked up “smoothly at its rotating speed and ramped to the
proper speed, little or no mechanical stress is present.
Configuration
Flying Start is activated by setting the [Flying Start En] parameter to “Enable”
169 [Flying Start En]
Enables/disables the function which
reconnects to a spinning motor at actual
RPM when a start command is issued.
Default:
0
“Disabled”
Options:
0
1
“Disabled”
“Enabled”
170
Restart Modes
The gain can be adjusted to increase responsiveness. Increasing the value in
[Flying StartGain] increases the responsiveness of the Flaying Start Feature
170 [Flying StartGain]
Sets the response of the flying start
function.
Default:
4000
169
Min/Max: 20/32767
Display: 1
Application Example
In some applications, such as large fans, wind or drafts may rotate the fan in the
reverse direction when the drive is stopped. If the drive were started in the normal
manner, its output would begin 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.
Cooling Tower Fans
Draft/wind blows idle fans in reverse direction. Restart at zero damages fans,
breaks belts. Flying start alleviates the problem
Fuses and Circuit Breakers
106
Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or
PowerFlex 700 Technical Data (publication 20B-TD001) for fuse information.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Grounding, General
Grounding, General
Refer to “Wiring and Grounding Guidelines for PWM AC Drives,” publication
DRIVES-IN001.
HIM Memory
See Copy Cat on page 65.
HIM Operations
Selecting a Language
See also Language on page 111. PowerFlex 700 drives support multiple
languages. When you first apply drive power, a language screen appears on the
HIM. Use the Up or Down Arrow to scroll through the available languages. Press
Enter to select the desired language. To switch to an alternate language, follow
the steps below.
Step
1. Press ALT and then the Up Arrow (Lang). The
Language screen will appear.
Key(s)
ALT +
2. Press the Up Arrow or Down Arrow to scroll through
the languages.
Example Displays
Speak English?
Parlez Francais?
Spechen Duetsch?
Plare Italiano?
3. Press Enter to select a language.
Using Passwords
By default the password is set to 00000 (password protection disabled).
Logging in to the Drive
Step
Key(s)
1. Press the Up or Down Arrow to enter your password.
Press Sel to move from digit to digit.
Example Displays
Login: Enter
Password 9999
2. Press Enter to log in.
Logging Out
Step
Key(s)
You are automatically logged out when the User
Display appears. If you want to log out before that,
select “log out” from the Main Menu.
Example Displays
To change a password
Step
Key(s)
1. Use the Up Arrow or Down Arrow to scroll to Operator
Intrfc. Press Enter.
2. Select “Change Password” and press Enter.
3. Enter the old password. If a password has not been
set, type “0.” Press Enter.
4. Enter a new password (1- 65535). Press Enter and
verify the new password. Press Enter to save the new
password.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Example Displays
Operator Intrfc:
Change Password
User Display
Parameters
Password:
Old Code: 0
New Code: 9999
Verify: 9999
107
Input Devices
The User Display
The User Display is shown when module keys have been inactive for a
predetermined amount of time. The display can be programmed to show
pertinent information.
Setting the User Display
Step
Key(s)
Example Displays
1. Press the Up Arrow or Down Arrow to scroll to
Operator Intrfc. Press Enter.
Operator Intrfc:
Change Password
User Display
Parameters
2. Press the Up Arrow or Down Arrow to scroll to User
Display. Press Enter.
3. Select the desired user display. Press Enter. Scroll to
the parameter that the user display will be based on.
Sel
4. Press Enter. Set a scale factor.
5. Press Enter to save the scale factor and move to the
last line.
6. Press the Up Arrow or Down Arrow to change the
text.
7. Press Enter to save the new user display.
Setting the Properties of the User Display
The following HIM parameters can be set as desired:
• User Display - Enables or disables the user display.
• User Display 1 - Selects which user display parameter appears on the top line
of the user display.
• User Display 2 - Selects which user display parameter appears on the bottom
line of the user display.
• User Display Time - Sets how many seconds will elapse after the last
programming key is touched before the HIM displays the user display.
Input Devices
Contactors
See Motor Start/Stop Precautions on page 120
Circuit Breakers / Fuses
See Fuses and Circuit Breakers on page 106
Filters, EMC
Refer to CE Conformity on page 63.
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Input Modes
Input Modes
The PowerFlex family of drives does not use a direct choice of 2-wire or 3-wire
input modes, but allows full configuration of the digital I/O. As a means of
defining the modes used, consider the following:
2-Wire Control
This input mode is so named because it
only utilizes one device and 2 wires to
control both the Start (normally
referred to as “RUN” in 2-wire) and Stop
functions in an application.
• A maintained contact device, such
PWR
as a thermostat, for example,
closes its contact to Run the drive
and opens to Stop the drive.
STS
Run/Stop
PORT
MOD
NET A
NET B
• In other applications, the
maintained device (such as a limit
switch), can directly control both
Run/Stop and direction control…
PWR
STS
Run Forward
PORT
MOD
NET A
NET B
Run Reverse
• Or, a combination of the two may
PWR
be desirable.
STS
Run
PORT
MOD
NET A
NET B
Forward/Reverse
3-Wire Control
This input mode utilizes 2 devices
requiring 3 wires to control the Start
(proper term for 3-wire) and Stop
functions in an application. In this case,
momentary contact devices, such as
pushbuttons are used.
• A Start is issued when the Start
button is closed, but unlike 2-wire
circuits, the drive does not Stop
when the Start button is released.
Instead, 3-wire control requires a
Stop input to Stop the drive.
• Direction control is accomplished
PWR
STS
Start
PORT
MOD
NET A
NET B
Stop
Start
either with momentary inputs…
PWR
STS
Stop
Forward
PORT
MOD
NET A
NET B
Reverse
• Or, with a maintained input.
PWR
STS
Start
Stop
PORT
MOD
NET A
NET B
Forward/Reverse
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109
Input Power Conditioning
Input Power Conditioning
Refer to Chapter 2 of “Wiring and Grounding Guidelines for PWM AC Drives,”
publication DRIVES-IN001A-EN-P.
Jog
Also refer to Jog on page 75.
When a JOG command is issued by any of the controlling devices (terminal
block digital input, communications adapter or HIM), the drive outputs voltage
and frequency to the motor as long as the command is present. When the
command is released, the drive output stops.
Whenever a jog command is present, the value programmed in parameter 100,
[ Jog Speed] becomes the active speed reference. Regardless of the [Speed Mode]
or [Feedback Select] setting, no modifications (i.e. no PI adder, no slip adder, no
trim adder, etc.) will be made to the reference.
For PowerFlex 70 and PowerFlex 700 with Standard Control, the jog reference
will always be a positive number limited between Minimum Speed and
Maximum Speed.
If [Direction Mode] = “Unipolar” the drive will jog using the Jog reference
parameter value and will use the direction currently selected via the DPI
commanded direction. When [Direction Mode] = “Bipolar” and a Jog command
(with no direction) is asserted, the drive will jog using the Jog reference parameter
(which is always positive or forward). To accommodate jogging with direction
while in Bipolar mode (such as from a terminal block), the drive will allow Jog
Fwd and Jog Rev to be configured as terminal block inputs. When these inputs
are asserted, the drive will jog the requested direction. This still implies that a
HIM can only jog in the forward direction when in Bipolar mode since they only
transmit a Jog command with no direction via DPI.
For PowerFlex 700 drives with Vector Control, 2 independent Jog Speeds (1 and
2) are provided. The jog reference is signed and limited between Minimum
Speed or Reverse Speed Limit (whichever is programmed)) and Maximum
Speed. In this control, the jog reference controls both speed and direction of the
jog operation. If the programmed Jog Speed is negative the drive will jog in the
reverse direction: if the Jog Speed value is positive, the drive will jog in the
forward direction.
When a jog command is issued, exclusive control of speed and direction is given
to the Jog function. If the master speed reference is bipolar and commanding
reverse direction but the programmed Jog Speed is a positive value, the drive will
jog in the forward direction, overriding the direction control of a bipolar speed
reference.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Language
Language
PowerFlex drives are capable of communicating in 7 languages; English, Spanish,
German, Italian, French, Portuguese and Dutch. All drive functions and
information displayed on an LCD HIM are shown in the selected language. The
desired language can be selected several different ways:
• On initial drive power-up, a language choice screen appears.
• The language choice screen can also be recalled at any time to change to a new
language. This is accomplished by pressing the “Alt” key followed by the
“Lang” key.
• The language can also be changed by selecting the [Language] parameter
(201). Note that this parameter is not functional when using an LED HIM.
Linking Parameters
(Vector Control Option Only)
Most parameter values are entered directly by the user. However, certain
parameters can be “linked,” so the value of one parameter becomes the value of
another. For Example: the value of an analog input can be linked to [Accel Time
2]. Rather than entering an acceleration time directly (via HIM), the link allows
the value to change by varying the analog signal. This can provide additional
flexibility for advanced applications.
Each link has 2 components:
• Source parameter – sender of information.
• Destination parameter – receiver of information.
Most parameters can be a source of data for a link, except parameter values that
contain an integer representing an ENUM (text choice). These are not allowed,
since the integer is not actual data (it represents a value). Table 13 lists the
parameters that can be destinations. All links must be established between equal
data types (parameter value formatted in floating point can only source data to a
destination parameter value that is also floating point).
Establishing A Link
Step
Key(s)
Example Displays
1. Select a valid destination parameter (see Table 13) to
be linked. The parameter value screen will appear.
FGP: Parameter
Accel Time 1
Accel Time 2
Decel Time 1
2. Press Enter to edit the parameter. The cursor will
move to the value line.
3. Press ALT and then View (Sel). Next, press the Up or
Down Arrow to change “Present Value” to “Define
Link.” Press Enter.
ALT + Sel
or
4. Enter the Source Parameter Number and press Enter.
The linked parameter can now be viewed two
different ways by repeating steps 1-4 and
selecting “Present Value” or “Define Link.” If
an attempt is made to edit the value of a
linked parameter, “Parameter is Linked!” will
be displayed, indicating that the value is
coming from a source parameter and can not
be edited.
Min: 0.1 Secs
Max: 3600.0 Secs
Dflt: 10.0 Secs
Present Value
.
.
Define Link
Parameter: #141
Accel Time 2
017
Link:
Analog In1 Value
5. To remove a link, repeat steps 1-5 and change the
source parameter number to zero (0).
6. Press Esc to return to the group list.
Esc
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
111
Linking Parameters
Table 13 Linkable Parameters
Number
54
56
57
58
59
62
63
69
70
71
72
84
85
86
87
91
92
94
95
97
98
100
101
102
103
104
105
106
107
119
120
121
122
123
127
129
130
131
132
133
140
141
142
143
146
148
149
151
152
153
154
158
159
112
Parameter
Maximum Voltage
Compensation
Flux Up Mode
Flux Up Time
SV Boost Filter
IR Voltage Drop
Flux Current Ref
Start/Acc Boost
Run Boost
Break Voltage
Break Frequency
Skip Frequency 1
Skip Frequency 2
Skip Frequency 3
Skip Freq Band
Speed Ref A Hi
Speed Ref A Lo
Speed Ref B Hi
Speed Ref B Lo
TB Man Ref Hi
TB Man Ref Lo
Jog Speed
Preset Speed 1
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
Trim Hi
Trim Lo
Slip RPM @ FLA
Slip Comp Gain
Slip RPM Meter
PI Setpoint
PI Integral Time
PI Prop Gain
PI Lower Limit
PI Upper Limit
PI Preload
Accel Time 1
Accel Time 2
Decel Time 1
Decel Time 2
S-Curve %
Current Lmt Val
Current Lmt Gain
PWM Frequency
Droop RPM @ FLA
Regen Power Limit
Current Rate Limit
DC Brake Level
DC Brake Time
Number
160
164
165
170
175
180
181
182
183
185
186
321
322
323
324
325
326
327
343
344
346
347
381
382
383
385
386
387
389
390
391
416
419
420
428
429
430
432
433
434
435
436
437
445
446
447
449
450
454
460
461
462
463
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Parameter
Bus Reg Ki
Bus Reg Kp
Bus Reg Kd
Flying StartGain
Auto Rstrt Delay
Wake Level
Wake Time
Sleep Level
Sleep Time
Power Loss Time
Power Loss Level
Anlg In Sqr Root
Analog In1 Hi
Analog In1 Lo
Analog In1 Loss
Analog In2 Hi
Analog In2 Lo
Analog In2 Loss
Analog Out1 Hi
Analog Out1 Lo
Analog Out2 Hi
Analog Out2 Lo
Dig Out1 Level
Dig Out1 OnTime
Dig Out1 OffTime
Dig Out2 Level
Dig Out2 OnTime
Dig Out2 OffTime
Dig Out3 Level
Dig Out3 OnTime
Dig Out3 OffTime
Fdbk Filter Sel
Notch Filter Freq
Notch Filter K
Torque Ref A Hi
Torque Ref A Lo
Torq Ref A Div
Torque Ref B Hi
Torque Ref B Lo
Torq Ref B Mult
Torque Setpoint
Pos Torque Limit
Neg Torque Limit
Ki Speed Loop
Kp Speed Loop
Kf Speed Loop
Speed Desired BW
Total Inertia
Rev Speed Limit
PI Reference Hi
PI Reference Lo
PI Feedback Hi
PI Feedback Lo
Masks
A mask is a parameter that contains one bit for each of the possible Adapters.
Each bit acts like a valve for issued commands. Closing the valve (setting a bit's
value to 0) stops the command from reaching the drive logic. Opening the valve
(setting a bit's value to 1) allows the command to pass through the mask into the
drive logic.
276 [Logic Mask]
288
thru
297
DP
I
DP Port
IP 5
DP o r t
4
I
DP Port
IP 3
DP o r t
2
I
Dig Port
ita 1
l In
Determines which adapters can control the drive. If the bit for an adapter is set to “0,” the
adapter will have no control functions except for stop.
x x x x x x x x x x 1 1 1 1 1 1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Control Permitted
0 =Control Masked
x =Reserved
Bit #
Factory Default Bit Values
277 [Start Mask]
See [Logic Mask].
Controls which adapters can issue start commands.
278 [Jog Mask]
See [Logic Mask].
Masks & Owners
Controls which adapters can issue jog commands.
COMMUNICATION
Masks
288
thru
297
288
thru
297
288
thru
297
279 [Direction Mask]
See [Logic Mask].
Controls which adapters can issue forward/reverse
direction commands.
280 [Reference Mask]
See [Logic Mask].
Controls which adapters can select an alternate
reference; [Speed Ref A, B Sel] or [Preset Speed 1-7].
281 [Accel Mask]
288
thru
297
See [Logic Mask].
288
thru
297
288
thru
297
288
thru
297
288
thru
297
Controls which adapters can select [Accel Time 1, 2].
282 [Decel Mask]
See [Logic Mask].
Controls which adapters can select [Decel Time 1, 2].
283 [Fault Clr Mask]
See [Logic Mask].
Controls which adapters can clear a fault.
284 [MOP Mask]
See [Logic Mask].
Controls which adapters can issue MOP commands to
the drive.
285 [Local Mask]
See [Logic Mask].
Controls which adapters are allowed to take exclusive
control of drive logic commands (except stop).
Exclusive “local” control can only be taken while the
drive is stopped.
288
thru
297
Example: A customer's process is normally controlled by a remote PLC, but the
drive is mounted on the machine. The customer does not want anyone to walk up
to the drive and reverse the motor because it would damage the process. The local
HIM (drive mounted Adapter 1) is configured with an operator's panel that
includes a “REV” Button. To assure that only the PLC (connected to Adapter 2)
has direction control, the [Direction Mask] can be set as follows:
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
113
MOP
Direction Mask
Adapter #
0
0
0
0
0
1
0
0
X
6
5
4
3
2
1
0
This “masks out” the reverse function from all adapters except Adapter 2, making
the local HIM (Adapter 1) REV button inoperable. Also see Owners on
page 125.
MOP
The Motor Operated Pot (MOP) function is one of the sources for the frequency
reference. The MOP function uses digital inputs to increment or decrement the
Speed reference at a programmed rate.
The MOP has three components:
• [MOP Rate] parameter
• [Save MOP Ref ] parameter
• [MOP Frequency] parameter
MOP increment input
MOP decrement input
The MOP reference rate is defined in [MOP rate]. The MOP function is defined
graphically below
MOP dec
MOP inc
MOP reference
MOP rate is defined in Hz/sec. The MOP reference will increase/decrease
linearly at that rate as long as the MOP inc or dec is asserted via TB or DPI port
(the MOP inputs are treated as level sensitive).
Both the MOP inc and dec will use the same rate (i.e. they can not be separately
configured). The MOP rate is the rate of change of the MOP reference. The
selected active MOP reference still feeds the ramp function to arrive at the
present commanded speed/frequency (eg. is still based on the accel/decel rates).
Asserting both MOP inc and dec inputs simultaneously will result in no change
to the MOP reference.
[Save MOP Ref ] is a packed boolean parameter with two bits used as follows:
Bit 0
0 = Don’t save MOP reference on power-down (default)
1 = Save MOP reference on power-down
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Motor Control
If the value is “SAVE MOP Ref ” when the drive power returns, the MOP
reference is reloaded with the value from the non-volatile memory. When the
bit is set to 0, the MOP reference defaults to zero when power is restored. The
MOP save reference parameter and the MOP rate parameter can be changed
while the drive is running.
Bit 1
0 = Reset MOP reference when STOP edge is asserted
1 = Don’t reset MOP reference when STOP is asserted (default)
Important: The MOP reset only occurs on the stop edge and is not continuously
cleared because the stop is asserted (this is always processed when a
stop edge is seen, even if the drive is stopped). The reset only applies
to the stop edge and not when a fault is detected.
In order to change the MOP reference (increment or decrement) a given DPI
port must have the MOP mask asserted (and the logic mask asserted). In the case
of the terminal block, if the MOP increment or MOP decrement function is
assigned to a digital input, then the act of asserting either of those inputs will
cause the TB to try and gain ownership of the MOP inc/dec reference change.
Ownership of the MOP function can be obtained even if the MOP reference is
not being used to control the drive. If ownership is granted, the owner has the
right to inc/dec the MOP reference. Whether this reference is the active speed
reference for the drive is separately selected via TB reference select, or Ref A/B
select through DPI.
The MOP Frequency parameter is an output which shows the active value of the
MOP reference in Hz x 10.
MOP handling with Direction Mode
If the Direction Mode is configured for “Unipolar,” then the MOP decrement
will clamp at zero not allowing the user to generate a negative MOP reference
that is clamped off by the reference generation. When Direction Mode =
“Bipolar” the MOP reference will permit the decrement function to produce
negative values. If the drive is configured for Direction Mode = “Bipolar” and
then is changed to “Unipolar”, the MOP reference will also be clamped at zero if
it was less than zero.
Motor Control
See Torque Performance Modes on page 201
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
115
Motor Nameplate
Motor Nameplate
[Motor NP Volts]
The motor nameplate base voltage defines the output voltage, when operating at
rated current, rated speed, and rated temperature.
[Motor NP FLA]
The motor nameplate defines the output amps, when operating at rated voltage,
rated speed, and rated temperature. It is used in the motor thermal overload, and
in the calculation of slip.
[Motor NP Hz]
The motor nameplate base frequency defines the output frequency, when
operating at rated voltage, rated current, rated speed, and rated temperature.
[Motor NP RPM]
The motor nameplate RPM defines the rated speed, when operating at motor
nameplate base frequency, rated current, base voltage, and rated temperature.
This is used to calculate slip.
[Motor NP Power]
The motor nameplate power is used together with the other nameplate values to
calculate default values for motor parameters to and facilitate the commissioning
process. This may be entered in horsepower or in kilowatts as selected in the
previous parameter or kW for certain catalog numbers and HP for others.
[Motor NP Pwr Units]
Determines the units for [Motor NP Power]. Possible setting are:
0 “Horsepower” - units are displayed in HP
1 “kilowatts” - units are displayed in kW
The following are only available with the PowerFlex 700 Vector option
2 “Convert HP” - converts units to HP (from kW) by dividing [Motor NP Power] by 0.746.
3 “Covert kW” - converts units to kW (from HP) by multiplying [Motor NP Power] by 0.746.
[Motor Poles]
Vector
Defines the number of motor poles in the motor. [Motor Poles] is calculated
automatically if the user enters the motor nameplate data through the Start-up
menu of an LCD HIM. The number of motor poles is defined by:
P=
116
120f
N
where:
P = motor poles
f = base motor frequency (Hz)
N = base motor speed (RPM)
P is rounded up to the nearest whole even number
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Motor Overload
Also see Motor Overload Protection on page 119.
The motor thermal overload uses an IT algorithm to model the temperature of
the motor. The curve is modeled after a Class 10 protection thermal overload
relay that produces a theoretical trip at 600% motor current in ten (10) seconds
and continuously operates at full motor current.
Motor Overload Curve
100000
Trip Time (Seconds)
Motor Overload
10000
Cold
Hot
1000
100
10
100
125
150
175
200
Full Load Amps (%)
225
250
Motor nameplate FLA programming is used to set the overload feature. This
parameter, which is set in the start up procedure, is adjustable from 0 - 200% of
drive rating and should be set for the actual motor FLA rating.
Setting the correct bit in [Fault Config x] to zero disables the motor thermal
overload. Most multimotor applications (using one drive and more than one
motor) will require the MTO to be disabled since the drive would be unable to
distinguish each individual motor’s current and provide protection.
Operation of the overload is based on three parameters; [Motor NP FLA],
[Motor OL Factor] and [Motor OL Hertz].
1. [Motor NP FLA] is the base value for motor protection.
2. [Motor OL Factor] is used to adjust for the service factor of the motor.
Within the drive, motor nameplate FLA is multiplied by motor overload
factor to select the rated current for the motor thermal overload. This can be
used to raise or lower the level of current that will cause the motor thermal
overload to trip without the need to adjust the motor FLA. For example, if
motor nameplate FLA is 10 Amps and motor overload factor is 1.2, then
motor thermal overload will use 12 Amps as 100%.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
117
Motor Overload
Changing Overload Factor
140
Continuous Rating
120
100
80
OL % = 1.20
OL % = 1.00
OL % = 0.80
60
40
20
0
10
20
30
40
50
60
70
80
90 100
% of Base Speed
3. [Motor OL Hertz] is used to further protect motors with limited speed
ranges. Since some motors may 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 should begin. As shown here, the motor overload
capacity is reduced when operating below the motor overload Hz. For all
settings of overload Hz other than zero, the overload capacity is reduced to
70% when output frequency is zero. During DC injection the motor current
may exceed 70% of FLA, but this will cause the Motor Thermal Overload to
trip sooner than when operating at base speed. At low frequencies, the
limiting factor may be the Drive Thermal Overload.
Changing Overload Hz
Continuous Rating
120
100
80
OL Hz = 10
OL Hz = 25
OL Hz = 50
60
40
20
0
10
20
30
40
50
60
70
80
90 100
% of Base Speed
Duty Cycle for the Motor Thermal Overload
When the motor is cold motor thermal overload will allow 3 minutes at 150%.
When the motor is hot motor thermal overload will allow 1 minute at 150%. A
continuous load of 102% will not trip. The duty cycle of the motor thermal
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.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Motor Overload Protection
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%
105
110
115
120
125
130
135
140
145
150
Motor Overload
Protection
Cold Trip
Time
6320
1794
934
619
456
357
291
244
209
180
Hot Trip
Time
5995
1500
667
375
240
167
122
94
74
60
FLA%
155
160
165
170
175
180
185
190
195
200
Cold Trip
Time
160
142
128
115
105
96
88
82
76
70
Hot Trip
Time
50
42
36
31
27
23
21
19
17
15
FLA%
205
210
215
220
225
230
235
240
245
250
Cold Trip
Time
66
62
58
54
51
48
46
44
41
39
Hot Trip
Time
14
12
11
10
10
9
8
8
7
7
PowerFlex 70
PowerFlex 70:
Class 10 motor overload protection according to NEC article 430
and motor over-temperature protection according to NEC article
430.126 (A)(2). UL 508C File E59272.
PowerFlex 700
Frames 0…6 Standard Control: PowerFlex 700 drives with standard control, identified by an N,
A, or B in position 15 of the catalog number, only provide Class
10 motor overload protection according to NEC article 430. They
do not provide speed sensitive overload protection, thermal
memory retention and motor over-temperature sensing
according to NEC article 430.126 (A) (2). If such protection is
needed in the end-use product, it must be provided by
additional means.
PowerFlex 700 drives with vector control, identified by a C or D in
Frames 0…6 Vector Control:
position 15 of the catalog number, provide class 10 motor
overload protection according to NEC article 430 and motor
over-temperature protection according to NEC article 430.126
(A) (2). UL 508C File E59272.
Frames 7…10 Vector Control: Class 10 motor overload protection according to NEC article 430
and motor over-temperature protection according to NEC article
430.126 (A)(2). UL 508C File E59272.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
119
Motor Start/Stop Precautions
Motor Start/Stop
Precautions
Input Contactor Precautions
!
!
ATTENTION: A contactor or other device that routinely disconnects
and reapplies the AC line to the drive to start and stop the motor can
cause drive hardware damage. The drive is designed to use control input
signals that will start and stop the motor. If an input device is used,
operation must not exceed one cycle per minute or drive damage will
occur.
ATTENTION: 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 exist, an
additional hardwired stop circuit may be required to remove the AC
line to the drive. An auxiliary braking method may be required.
Output Contactor Precaution
!
ATTENTION: To guard against drive damage when using output
contactors, the following information must be read and understood.
One or more output contactors may be installed between the drive and
motor(s) for the purpose of disconnecting or isolating certain motors/
loads. If a contactor is opened while the drive is operating, power will be
removed from the respective motor, but the drive will continue to
produce voltage at the output terminals. In addition, reconnecting a
motor to an active drive (by closing the contactor) could produce
excessive current that may cause the drive to fault. If any of these
conditions are determined to be undesirable or unsafe, an auxiliary
contact on the output contactor should be wired to a drive digital input
that is programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is opened.
Bypass Contactors
!
ATTENTION: An incorrectly applied or installed bypass system can
result in component damage or reduction in product life. The most
common causes are:
• Wiring AC line to drive output or control terminals.
• Improper bypass or output circuits not approved by Allen-Bradley.
• Output circuits which do not connect directly to the motor.
Contact Allen-Bradley for assistance with application or wiring.
120
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Notch Filter
Notch Filter
Vector FV The 700 Vector has a notch filter in the torque reference loop used
to eliminate mechanical resonance created by a gear train. [Notch Filter Freq]
sets the center frequency for the 2 pole notch filter, and [Notch Filter K] sets the
gain.
Figure 24 Notch Filter Frequency
Gain
Notch Filter K
0 db
Notch Filter Frequency
Hz
Due to the fact that most mechanical frequencies are described in Hertz, [Notch
Filter Freq] and [Notch Filter K] are in Hertz as well. The following is an
example of a notch filter.
A mechanical gear train consists of two masses (the motor and the load) and
spring (mechanical coupling between the two loads). See Figure 25.
Figure 25 Mechanical Gear Train
Bm
BL
Kspring
Jm
Jload
The resonant frequency is defined by the following equation:
resonance =
( Jm + Jload )
Kspring --------------------------------Jm × Jload
Jm is the motor inertia (seconds)
Jload is the load inertia (seconds)
Kspring is the coupling spring constant (rad2/sec)
Figure 26 shows a two mass system with a resonant frequency of 62 radians/
second (9.87 Hz). One Hertz is equal to 2ðπ radians/second.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
121
Notch Filter
Figure 26 Resonance
The insert shows the resonant frequency in detail.
Figure 27 shows the same mechanical gear train as Figure 26. [Notch Filter Freq]
is set to 10.
Figure 27 10 Hz Notch
122
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Output Current
Output Current
[Output Current]
This parameter displays the total output current of the drive. The current value
displayed here is the vector sum of both torque producing and flux producing
current components.
Output Devices
Drive Output Contactor
!
ATTENTION: To guard against drive damage when using output
contactors, the following information must be read and understood.
One or more output contactors may be installed between the drive and
motor(s) for the purpose of disconnecting or isolating certain motors/
loads. If a contactor is opened while the drive is operating, power will be
removed from the respective motor, but the drive will continue to
produce voltage at the output terminals. In addition, reconnecting a
motor to an active drive (by closing the contactor) could produce
excessive current that may cause the drive to fault. If any of these
conditions are determined to be undesirable or unsafe, an auxiliary
contact on the output contactor should be wired to a drive digital input
that is programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is opened.
Also see Input Devices on page 108.
Cable Termination
Voltage doubling at motor terminals, known as reflected wave phenomenon,
standing wave or transmission line effect, can occur when using drives with long
motor cables.
Inverter duty motors with phase-to-phase insulation ratings of 1200 volts or
higher should be used to minimize effects of reflected wave on motor insulation
life.
Applications with non-inverter duty motors or any motor with exceptionally long
leads may require an output filter or cable terminator. A filter or terminator will
help limit reflection to the motor, to levels which are less than the motor
insulation rating.
Cable length restrictions for unterminated cables are discussed on page 61.
Remember that the voltage doubling phenomenon occurs at different lengths for
different drive ratings. If your installation requires longer motor cable lengths, a
reactor or cable terminator is recommended.
Optional Output Reactor
Bulletin 1321 Reactors can be used for drive input and output. These reactors are
specifically constructed to accommodate IGBT inverter applications with
switching frequencies up to 20 kHz. They have a UL approved dielectric strength
of 4000 volts, opposed to a normal rating of 2500 volts. The first two and last two
turns of each coil are triple insulated to guard against insulation breakdown
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
123
Output Frequency
resulting from high dv/dt. When using motor line reactors, it is recommended
that the drive PWM frequency be set to its lowest value to minimize losses in the
reactors.
By using an output reactor the effective motor voltage will be lower because of the
voltage drop across the reactor - this may also mean a reduction of motor torque.
Output Frequency
[Output Frequency]
This parameter displays the actual output frequency of the drive. The output
frequency is created by a summation of commanded frequency and any active
speed regulator such as slip compensation, PI Loop, bus regulator. The actual
output may be different than the commanded frequency.
Output Power
This parameter displays the output kW of the drive. The output power is a
calculated value and tends to be inaccurate at lower speeds. It is not
recommended for use as a process variable to control a process.
Output Voltage
[Output Voltage]
This parameter displays the actual output voltage at the drive output terminals.
The actual output voltage may be different than that determined by the sensorless
vector or V/Hz algorithms because it may be modified by features such as the
Auto-Economizer.
Overspeed Limit
The Overspeed Limit is a user programmable value that allows operation at
maximum speed but also provides an “overspeed band” that will allow a speed
regulator such as encoder feedback or slip compensation to increase the output
frequency above maximum Speed in order to maintain maximum Motor Speed.
Figure 28 illustrates a typical Custom V/Hz profile. Minimum Speed determines
the lower speed reference limit during normal operation. Maximum Speed
determines the upper speed reference limit. The two “Speed” parameters only
limit the speed reference and not the output frequency.
The actual output at maximum speed reference is the sum of the speed reference
plus “speed adder” components from functions such as slip compensation,
encoder feedback or process trim.
The Overspeed Limit is added to Maximum Speed and the sum of the two
(Speed Limit) limits is output. This sum (Speed Limit) is compared to Maximum
Frequency and an alarm is initiated which prevents operation if the Speed Limit
exceeds Maximum Frequency.
124
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Owners
Figure 28 Typical V/Hz Curve for Full Custom (with Speed/Frequency Limits
Allowable Output Frequency Range Bus Regulation or Current Limit
Allowable Output Frequency Range - Normal Operation
(lower limit on this range can be 0 depending on the value of Speed Adder)
Allowable Speed Reference Range
Maximum
Voltage
Output Voltage
Motor NP
Voltage
Frequency Trim
due to Speed
Control Mode
Overspeed
Limit
Break
Voltage
Start
Boost
Run
Boost
0
Minimum
Break
Speed Frequency
Motor NP Hz
Frequency
Owners
Maximum
Speed
Output
Maximum
Frequency Frequency
Limit
An owner is a parameter that contains one bit for each of the possible DPI or
SCANport adapters. The bits are set high (value of 1) when its adapter is
currently issuing that command, and set low when its adapter is not issuing that
command. Ownership falls into two categories;
Exclusive
Only one adapter at a time can issue the command and only one bit in the
parameter will be high.
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, therefore, is exclusive ownership.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
125
Owners
Non Exclusive
Multiple adapters can simultaneously issue the same command and multiple bits
may be high.
288 [Stop Owner]
Read Only
DP
I
DP Port
IP 5
DP o r t
4
I
DP Port
IP 3
DP o r t
2
I
Dig Port
ita 1
l In
Adapters presently issuing a valid stop command.
276
thru
285
x x x x x x x x x x 0 0 0 0 0 1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Issuing Command
0 =No Command
x =Reserved
Bit #
289 [Start Owner]
See [Stop Owner]
Masks & Owners
COMMUNICATIONS
Adapters that are presently issuing a valid start command.
276
thru
285
276
thru
285
290 [Jog Owner]
See [Stop Owner]
Adapters that are presently issuing a valid jog
command.
291 [Direction Owner]
See [Stop Owner]
Adapter that currently has exclusive control of direction
changes.
292 [Reference Owner]
276
thru
285
See [Stop Owner]
Adapter that has the exclusive control of the command
frequency source selection.
293 [Accel Owner]
276
thru
285
See [Stop Owner]
140
276
thru
285
142
276
thru
285
276
thru
285
276
thru
285
Adapter that has exclusive control of selecting [Accel
Time 1, 2].
294 [Decel Owner]
See [Stop Owner]
Adapter that has exclusive control of selecting [Decel
Time 1, 2].
295 [Fault Clr Owner]
See [Stop Owner]
Adapter that is presently clearing a fault.
296 [MOP Owner]
See [Stop Owner]
Adapters that are currently issuing increases or
decreases in MOP command frequency.
297 [Local Owner]
See [Stop Owner]
Adapter that has requested exclusive control of all drive
logic functions. If an adapter is in local lockout, all other
functions (except stop) on all other adapters are locked
out and non-functional. Local control can only be
obtained when the drive is not running.
276
thru
285
Conversely, any number of adapters can simultaneously issue Stop Commands.
Therefore, Stop Ownership is not exclusive.
Example:
The operator presses the Stop button on the Local HIM 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.
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Parameter Access Level
The operator first views the Start owner to be certain that the Start button on the
HIM is issuing a command.
Start Owner
Adapter #
0
0
0
0
0
0
0
0
X
6
5
4
3
2
1
0
When the local Start button is pressed, the display indicates that the command is
coming from the HIM.
Start Owner
Adapter #
0
0
0
0
0
0
1
0
X
6
5
4
3
2
1
0
The [Start Owner] indicates that there is not any maintained Start commands
causing the drive to run.
Stop Owner
Adapter #
0
0
0
0
0
0
0
1
X
6
5
4
3
2
1
0
The operator then checks the Stop Owner. 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 reclosed, a permanent Start Inhibit condition exists and the
drive will not restart.
Also refer to Start Inhibits and Start Permissives.
Parameter Access Level
The PowerFlex 70 allows the user to restrict the number of parameters that are
viewable on the LCD or LED HIM. By limiting the parameter view to the most
commonly adjusted set, additional features that may make the drive seem more
complicated are hidden.
If you are trying to gain access to a particular parameter and the HIM skips over
it, you must change the parameter view from “Basic” to “Advanced.” This can be
accomplished in two different ways:
• Press “Alt” and then “View” from the HIM and change the view.
or
• Reprogram Parameter 196 [Param Access Lvl] to “Advanced”.
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127
PET
PET
Pulse Elimination Technique – See Reflected Wave on page 149.
Power Loss
Some processes or applications cannot tolerate drive output interruptions caused
by momentary power outages. When AC input line power is interrupted to the
drive, user programming can determine the drive’s reaction.
Terms
The following is a definition of terms. Some of these values are drive parameters
and some are not. The description of how these operate is explained below
Term
Vbus
Vmem
Vslew
Vrecover
Vtrigger
Definition
The instantaneous DC bus voltage.
The average DC bus voltage. A measure of the “nominal” bus voltage determined by heavily filtering bus
voltage. Just after the pre-charge relay is closed during the initial power-up bus pre-charge, bus memory
is set equal to bus voltage. Thereafter it is updated by ramping at a very slow rate toward Vbus. The filtered
value ramps at 2.4V DC per minute (for a 480VAC drive). An increase in Vmem is blocked during
deceleration to prevent a false high value due to the bus being pumped up by regeneration. Any change to
Vmem is blocked during inertia ride through.
The rate of change of Vmem in volts per minute.
The threshold for recovery from power loss.
The threshold to detect power loss.
PowerFlex 700
The level is adjustable. The default is the value in the PF700 Bus Level table. If “Pwr Loss Lvl” is selected as
an input function AND energized, Vtrigger is set to Vmem minus [Power Loss Level].
Vopen is normally 60V DC below Vtrigger (in a 480VAC drive). Both Vopen and Vtrigger are limited to a
minimum of Vmin. This is only a factor if [Power Loss Level] is set to a large value.
Vinertia
Vclose
Vopen
Vmin
Voff
PowerFlex 70
This is a fixed value.
WARNING:
When using a value of Parameter #186 [Power Loss Level] larger than default, the customer must provide a
minimum line impedance to limit inrush current when the power line recovers. The input impedance
should be equal or greater than the equivalent of a 5% transformer with a VA rating 5 times the drive’s
input VA rating.
The software regulation reference for Vbus during inertia ride through.
The threshold to close the pre-charge contactor.
The threshold to open the pre-charge contactor.
The minimum value of Vopen.
The bus voltage below which the switching power supply falls out of regulation.
Table 14 PF70 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1
Vtrigger2
Vopen
Vmin
Voff 3
128
200/240 VAC
1.2V DC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
204V DC
?
400/480 VAC
2.4V DC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
407V DC
300V DC
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
600/690 VAC
3.0V DC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
509V DC
?
Power Loss
Line Loss Mode = Decel
700
Recover
Close
Trigger
Open
650
600
DC Bus Volts
DC Bus Volts
650
Line Loss Mode = Coast
700
550
600
550
500
500
450
450
400
Recover
Close
Trigger
Open
400
350
400
AC Input Volts
450
350
400
AC Input Volts
450
Table 15 PF700 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1,2
Vtrigger1,3
Vopen
Vopen4
Vmin
Voff 5
200/240V AC
1.2V DC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
153V DC
153V DC
–
400/480V AC
2.4V DC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
305V DC
305V DC
200V DC
600/690V AC
3.0V DC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
382V DC
382V DC
–
Note 1:Vtrigger is adjustable, these are the standard values.
Line Loss Mode = Coast
Line Loss Mode = Decel
700
650
Recover
Close
Trigger
Open
650
600
550
DC Bus Volts
DC Bus Volts
600
700
500
450
550
500
450
400
400
350
350
300
Recover
Close
Trigger
Open
300
350
400
AC Input Volts
450
350
400
AC Input Volts
450
Line Loss Mode = Continue
700
650
DC Bus Volts
600
Recover
Close
Trigger
Open
550
500
450
400
350
300
350
400
AC Input Volts
450
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129
Power Loss
Restart after Power Restoration
If a power loss causes the drive to coast and power recovers the drive will return to
powering the motor if it is in a “run permit” state. The drive is in a “run permit”
state if:
3 wire mode – it is not faulted and if all Enable and Not Stop inputs are
energized.
2 wire mode – it is not faulted and if all Enable, Not Stop, and Run inputs are
energized.
Power Loss Actions
The drive is designed to operate at a nominal bus voltage. When Vbus 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 will have
three methods of dealing with low bus voltages:
• “Coast” – Disable the transistors and allow the motor to coast.
• “Decel” – Decelerate the motor at just the correct rate so that the energy
absorbed from the mechanical load balances the losses.
• “Continue” – Allow the drive to power the motor down to half bus voltage.
Default:
0
“Coast”
Sets the reaction to a loss of input power. Power loss is Options:
recognized when:
0
1
2
3
4
“Coast”
“Decel”
“Continue”
“Coast Input”
“Decel Input”
Power Loss
184 [Power Loss Mode]
•
•
DC bus voltage is ≤73% of [DC Bus Memory]
and [Power Loss Mode] is set to “Coast”.
DC bus voltage is ≤82% of [DC Bus Memory]
and [Power Loss Mode] is set to “Decel”.
013
185
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.
The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts.
The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1]
is set.
The drive faults with a F003 – Power Loss Fault if the power loss timer exceeds
[Power Loss Time] and the Power Loss bit in [Fault Config 1] is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below
Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes if the
bus voltage rises above Vclose
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Power Loss
If the bus voltage rises above Vrecover for 20mS, 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.
680V
620V
560V
500V
Bus Voltage
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 15 for further information.
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 up. If AC input power is restored, the drive can ramp the motor to the
correct speed without the need for reconnecting.
The drive determines a power loss has occurred if the bus voltage drops below
Vtrigger.
If the drive is running, the inertia ride through function is activated.
The load is decelerated at just the correct rate so that the energy absorbed from
the mechanical load balances the losses and bus voltage is regulated to the value
Vinertia.
The Power Loss alarm in [Drive Alarm 1] is set and the power loss timer starts.
The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1]
is set.
The drive faults with a F003 – Power Loss fault if the power loss timer exceeds
[Power Loss Time] and the Power Loss bit in [Fault Config 1] is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below
Vmin and the UnderVoltage bit in [E238 Fault Config 1] is set.
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131
Power Loss
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.
The pre-charge relay opens if the bus voltage drops below Vopen.
The pre-charge relay closes if the bus voltage rises above Vclose
If the bus voltage rises above Vrecover for 20mS, the drive determines the power
loss is over. The power loss alarm is cleared.
If the drive is still in inertia ride through operation, 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.
680V
620V
560V
500V
Bus Voltage
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 15 for further information.
Half Voltage
This mode provides the maximum power ride through. In a typical application
230VAC motors are used with a 480VAC drive, the input voltage can then drop
to half and the drive is still able to supply full power to the motor.
!
ATTENTION: To guard against drive damage, a minimum line
impedance must be provided to limit inrush current when the power
line recovers. The input impedance should be equal or greater than
the equivalent of a 5% transformer with a VA rating 6 times the drive’s
input VA rating.
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.
If the bus voltage drops below Vopen/Vmin (In this mode of operation Vopen
and Vmin are the same value) or if the Enable input is de-energized, the inverter
output is disabled and the motor coasts. If the Not Stop or Run inputs are
de-energized, the drive stops in the programmed manner.
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Power Loss
The pre-charge relay opens if the bus voltage drops below Vopen/Vmin and closes
if the bus voltage rises above Vclose.
The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts.
The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1]
is set.
The drive faults with a F003 – Power Loss fault if the power loss timer exceeds
[Power Loss Time] and the Power Loss bit in [Fault Config 1] is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below
Vmin and the UnderVoltage bit in [Fault Config 1] is set.
If the bus voltage rises above Vrecover for 20mS, the drive determines the power
loss is over. The power loss alarm is cleared.
If the drive is coasting and if 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.
680V
620V
560V
Bus Voltage
365V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 15 for further information.
Coast Input (PowerFlex700 Only)
This mode can provide additional ride through time by sensing the power loss via
an external device that monitors the power line and provides a hardware power
loss signal. This signal is then connected to the drive through the “pulse” input
(because of its high-speed capability). Normally this hardware power loss input
will provide a power loss signal before the bus drops to less than Vopen.
The drive determines a power loss has occurred if the “pulse” input is
de-energized OR the bus voltage drops below Vopen. If the drive is running, the
inverter output is disabled.
The Power Loss alarm in [Drive Alarm 1] is set and the power loss timer starts.
The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1]
is set.
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133
Power Loss
The drive faults with a F003 – Power Loss fault if the power loss timer exceeds
[Power Loss Time] and the Power Loss bit in [Fault Config 1] is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below
Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes if the
bus voltage rises above Vclose.
If the “pulse” input is re energized and the pre-charge relay is closed, 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.
Decel Input (PF700 only)
This mode can provide additional ride through time by sensing the power loss via
an external device that monitors the power line and provides a hardware power
loss signal. This signal is then connected to the drive through the “pulse” input
(because of its high-speed capability). Normally this hardware power loss input
will provide a power loss signal before the bus drops to less than Vopen.
The drive determine a power loss has occurred if the “pulse” input is de-energized
or the bus voltage drops below Vopen.
If the drive is running, the inertia ride through function is activated. The load is
decelerated at just the correct rate so that the energy absorbed from the
mechanical load balances the losses and bus voltage is regulated to the value
Vmem.
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, the inverter output is disabled
and the motor coasts.
The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts.
The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1]
is set.
The drive faults with a F003 – Power Loss fault if the power loss timer exceeds
[Power Loss Time] and the Power Loss bit in [E238 Fault Config 1] is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below
Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes if the
bus voltage rises above Vclose.
If power recovers while the drive is still in inertia ride through the power loss
alarm is cleared and it then accelerates at the programmed rate to the set speed.
Otherwise, if power recovers before power supply shutdown, 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.
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Preset Frequency
Preset Frequency
There are 7 Preset Frequency parameters that are used to store a discrete
frequency value. This value can be used for a speed reference or PI Reference.
When used as a speed reference, they are accessed via manipulation of the digital
inputs or the DPI reference command. Preset frequencies have a range of plus/
minus [Maximum Speed].
Process PI Loop
[PI Config]
[PI Control]
[PI Reference Sel]
[PI Setpoint]
[PI Feedback Sel]
[PI Integral Time]
[PI Prop Gain]
[PI Upper/Lower Limit]
[PI Preload]
[PI Status]
[PI Ref Meter]
[PI Feedback Meter]
[PI Error Meter]
[PI Output Meter]
The internal PI 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 external control devices. The PI
function allows the microprocessor to follow a single process control loop.
The PI function reads a process variable input to the drive and compares it to a
desired setpoint stored in the drive. The algorithm will then adjust the output of
the PI regulator, changing drive output frequency to try and make the process
variable equal the setpoint.
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 and, conversely, if the error is cut in half then the
output of the proportional output will be cut in half. With proportional control
there is always an error, so the feedback and the reference are never equal.
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 will continue 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).
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 generally not required and, when it is
used, is almost always combined with proportional and integral control (PID).
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135
Process PI Loop
The PI function can perform a combination of proportional and integral control.
It does not perform derivative control, however, the accel / decel control of the
drive can be considered as providing derivative control.
There are two ways the PI Controller can be configured to modify the
commanded speed.
• Process Trim - The PI Output can be added to the master speed reference
• Process Control - PI can have exclusive control of the commanded speed.
The selection between these two modes of operation is done in the [PI
Configuration] parameter.
Process Trim
Process Trim takes the output of PI regulator and sums it with a master speed
reference to control the process. In the following example, the master speed
reference sets the wind/unwind speed and the dancer pot signal is used as a PI
Feedback to control the tension in the system. An equilibrium point is
programmed as PI Reference, 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
Equilibrium Point
[PI Reference Sel]
Dancer Pot
[PI Feedback Sel]
10 Volts
Master Speed Reference
When the PI is disabled the commanded speed is the ramped speed reference.
Slip
Comp
+
Slip Adder
+
Spd Ref
PI Ref
PI Fbk
136
Open
Loop
Linear Ramp
& S-Curve
Spd Cmd
+
Process PI
Controller
PI Disabled
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
+
Process
PI
Speed Control
Process PI Loop
When the PI is enabled, the output of the PI Controller is added to the ramped
speed reference.
Slip
Comp
+
Slip Adder
+
Spd Ref
PI Ref
PI Fbk
Open
Loop
Linear Ramp
& S-Curve
Spd Cmd
+
Process PI
Controller
PI Enabled
+
Process
PI
Speed Control
Exclusive Control
Process Control takes the output of PI regulator as the speed command. No
master speed reference exists and the PI Output directly controls the drive
output.
In the pumping application example below, the reference or setpoint is the
required pressure in the system. The input from the transducer is the PI 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
Motor
PI Feedback
Pressure
Transducer
Desired Pressure
[PI Reference Sel]
However, when additional valves in the system are opened and the pressure in the
system drops, the PI error will alter its output frequency to bring the process back
into control.
When the PI is disabled the commanded speed is the ramped speed reference.
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137
Process PI Loop
Slip
Comp
+
Slip Adder
+
Linear Ramp
& S-Curve
Spd Ref
Open
Loop
Spd Cmd
Process
PI
PI Ref
PI Fbk
Process PI
Controller
Speed Control
PI Disabled
When the PI is enabled, the speed reference is disconnected and PI Output has
exclusive control of the commanded speed, passing through the linear ramp and
s-curve.
+
Slip Adder
+
Linear Ramp
& S-Curve
Spd Ref
Slip
Comp
Open
Loop
Spd Cmd
Process
PI
PI Ref
PI Fbk
Process PI
Controller
PI Enabled
Speed Control
Configuration
To operate the drive in PI Regulator Mode for the Standard Control option,
change the mode by selecting “Process PI” through the [Speed Mode] parameter.
Three parameters are used to configure, control, and indicate the status of the
logic associated with the Process PI controller; [PI Configuration], [PI Control],
and [PI Status]. Together these three parameters define the operation of the PI
logic.
1. [PI Configuration] is a set of bits that select various modes of operation. The
value of this parameter can only be changed while the drive is stopped.
• Exclusive Mode - see page 137.
• 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 might be 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 PI has the option to change the sign of PI Error. This is used when an
increase in feedback should cause an increase in output.
The option to invert the sign of PI Error is selected in the PI
Configuration parameter.
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Process PI Loop
PI_Config
.Invert
+
PI Ref Sel
PI Fdbk Sel
PI Error
–
PI_Config
.Sqrt
PI Fbk
• Preload Integrator - This feature allows the PI Output to be stepped to a
preload value for better dynamic response when the PI Output is enabled.
Refer to diagram 2 below.
If PI is not enabled the PI Integrator may be initialized to the PI Pre-load
Value or the current value of the commanded speed. The operation of
Preload is selected in the PI Configuration parameter.
PI_Config
.PreloadCmd
PI_Status
.Enabled
Preload Value
PI Integrator
Spd Cmd
By default, Pre-load Command is off and the PI Load Value is zero, causing
a zero to be loaded into the integrator when the PI is disabled. As below
shown on the left, when the PI is enabled the PI output will start from zero
and regulate to the required level. When PI is enabled with PI Load Value
is set to a non-zero value the output begins with a step as shown below on
the right. This may result in the PI reaching steady state sooner, however if
the step is too large the drive may go into current limit which will extend
the acceleration.
PI Enabled
PI Pre-load Value
PI Output
Spd Cmd
PI Pre-load Value = 0
PI Pre-load Value > 0
Pre-load command may be used when the PI has exclusive control of the
commanded speed. With the integrator preset to the commanded speed
there is no disturbance in commanded speed when PI is enabled. After PI
is enabled the PI output is regulated to the required level.
When the PI 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.
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139
Process PI Loop
PI Enabled
Start at Spd Cmd
PI Output
Spd Cmd
Pre-load to Command Speed
• Ramp Ref - The PI Ramp Reference feature is used to provide a smooth
transition when the PI is enabled and the PI output is used as a speed trim
(not exclusive control),.
When PI Ramp Reference is selected in the PI Configuration parameter,
and PI is disabled, the value used for the PI reference will be the PI
feedback. This will cause PI error to be zero. Then when the PI is enabled
the value used for the PI reference will ramp to the selected value for PI
reference at the selected acceleration or deceleration rate. After the PI
reference reaches the selected value the ramp is bypassed until the PI is
disabled and enabled again. S-curve is not available as part of the PI linear
ramp.
• Zero Clamp - This feature limits the possible drive action to one direction
only. Output from the drive will be 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.
The PI has the option to limit operation so that the output frequency will
always have the same sign as the master speed reference. The zero clamp
option is selected in the PI Configuration parameter. Zero clamp is
disabled when PI has exclusive control of speed command.
For example, if master speed reference is +10 Hz and the output of the PI
results in a speed adder of –15 Hz, zero clamp would limit the output
frequency to not become less than zero. Likewise, if master speed reference
is –10 Hz and the output of the PI results in a speed adder of +15 Hz, zero
clamp would limit the output frequency to not become greater than zero.
≥0
Spd Ref
Linear
Ramp
& S-Curve
Spd Ramp
PI_Config
.ZeroClamp
+
+32K
0
0
Spd Cmd
+
-32K
+32K
PI Output
PI Ref
Process PI
Controller
PI Fbk
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
-32K
Process PI Loop
• Feedback Square Root - This feature uses the square root of the feedback
signal as the PI feedback. This is useful in processes that control pressure,
since centrifugal fans and pumps vary pressure with the square of speed.
The PI 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 PI Configuration parameter.
Normalized SQRT(Feedback)
100.0
75.0
50.0
25.0
0.0
-25.0
-50.0
-75.0
-100.0
-100.0
-75.0
-50.0
-25.0
0.0
25.0
50.0
75.0
100.0
Normalized Feedback
• Stop Mode (PowerFlex 700 Only). When Stop Mode is set to “1” and a
Stop command is issued to the drive, the PI loop will continue to operate
during the decel ramp until the PI output becomes more than the master
reference. When set to “0,” the drive will disable PI and perform a normal
stop. This bit is active in Trim mode only.
• Anti-Wind Up (PowerFlex 700 Only). When Anti-Windup is set to “1”
the PI loop will automatically prevent the integrator from creating an
excessive error that could cause loop instability. The integrator will be
automatically controlled without the need for PI Reset or PI Hold inputs.
•
Vector FV Torque Trim. When Torque Trim is set to “1” the output of
the process PI loop will be added to Torque Reference A and B, instead of
being added to the speed reference.
2. [PI Control] is a set of bits to dynamically enable and disable the operation of
the process PI 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.
• PI Enable - The PI loop can be enabled/disabled. The Enabled status of
the PI loop determines when the PI regulator output is part or all of the
commanded speed. The logic evaluated for the PI Enabled status is shown
in the following ladder diagram.
The drive must be in run before the PI Enabled status can turn on. The PI
will remain disabled when the drive is jogged. The PI is disabled when the
drive begins a ramp to stop, except in the PowerFlex 700 when it is in Trim
mode and the Stop mode bit in [PI Configuration] is on.
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141
Process PI Loop
When a digital input is configured as “PI Enable,” the PI Enable bit of [PI
Control] must be turned on for the PI loop to become enabled.
If a digital input is not configured as “PI Enable” and the PI Enable bit in
[PI Control] is turned on, then the PI loop may become enabled. If the PI
Enable bit of [PI Control] is left continuously, then the PI may become
enabled as soon as the drive goes into run. If analog input signal loss is
detected, the PI loop is disabled.
Running
Stopping
DigInCfg
.PI_Enable
DigIn
.PI_Enable
DigInCfg
.PI_Enable
PI_Control
.PI_Enable
Signal Loss
PI_Status
.Enabled
PI_Control
.PI_Enable
• PI Hold - The Process PI Controller has the option to hold the integrator
at the current value so if some part of the process is in limit the integrator
will maintain 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
will turn on.
– If a digital input is configured to provide PI Hold and that digital input is
turned on then the PI integrator will stop changing. Note that when a
digital input is configured to provide PI Hold that takes precedence over
the PI Control parameter.
– If a digital input is not configured to provide PI Hold and the PI Hold bit
in the PI Control parameter is turned on then the PI integrator will stop
changing.
– If the current limit or voltage limit is active then the PI is put into hold.
DigInCfg
.PI_Hold
DigInCfg
.PI_Hold
DigIn
.PI_Hold
PI_Status
.Hold
PI_Control
.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 may be used
for integrator preloading during transfer and can be used to hold the
integrator at zero during “manual mode”. Take the example of a process
whose feedback signal is below the reference point, creating error. The
drive will increase 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 will be commanded. When the drive
reaches programmed Maximum Frequency, it is possible that a significant
amount of integral value has been “built up” (windup). This may cause
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Process PI Loop
undesirable and sudden operation if the system were switched to manual
operation and back. Resetting the integrator eliminates this windup.
NOTE: In the PowerFlex 70, once the drive has reached the
programmable positive and negative PI limits, the integrator stops
integrating and no further “windup” is possible.
3. [PI Status] parameter is a set of bits that indicate the status of the process PI
controller
• Enabled – The loop is active and controlling the drive output.
• Hold – A signal has been issued and the integrator is being held at its
current value.
• Reset – A signal has been issued and the integrator is being held at zero.
• In Limit – The loop output is being clamped at the value set in [PI Upper/
Lower Limit].
PI Reference and Feedback
The selection of the source for the reference signal is entered in the PI Reference
Select parameter. The selection of the source for the feedback signal is selected in
the PI Feedback Select parameter. The reference and feedback have the same
limit of possible options.
PowerFlex 70 options include DPI adapter ports, MOP, preset speeds, analog
inputs and PI setpoint parameter. In the PowerFlex 700, options are expanded to
also include additional analog inputs, pulse input, and encoder input.
The value used for reference is displayed in PI Reference as a read only parameter.
The value used for feedback is displayed in PI Feedback as a read only parameter.
These displays are active independent of PI Enabled. Full scale is displayed as
±100.00.
Refer to Analog Input Configuration on page 19.
Vector
PI Reference Scaling
The PI reference can be scaled by using [PI Reference Hi] and [PI Reference Lo].
[PI Reference Hi] determines the high value, in percent, for the PI reference. [PI
Reference Lo] determines the low value, in percent, for the PI reference.
The PI feedback can be scaled by using [PI Feedback Hi] and [PI Feedback Lo].
[PI Feedback Hi] determines the high value, in percent, for the PI feedback. [PI
Feedback Lo] determines the low value, in percent, for the PI feedback.
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143
Process PI Loop
Configuration Example:
The PI reference meter and PI feedback meter should be displayed as positive and
negative values. Feedback from our dancer comes into Analog Input 2 as a 0-10V
DC signal.
•
•
•
•
•
•
•
•
•
[PI Reference Sel] = 0 “PI Setpoint”
[PI Setpoint] = 0 %
[PI Feedback Sel] = 2 “Analog In 2”
[PI Reference Hi] = 100 %
[PI Reference Lo] = –100 %
[PI Feedback Hi] = 100 %
[PI Feedback Lo] = –100 %
[Analog In 2 Hi] = 10V
[Analog In 2 Lo] = 0V
PI Feedback Scaling
[Torque Ref A Sel] = “Analog In 1”
[Analog In 2 Hi]
[PI Feedback Hi]
10 V
100 %
[Analog In 1 Lo]
[PI Feedback Lo]
0V
-100 %
Now 5V corresponds to 0% on the PI Feedback, so we will try to maintain a PI
setpoint of 0% (5V). Now [PI Ref Meter] and [PI Fdback Meter] are displayed as
bipolar values.
PI Setpoint
This parameter can be used as an internal value for the setpoint or reference for
the process. If [PI Reference Sel] points to this Parameter, the value entered here
will become the equilibrium point for the process.
PI Output
The PI Error is then sent to the Proportional and Integral functions, which are
summed together.
PI Gains
The PI Proportional Gain and the PI Integral Gain parameters determine the
response of the PI.
The PI Proportional Gain is unitless and defaults to 1.00 for unit gain. With PI
Proportional Gain set to 1.00 and PI Error at 1.00% the PI output will be 1.00%
of maximum frequency.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Process PI Loop
The PI Integral Gain is entered in seconds. If the PI Integral Gain is set to 2.0
seconds and PI Error is 100.00% the PI output will integrate from 0 to 100.00%
in 2.0 seconds.
Positive and Negative Limits
The PI has parameters to define the positive and negative limits of the output PI
Positive Limit, and PI Negative Limit. The limits are used in two places; on the
integrator and on the sum of the Kp + Ki terms.
Providing an external source doesn't turn on Hold, the integrator is allowed to
integrate all the way to Positive or Negative limit. If the integrator reaches the
limit the value is clamped and the InLimit bit is set in the PI Status parameter to
indicate this condition.
The limits are entered in the range of ±100.00.
PI Positive Limit must always be greater than PI Negative Limit.
If the application is Process Control, typically these limits would be set to the
maximum allowable frequency setting. This allows the PI regulator to control
over the entire required speed range.
If the application is Process Trim, large trim corrections may not be desirable and
the limits would be programmed for smaller values.
PI PosLmt
PI NegLmt
PI Kp
+
PI Error
PI Output
*
+
PI_Status
.Hold
*
+
+
In Limit
PI Ki
-1
Z
Output Scaling
The output value produced by the PI is displayed as ±100.00. Internally this is
represented by ±32767 which corresponds to ±maximum frequency.
Vector
FV
Output Scaling for Torque Trim
The output value from the Process PI loop, when in torque trim mode, is
displayed as +/–100% which corresponds to +/–100% of rated motor torque.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
145
Process PI Loop
Figure 29 Process PI Block Diagram
PI_Config
.ZeroClamp
PI_Config
.Exclusive
PI_Status
.Enabled
Linear Ramp
& S-Curve
Spd Ref
+
+32K
+
-32K
Spd Cmd
Spd Ramp
PI Pos Limit
+32K
PI Neg Limit
0
0
PI Kp
PI ExcessErr
abs
*(PI Ref Sel)
PI Ref
Linear
Ramp
PI Cmd
+
≥
≥0
PI XS Error
-
PI Output
*
-
PI_Status
.Enabled
Zclamped
+
PI Error
+
+
*
+
PI_Config
.RampCmd
In Limit
-1
z
0
*(PI Fbk Sel)
PI Fbk
PI_Config
.Sqrt
PI_Config
.Invert
PI Ki
PI_Status
.Hold
Preload Value
Spd Cmd
Spd Cmd
PI_Config
.PreloadCmd
PI_Config
.Exclusive
PI_Status
.Enabled
Current Limit
or Volt Limit
146
-32K
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Process PI Loop
Figure 30 Vector Control Option Process PI Loop Overview
PI Ref Hi
PI
Reference
Sel
126
PI Configuration
124 1
460
PI Ref
135
Hi/Lo
Scale
PI Configuration
PI
Feedback
Select
128
3
124
461
PI Fdbk Hi
462
Linear
Ramp
PI Ref Lo
PI
Config
0
124
5
PI Cmd
PI Error
137
Limit
PI Status
134 4
Ki
PI Integral Time
PI Fdbk
In Limit
124
PI Configuration
124 2
136
Limit
Hold
129
PI Configuration 7
Anti-Windup
Ramp
Ref
132
Kp
PI Status
134 1
Invert
Enable
Hi/Lo
PI Upper Limit
131
PI Prop Gain
130
139
PI BW
Filter
PI Status
134 0
PI Lower Limit
Z
-1
PI Status
134 0
Scale
Fdbk
Sqrt
463
PI Configuration
124 0
Preload Value
Current or
Voltage
Enable
Speed Cmd
Preload
PI Fdbk Lo
Exclusive
138
Limit
PI Configuration
PI Status
134
PI Configuration
124
PI Output
Speed Cmd
8
124
PI Configuration
124 4
0
0
Linear
Ramp &
S-Curve
Speed Ref
+32K
Speed Cmd
Speed Ramp
–32K
+32K
Enable
Zero
Clamp
Exclusive
Torque Ref B Mult
434
Torque
Ref B Sel
0
0
–32K
≥0
Scale
431
+800
Torque Cmd
Torque
Trim
–800
Torque
Ref A Sel
1
Scale
427
+800
Zero
Clamp
430
0
0
Torque Ref A Div
≥0
–800
PowerFlex 700 Firmware 3.001 (& later) Enhancements
Process PID Control and Trim enhancements have been included in firmware
version 3.001 (and later) for the PowerFlex 700 Vector Control drive, including:
•
•
•
•
Derivative term added to Process PI controller to create PID
Ability to scale output of PID to a percentage of Speed Reference
Connect scale blocks to the Reference and Feedback selections on PID
Ability to select % of Reference for the Speed Trim function
Derivative Term
The Derivative term has been added to the Process PI. This adds to the flexibility
of the Process control.
459
Vector v3
[PI Deriv Time]
Refer to formula below:
PIOut = KD (Sec) x
dPI Error (%)
dt (Sec)
Default:
0.00 Secs
Min/Max: 0.00/100.00 Secs
0.01 Secs
Units:
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
147
Process PI Loop
For example, winders using torque control rely on PD control not PI control.
Also, [PI BW Filter] is useful in filtering out unwanted signal response in the PID
loop. The filter is a Radians/Second low pass filter.
Percent of Reference
124 [PI Configuration]
124
thru
138
%
of
To Ref
rqu **
An e T
ti rim
Sto -Win *
p d
Fe Mo Up
ed de
Ze bak
ro S
Ra Cla qrt
m m
Pre p Re p
lo f
Inv ad M
e
o
Ex rt Er de
cl ror
Mo
de
Sets configuration of the PI regulator.
1 =Enabled
0 =Disabled
x =Reserved
x x x x x x 0 0 0 0 0 0 0 0 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
Factory Default Bit Values
* Vector Control Option Only
** Vector firmware 3.001 & later
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.
Example
% of Ref selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum
Frequency = 130 Hz. 4.3 Hz will be added to the final speed reference.
% of Ref not selected, Speed Reference = 43 Hz, PID Output = 10%, Maximum
Frequency = 130 Hz. 13.0 Hz will be added to the final speed reference.
Scale Blocks with PID
Scale Blocks are now included in the Reference and Feedback selections of the
Process PID controller. This selects the output of the scale block for use as
Reference or Feedback to the Process PID.
126 [PI Reference Sel]
Selects the source of the PI reference.
Default:
0
“PI Setpoint”
Options:
0
1
2
3-6
7
8
9
10
11-1
7
18-2
2
23-2
4
25
26
27
28
“PI Setpoint”
“Analog In 1”
“Analog In 2”
“Reserved”
“Pulse In”
“Encoder”
“MOP Level”
“Master Ref”
“Preset Spd1-7”
“DPI Port 1-5”
“Reserved”
“Scale Block 1” (1)
“Scale Block 2” (1)
“Scale Block 3” (1)
“Scale Block 4” (1)
(1) Vector firmware 3.001 and later.
024
124
thru
138
Trim % of Reference
The Trim function of the drive can be selected as % of Reference or % of
Maximum Frequency.
148
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Reflected Wave
118 [Trim Out Select]
117
119
120
Ad
d
Tri or %
m
*
Tri Ref
m B
Re
fA
Specifies which speed references are to be trimmed.
x x x x x x x x x x x x x 0 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Trimmed/%
0 =Not Trimmed/Add
x =Reserved
* Vector firmware 3.001 & later.
Bit #
Factory Default Bit Values
For example, % selected, Max Frequency = 130, Speed Reference = 22 Hz, Trim
Reference = 20%. 4.4 Hz will be added to the Speed Reference.
% not selected, Max Frequency = 130, Speed Reference = 22 Hz, Trim Reference
= 20%. 26 Hz will be added to the Speed Reference.
Reflected Wave
[Compensation]
The pulses from a Pulse Width Modulation (PWM) inverter using IGBTs are
very short in duration (50 nanoseconds to 1 millisecond). These short pulse
times combined with the fast rise times (50 to 400 nanoseconds) of the IGBT,
will result in excessive over-voltage transients at the motor.
Voltages in excess of twice the DC bus voltage (650V DC nominal at 480V
input) will occur at the motor and can cause motor winding failure.
The patented reflected wave correction software in the PowerFlex 70/700 will
reduce these over-voltage transients from a VFD to the motor. The correction
software modifies the PWM modulator to prevent PWM pulses less than a
minimum time from being applied to the motor. The minimum time between
PWM pulses is 10 microseconds. The modifications to the PWM modulator
limit the over-voltage transient to 2.25 per unit volts line-to-line peak at 600 feet
of cable.
400 V Line = 540V DC bus x 2.25 = 1215V
480 V Line = 650V DC bus x 2.25 = 1463V
600 V Line = 810V DC bus x 2.25 = 1823 V
The software is standard and requires no special parameters or settings.
500
V/div
Inverter
<Tα
0
1670 Vpk
Motor
500
V/div
0
0
5
10
15
20
25
30
35
40
45
50
Time (µsec)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
149
Reflected Wave
The above figure shows the inverter line-to-line output voltage (top trace) and
the motor line-to-line voltage (bottom trace) for a 10 HP, 460V AC inverter, and
an unloaded 10 HP AC induction motor at 60 Hz operation. 500 ft. of #12
AWG cable connects the drive to the motor.
Initially, the cable is in a fully charged condition. A transient disturbance occurs
by discharging the cable for approximately 4ms. The propagation delay between
the inverter terminals and motor terminals is approximately 1ms. The small time
between pulses of 4ms does not provide sufficient time to allow the decay of the
cable transient. Thus, the second pulse arrives at a point in the motor terminal
voltage's natural response and excites a motor over-voltage transient greater than
2 pu. The amplitude of the double pulsed motor over-voltage is determined by a
number of variables. These include the damping characteristics of the cable, bus
voltage, and the time between pulses, the carrier frequency, modulation
technique, and duty cycle.
The plot below shows the per unit motor overvoltage as a function of cable
length. This is for no correction versus the modulation correction code for varied
lengths of #12 AWG cable to 600 feet for 4 and 8 kHz carrier frequencies. The
output line-to-line voltage was measured at the motor terminals in 100 feet
increments.
No Correction vs Correction Method at 4 kHz and 8 kHz Carrier
Frequencies - Vbus = 650, fe = 60 Hz
2.6
No Correction 4 kHz Carrier
Corrected 4 kHz Carrier
No Correction 8 kHz Carrier
Corrected 8 kHz Carrier
2.5
per Unit Vout/Vbus
2.4
2.3
2.2
2.1
2
1.9
1.8
1.7
1.6
0
100
200
300
400
Cable Length (Feet)
500
600
Without the correction, the overvoltage increases to unsafe levels with increasing
cable length for both carrier frequencies.
The patented modulation correction code reduces the overvoltage for both
carrier frequencies and maintains a relatively flat overvoltage level for increasing
cable lengths beyond 300 feet.
To determine the maximum recommended motor cable lengths for a particular
drive refer to Cable, Motor Lengths on page 61.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Regen Power Limit
Regen Power Limit
Vector FV The [Regen Power Lim] is programmed as a percentage of the
rated power. The mechanical energy that is transformed into electrical power
during a deceleration or overhauling load condition is clamped at this level.
Without the proper limit, a bus overvoltage may occur.
When using the bus regulator [Regen Power Lim] can be left at factory default, –
50%. When using dynamic braking or a regenerative supply, [Regen Power Lim]
can be set to the most negative limit possible (–800%). When the user has
dynamic braking or regenerative supply, but wishes to limit the power to the
dynamic brake or regenerative supply, [Regen Power Lim] can be set to a level
specified by the user.
Reset Meters
The Elapsed kW Hour meter and/or Elapsed Time meter parameters are reset
when parameter 200 is set to a value not equal to zero. After the reset has
occurred, this parameter automatically returns to a value of zero.
200 [Reset Meters]
Resets selected meters to zero.
Default:
0
“Ready”
Options:
0
1
2
“Ready”
“MWh”
“Elapsed Time”
0 = Ready
1 = Reset kW Hour Meter
2 = Reset Elapsed Time Meter
Reset Run
Refer to Auto Restart (Reset/Run) on page 38.
RFI Filter Grounding
Refer to “Wiring and Grounding Guidelines for PWM AC Drives,” publication
DRIVES-IN001.
S Curve
The S Curve function of the PowerFlex family of drives allows control of the
“jerk” component of acceleration and deceleration through user adjustment of
the S Curve parameter. Jerk is the rate of change of acceleration and controls the
transition from steady state speed to acceleration or deceleration and vice versa.
By adjusting the percentage of S Curve applied to the normal accel/decel ramps,
the ramp takes the shape of an “S”. This allows a smoother transition that
produces less mechanical stress and smoother control for light loads.
Linear Accel & Decel
Acceleration is defined as moving away from zero; deceleration is defined as
moving toward zero. The linear acc / dec ramp is active when the S curve% is set
to zero. The accel time and maximum frequency determine the ramp rate for
speed increases while decel time and maximum frequency determine the ramp
rate for speed decreases. Separate times can be set for accel and decel. In addition,
a second set of accel and decel times is available. In this example Ta = 1.0 sec, Td
= 2.0 sec and Maximum Frequency is set to 60.0 Hz.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
151
S Curve
80.0
60.0
40.0
Hz
20.0
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Seconds
S-Curve Selection
S-curve is enabled by defining the time to extend the acceleration and
deceleration. The time is entered as a percentage of acceleration and deceleration
time. In this case acceleration time is 2.0 seconds. The line on the left has s-curve
set to 0%. The other lines show 25%, 50%, and 100% S-curve. At 25% S-curve
acceleration time is extended by 0.5 seconds (2.0 * 25%). Note that the linear
portion of this line has the same slope as when s-curve is set to zero.
70.0
60.0
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
Seconds
The acceleration and deceleration times are independent but the same S-curve
percentage is applied to both of them. With S-curve set to 50%, acceleration time
is extended by 0.5 seconds (1.0 * 50%), and deceleration time is extended by 1.0
seconds (2.0 * 50%).
70.0
60.0
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
1.0
2.0
3.0
Seconds
152
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
4.0
5.0
6.0
S Curve
Time to Max Speed
Note that S-curve time is defined for accelerating from 0 to maximum speed.
With maximum speed = 60 Hz, Ta = 2.0 sec, and S-curve = 25%, acceleration
time is extended by 0.5 seconds (2.0 * 25%). When accelerating to only 30 Hz the
acceleration time is still extended by the same amount of time.
70.0
60.0
50.0
Hz
40.0
30.0
20.0
10.0
0.0
0.0
0.5
1.0
1.5
Seconds
2.0
2.5
3.0
Crossing Zero Speed
When the commanded frequency passes through zero the frequency will S-curve
to zero and then S-curve to the commanded frequency.
80.0
60.0
40.0
20.0
Hz
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
4.0
5.0
Seconds
The following graph shows an acceleration time of 1.0 second. After 0.75
seconds, the acceleration time is changed to 6.0 seconds. When the acceleration
rate is changed, the commanded rate is reduced to match the requested rate based
on the initial S-curve calculation. After reaching the new acceleration rate, the
S-curve is then changed to be a function of the new acceleration rate.
70.0
60.0
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
1.0
2.0
3.0
4.0
5.0
Seconds
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153
Scale Blocks
Scale Blocks
See also Analog Scaling on page 22 and page 32.
Vector
Scale blocks are used to scale a parameter value. [Scalex In Value] is
linked to the parameter that you wish to scale. [Scalex In Hi] determines the high
value for the input to the scale block. [Scalex Out Hi] determines the
corresponding high value for the output of the scale block. [Scalex In Lo]
determines the low value for the input to the scale block. [Scalex Out Lo]
determines the corresponding low value for the output of the scale block. [Scalex
Out Value] is the resulting output of the scale block.
There are (3) ways to use the output of the scale block:
1. A linkable destination parameter can be linked to [Scalex Out Value]. See
Example Configuration #1.
2. [Analog Outx Sel] can be set to:
– 20, “Scale Block1”
– 21, “Scale Block2”
– 22, “Scale Block3”
– 23, “Scale Block4”
Note that when the Analog Outputs are set to use the scale blocks, the [Scale x
Out Hi] and [Scale x Out Lo] parameters are not active. Instead, [Analog
Outx Hi] and [Analog Outx Lo] determine the scaling for the output of the
scale block. See Example Configuration #2.
3. [PI Reference Sel] and [PI Feedback Sel] can also use the output of the scale
block by setting them to:
– 25, “Scale Block1 Out”
– 26, “Scale Block2 Out”
Note that when [PI Reference Sel] and [PI Feedback Sel] are set to use the
scale blocks, the [Scale x Out Hi] and [Scale x Out Lo] parameters are not
active. Instead, [PI Reference Hi] and [PI Reference Lo], or [PI Feedback Hi]
and [PI Feedback Lo], determine the scaling for the output of the scale block.
See Example Configuration #3.
Example Configuration #1
RP
=8
00
400
R
pd
pd =
4
00
=
pd
dS
dS
dS
6
Cm
40
60
Cm
8
M
M
PM
10
Cm
Scale1 In Value =
Analog In2 Val (Volts)
Use the scale blocks to add a speed trim as a percentage of the speed reference
instead of as a percent of full speed. Analog In 2 will be used to provide a 0-10V
DC trim signal. For example, when the commanded speed is 800 RPM, the
maximum trim with 10V DC at Analog In 2 will be 80 RPM. If the commanded
speed is 1800 RPM the maximum trim will be 180 RPM.
RP
12
Cm
pd
dS
80 0
=1
RPM
2
0
0
20
80 100 120 140 180
Preset Speed 1 (RPM)
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Scale Blocks
Parameter Settings
Parameter
[Trim In Select]
[Scale1 In Hi]
[Scale1 In Lo]
[Scale1 Out Lo]
[Scale2 In Hi]
[Scale2 In Lo]
[Scale2 Out Hi]
[Scale2 Out Lo]
Value
11, Preset 1
10.0 V
0V
0 RPM
1800 RPM
0 RPM
180 RPM
0 RPM
Description
Preset 1 becomes the trim speed
Hi value of Analog In 2
Lo value of Analog In 2
Lo value of desired Trim
Hi value of Commanded Speed (Max Speed)
Lo value of Commanded Speed
10% of Max Speed
Corresponds to lo value of Commanded Speed
Destination Parameter
[Scale1 In Value]
[Scale2 In Value]
[Scale1 Out Hi]
Source Parameter
[Analog In2 Value]
[Commanded Speed]
[Scale2 Out Value]
[Preset Speed 1]
[Scale 1 Out Value]
Description
We are scaling Analog In 2 for our trim
Use Commanded Speed as Input to Scale Block 2
Use the output of Scale Block 2 to set the upper limit of Scale
Block 1 output
Use the scaled analog input as the trim reference into Preset
Speed 1
Parameter Links
Commanded Speed
2
Analog In2 Value
2
483
Scale2 In Hi
Scale2 Out Hi
485
482
Scale2 In Value
Scale2 Out
Value
487
484
Scale2 In Lo
Scale2 Out Lo
486
477
Scale1 In Hi
Scale1 Out Hi
479
476
Scale1 In Value
Scale1 Out
Value
481
478
Scale1 In Lo
Scale1 Out Lo
480
= Link
Preset Speed 1
101
Example Configuration #2
Scale1 In Value =
Encoder Speed (RPM)
Setup a scale block to send parameter 415, [Encoder Speed] to Analog Output 1
as a 0-10V signal.
1800
1500
1200
900
600
300
0
0
1
2
3
4
5
6
7
8
9 10
Analog Out1 Value (Volts)
Parameter Settings
Parameter
[Analog Out1 Sel]
[Analog Out1 Hi]
[Analog Out1 Lo]
[Scale1 In Hi]
[Scale1 In Lo]
Value
Scale Block1 Out
10 V
0V
1800 RPM
0 RPM
Description
Scale Block1 Output goes to Analog Out1
Hi value of Analog Output 1 corresponding to Hi value of encoder speed
Lo value of Analog Output 1 corresponding to Lo value of encoder speed
Hi value of the encoder speed
Lo value of the encoder speed
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155
Scale Blocks
Parameter Links
Destination Parameter
[Scale1 In Value]
Encoder Speed
415
Source Parameter
[Encoder Speed]
477
Scale1 In Hi
476
Scale1 In Value
478
Scale1 In Lo
Description
We are scaling Encoder Speed
Analog Out1 Hi
343
Scale1 Out
Value
481
Analog Out1 Lo
344
= Link
Analog Out1
Example Configuration #3
Scale1 In Value =
Analog In2 Value (Volts)
In this configuration Analog In 2 is a –10V to +10V signal which corresponds to
–800% to +800% motor torque from another drive. We want to use the –200%
to +200% range (–2.5V to +2.5V) of that motor torque and correspond it to –
100% to +100% of the PI Reference.
2.5
1.5
0.5
-0.5
-1.5
-2.5
-100 -80 -60 -40 -20 0 20 40 60 80 100
PI Reference
Parameter Settings
Parameter
[Scale 1 In Hi]
[Scale 1 In Lo]
[PI Reference Sel]
[PI Reference Hi]
[PI Reference Lo]
Value
2.5 V
–2.5V
25, Scale Block1 Out
100 %
–100 %
Description
2.5 V = 200% torque from other drive
–2.5 V = –200% torque from other drive
The PI Reference becomes the output of the scale block
100% PI Reference corresponds to 200% torque from other drive
–100% PI Reference corresponds to –200% torque from other drive
Parameter Links
Destination Parameter
[Scale1 In Value]
Analog In2 Value
2
156
Source Parameter
[Analog In2 Value]
477
Scale1 In Hi
476
Scale1 In Value
478
Scale1 In Lo
Description
We are scaling Analog In 2 value
PI Reference Hi
460
Scale1 Out
Value
481
PI Reference Lo
461
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
= Link
PI Reference
Shear Pin Fault
This feature allows the user to select programming that will fault the drive if the
drive output current exceeds the programmed current limit. As a default,
exceeding the set current limit is not a fault condition. However, if the user wants
to stop the process in the event of excess current, the Shear Pin feature can be
activated. By programming the drive current limit value and enabling the
electronic shear pin, current to the motor is limited, and if excess current is
demanded by the motor, the drive will fault.
Configuration
The Shear Pin Fault is activated by setting Bit 4 of [Fault Config 1] to “1.”
238 [Fault Config 1]
Ou
t
Sh Phas
ea eL
rPN os
oA s*
cc
Lo
ad
*
In Los
Ph s
Mo ase *
to Lo
De r Th ss *
ce erm
Au l Inh *
tR ib
Sh st Tr t
ea ie
Mo r Pi s
tor n
Ov
erL
Un
d
de
Po rVo
we lta
r L ge
os
s
Enables/disables annunciation of the listed faults.
1 =Enabled
0 =Disabled
x =Reserved
x x x 0 0 x 0 0 0 1 0 0 1 x 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
Factory Default Bit Values
* Vector firmware 3.001 & later
The programmable current limit [Current Lmt Sel] should also set to identify
the source of the current limit value. If “Cur Lim Val” is selected, then [Current
Lmt Val] should be set to the required limit value.
DYNAMIC CONTROL
Shear Pin Fault
147 [Current Lmt Sel]
Default:
0
“Cur Lim Val”
Selects the source for the adjustment of
Options:
current limit (i.e. parameter, analog input,
etc.).
0
1
2
“Cur Lim Val”
“Analog In 1”
“Analog In 2”
146
149
A separate fault (Shear Pin Fault, F63) dedicated to the Shear Pin feature, will be
generated if the function is activated.
Application Example
In some applications, mechanical hardware can be damaged if the motor is
allowed to develop excess torque. If a mechanical jam should occur, shutting
down the system may be the only way to prevent damage. For example, a chain
conveyor may be able to “hook” itself, causing a jam on the conveyor. Excess
torque from the motor could cause chain or other mechanical damage.
By programming the Shear Pin feature, the user can cause the drive to fault,
stopping the excess torque before mechanical damage occurs.
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157
Skip Frequency
Skip Frequency
Figure 31 Skip Frequency
Frequency
Command
Frequency
Drive Output
Frequency
(A)
(A)
Skip + 1/2 Band
35 Hz
Skip Frequency
30 Hz
Skip – 1/2 Band
(B)
25 Hz
(B)
Time
Some machinery may have a resonant operating frequency that must be avoided
to minimize the risk of equipment damage. To assure that the motor cannot
continuously operate at one or more of the points, skip frequencies are used.
Parameters 084-086, ([Skip Frequency 1-3]) are available to set the frequencies to
be avoided.
The value programmed into the skip frequency parameters sets the center point
for an entire “skip band” of frequencies. The width of the band (range of
frequency around the center point) is determined by parameter 87, [Skip Freq
Band]. The range is split, half above and half below the skip frequency parameter.
If the commanded frequency of the drive is greater than or equal to the skip
(center) frequency and less than or equal to the high value of the band (skip plus
1/2 band), the drive will set the output frequency to the high value of the band.
See (A) in Figure 31.
If the commanded frequency is less than the skip (center) frequency and greater
than or equal to the low value of the band (skip minus 1/2 band), the drive will
set the output frequency to the low value of the band. See (C) in Figure 31.
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Skip Frequency
Skip Frequency Examples
The skip frequency will have hysteresis
so the output does not toggle between
high and low values. Three distinct
bands can be programmed. If none of
the skip bands touch or overlap, each
band has its own high/low limit.
Max. Frequency
Skip Frequency 1
Skip Band 1
Skip Frequency 2
Skip Band 2
0 Hz
If skip bands overlap or touch, the
center frequency is recalculated based
on the highest and lowest band values.
400 Hz.
Skip Frequency 1
Skip Frequency 2
Adjusted
Skip Band
w/Recalculated
Skip Frequency
0 Hz
If a skip band(s) extend beyond the max
frequency limits, the highest band
value will be clamped at the max
frequency limit. The center frequency is
recalculated based on the highest and
lowest band values.
400 Hz.
Max.Frequency
Skip
Adjusted
Skip Band
w/Recalculated
Skip Frequency
0 Hz
If the band is outside the limits, the skip
band is inactive.
400 Hz.
Skip Frequency 1
Inactive
Skip Band
60 Hz. Max.
Frequency
0 Hz
Acceleration and deceleration are not affected by the skip frequencies. Normal
accel/decel will proceed through the band once the commanded frequency is
greater than the skip frequency. See (A) & (B) in Figure 31. This function affects
only continuous operation within the band.
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159
Sleep Mode
Sleep Mode
Operation
The basic operation of the Sleep-Wake function is to Start (wake) the drive when
an analog signal is greater than or equal to the user specified [Wake Level], and
Stop (sleep) the drive when an analog signal is less than or equal to the user
specified [Sleep Level]. Setting [Sleep-Wake Mode] to “Direct” enables the sleep
wake function.
Requirements
In addition to enabling the sleep function with [Sleep-Wake Mode], at least one
of the following assignments must be made to a digital input: Enable, Stop-CF,
Run, Run Fwd or Run Rev, and the input must be closed. All normal Start
Permissives must also be satisfied (Not Stop, Enable, Not Fault, Not Alarm, etc.).
Conditions to Start/Restart
!
ATTENTION: Enabling the Sleep-Wake function can cause
unexpected machine operation during the Wake mode. Equipment
damage and/or personal injury can result if this parameter is used in an
inappropriate application. Do Not use this function without
considering the table below and applicable local, national &
international codes, standards, regulations or industry guidelines.
Table 16 Conditions Required to Start Drive (1)(2)(3)
Input
After Power-Up
Stop
Stop Closed
Wake Signal
Enable
Enable Closed
Wake Signal (4)
Run
Run For.
Run Rev.
Run Closed
Wake Signal
After a Drive Fault
Reset by Stop-CF,
HIM or TB
Stop Closed
Wake Signal
New Start or Run Cmd.(4)
Enable Closed
Wake Signal
New Start or Run Cmd.(4)
New Run Cmd.(5)
Wake Signal
Reset by Clear
Faults (TB)
Stop Closed
Wake Signal
Enable Closed
Wake Signal
Run Closed
Wake Signal
After a Stop Command
HIM or TB
Stop Closed
Analog Sig. > Sleep Level (6)
New Start or Run Cmd.(4)
Enable Closed
Analog Sig. > Sleep Level (6)
New Start or Run Cmd.(4)
New Run Cmd.(5)
Wake Signal
(1) When power is cycled, if all conditions are present after power is restored, restart will occur.
(2) If all conditions are present when [Sleep-Wake Mode] is “enabled,” the drive will start.
(3) The active speed reference is determined as explained in the User Manual. The Sleep/Wake function and the
speed reference may be assigned to the same input.
(4) Command must be issued from HIM, TB or network.
(5) Run Command must be cycled.
(6) Signal does not need to be greater than wake level.
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Sleep Mode
Timers
Timers will determine the length of time required for Sleep/Wake levels to
produce true functions. These timers will start counting when the Sleep/Wake
levels are satisfied and will count in the opposite direction whenever the
respective level is dissatisfied. 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 power up, 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 to this, which
will ignore the Sleep/Wake function:
1. When a device is commanding “local” control
2. When a jog command is being issued.
When a device is commanding “local” control, the port that is commanding it has
exclusive start control (in addition to ref select), essentially overriding the Sleep/
Wake function, and allowing the drive to run in the presence of a sleep situation.
This holds true even for the case of Port 0, where a digital input start or run will
be able to override a sleep situation.
Sleep/Wake Levels
Normal operation will require that [Wake Level] be set greater than or equal to
[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 [Sleep Level] is made
greater than [Wake Level] while the drive is running, the drive will continue to
run as long as the analog input remains at a level that doesn’t trigger the sleep
condition. Once the drive goes to sleep in this situation, it will not be allowed to
restart until the level settings are corrected (increase wake, or decrease sleep). If
however, the levels are corrected prior to the drive going to sleep, normal Sleep/
Wake operation will continue.
Sleep/Wake Sources
All defined analog inputs for a product shall be considered as valid Sleep/Wake
sources. The Sleep/Wake function is completely independent of any other
functions that are also using the assigned analog input. Thus, using the same
analog input for both speed reference and wake control is permitted. Also,
[Analog In x Hi] and [Analog In x Lo] parameters have no affect on the function.
However, the factory calibrated result will be used. In addition, the absolute value
of the calibrated result will be used, thus making the function useful for bipolar
direction applications. The analog in loss function is unaffected and therefore
operational with the Sleep/Wake function, but not tied to the sleep or wake
levels.
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Speed Control, Mode, Regulation & Vector Speed Feedback
Figure 32 Sleep/Wake Function
Drive
Run
Sleep-Wake
Function
Wake Up
Go to Sleep
Start
Stop
Sleep Timer
Satisfied
Sleep Level
Satisfied
Wake Timer
Satisfied
Wake
Time
Wake Level
Satisfied
Sleep
Time
Wake
Time
Sleep
Time
Wake Level
Sleep Level
Example Conditions
Wake Time = 3 Seconds
Sleep Time = 3 Seconds
Analog Signal
Speed Control, Mode,
Regulation & Vector
Speed Feedback
The purpose of speed regulation is to allow the drive to adjust certain operating
conditions, such as output frequency, to compensate for actual motor speed losses
in an attempt to maintain motor shaft speed within the specified regulation
percentage.
The [Speed Mode] parameter selects the speed regulation method for the drive,
and can be set to one of 3 choices on the PowerFlex 70/700. The PowerFlex 700
Vector option has 5 choices. In addition, [Feedback Select] in the Vector option,
chooses the feedback used for the speed regulator.
• Open Loop - No speed control is offered
• Slip Comp - Slip Compensation is active – approximately 5% regulation
• Process PI - The PI Loop sets the actual speed based on process variables
080
Standard
[Speed Mode]
Sets the method of speed regulation.
Vector
[Feedback Select]
Default:
0
“Open Loop”
Options:
0
1
2
0
“Open Loop”
“Slip Comp”
“Process PI”
“Open Loop”
0
1
2
3
4
5
“Open Loop”
“Slip Comp”
“Reserved”
“Encoder”
“Reserved”
“Simulator”
Default:
Options:
Selects the source for motor speed feedback. Note
that all selections are available when using Process PI.
“Open Loop” (0) - no encoder is present, and slip
compensation is not needed.
“Slip Comp” (1) - tight speed control is needed, and
encoder is not present.
“Encoder” (3) - an encoder is present.
“Simulator” (5) - Simulates a motor for testing drive
operation & interface check.
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Speed Control, Mode, Regulation & Vector Speed Feedback
Open Loop
As the load on an induction motor increases, the rotor speed or shaft speed of the
motor decreases, creating additional slip (and therefore torque) to drive the larger
load. This decrease in motor speed may have adverse effects on the process. If the
[Speed Mode] parameter is set to “Open Loop,” no speed control will be
exercised. Motor speed will be dependent on load changes and the drive will
make no attempt to correct for increasing or decreasing output frequency due to
load.
Slip Compensation
As the load on an induction motor increases, the rotor speed or shaft speed of the
motor decreases, creating additional slip (and therefore torque) to drive the larger
load. This decrease in motor speed may have adverse effects on the process. If
speed control is required to maintain proper process control, the slip
compensation feature of the PowerFlex drives can be enabled by the user to more
accurately regulate the speed of the motor without additional speed transducers.
When the slip compensation mode is selected, the drive calculates an amount to
increase the output frequency to maintain a consistent motor speed independent
of load. The amount of slip compensation to provide is selected in [Slip RPM @
FLA]. During drive commissioning this parameter is set to the RPM that the
motor will slip when operating with Full Load Amps. The user may adjust this
parameter to provide more or less slip.
As mentioned above, induction motors exhibit slip which is the difference
between the stator electrical frequency, or output frequency of the drive, and the
induced rotor frequency.
The slip frequency translates into a slip speed resulting in a reduction in rotor
speed as the load increases on the motor. This can be easily seen by examining
Figure 33.
Rotor Speed
Figure 33 Rotor Speed with/without Slip Compensation
Slip Compensation
Inactive
Slip Compensation
Active
Load
Applied
Load
Applied
No Load
1.5 p.u. Load
1.0 p.u. Load
0.5 p.u. Load
0.5 p.u. Load
1.0 p.u. Load
1.5 p.u. Load
Slip Compensation
Active
Load
Removed
Slip @
F.L.A.
0
0
Time
Without slip compensation active, as the load increases from no load to 150% of
the motor rating, the rotor speed decreases approximately proportional to the
load.
With slip compensation, the correct amount of slip compensation is added to the
drive output frequency based on motor load. Thus, the rotor speed returns to the
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Speed Control, Mode, Regulation & Vector Speed Feedback
original speed. Conversely, when the load is removed, the rotor speed increases
momentarily until the slip compensation decays to zero.
Motor nameplate data must be entered by the user in order for the drive to
correctly calculate the proper amount of slip compensation. The motor
nameplate reflects slip in the rated speed value at rated load. The user can enter
the Motor Nameplate RPM, Motor Nameplate Frequency, the Motor Nameplate
Current, Motor Nameplate Voltage, and Motor Nameplate HP/kW and during
commissioning the drive calculates the motor rated slip frequency and displays it
in [Slip RPM @ FLA]. The user can adjust the slip compensation for more
accurate speed regulation, by increasing or decreasing [Slip RPM @ FLA] value.
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 auto tune 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). The effect of slip compensation during transient
operation is illustrated in Figure 34. Initially, the motor is operating at some
speed and no load. At some time later, an impact load is applied to the motor and
the rotor speed decreases as a function of load and inertia. And finally, the impact
load is removed and the rotor speed increases momentarily until the slip
compensation is reduced based on the applied load.
When slip compensation is enabled the dynamic speed accuracy is dependent on
the filtering applied to the torque current. The filtering delays the speed response
of the motor/drive to the impact load and reduces the dynamic speed accuracy.
Reducing the amount of filtering applied to the torque current can increase the
dynamic speed accuracy of the system. However, minimizing the amount of
filtering can result in an unstable motor/drive. The user can adjust the Slip Comp
Gain parameter to decrease or increase the filtering applied to the torque current
and improve the system performance.
Figure 34 Rotor Speed Response Due to Impact Load and Slip Com Gain
Impact Load
Removed
Increasing Slip
Comp Gain
Speed
Impact Load
Applied
Rotor Speed
Increasing Slip
Comp Gain
Reference
0
0
164
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Speed Control, Mode, Regulation & Vector Speed Feedback
Application Example - Baking Line
The diagram below shows a typical application for the Slip Compensation
feature. The PLC controls the frequency reference for all four of the drives. Drive
#1 and Drive #3 control the speed of the belt conveyor. Slip compensation will be
used to maintain the RPM independent of load changes caused by the cutter or
dough feed. By maintaining the required RPM, the baking time remains constant
and therefore the end product is consistent.
With the Slip Compensation feature, the process will only require a new speed
reference when the product is changed. The user will not have to tune the drive
due to a different load characteristic.
Dough Stress
Relief
Cookie Line
CUTTERS
OVEN
5/40
PowerFlex
Drive
PowerFlex
Drive
PowerFlex
Drive
PowerFlex
Drive
#1
#2
#3
#4
Process PI – See Process PI Loop on page 135
Vector
Encoder
There is (1) encoder input on the I/O board of the PowerFlex 700VC. The
encoder input must be line driver type, quadrature (dual channel) or pulse (single
channel). The encoder input accepts 8 or 12V DC encoder signals. There is a
12V DC supply on the drive that can be used to supply power for the encoders.
An encoder offers the best performance for both speed and torque regulation
applications. Encoder feedback is required for applications with high bandwidth
response, tight speed regulation, torque regulation of (+/- 2%) or when the
motor is required to operate at less than 1/120th its’ base speed.
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165
Speed Feedback Filter
[Motor Fdbk Type] selects the type of encoder:
• “Quadrature” – dual channel.
• “Quad Check” – dual channel and detects loss of encoder signal when using
differential inputs.
• “Single Chan” – pulse type, single channel.
• “Single Check” – pulse type, single channel and detects loss of encoder signal
when using differential inputs.
[Encoder PPR] sets the number of encoder pulses per revolution.
[Enc Position Fdbk] displays the raw encoder count. For single channel encoders,
this count will increase (per rev.) by the amount in [Encoder PPR]. For
quadrature encoders this count will increase by 4 times the amount defined in
[Encoder PPR].
Vector
Encoderless/Deadband
Encoderless/Deadband is recommended when more than a 120:1 speed range of
operation is not required and the user will set the speed reference below 0.5Hz/
15 RPM. The deadband will help prevent cogging and unstable motor operation
below a reference of 0.5Hz/15RPM by clamping the speed and torque regulators
to zero.
Vector
Simulator
The simulator mode allows the drive to be operated without a motor connected
and is meant for demo purposes only. If a motor is connected with this mode
selected very erratic and unpredictable operation will occur.
Speed Feedback Filter
Vector
[Fdbk Filter Select] determines the type of filter to use for the speed
feedback. The filter is used to filter out high frequency signals (noise) by
reducing the gain at high frequencies. The selections for the filter are:
Description
No filter
To select this type of filter . . .
Select this value . . .
0
Gain
0 db
Rad/Sec
A light 35/49 radian
feedback filter
1
Gain
0 db
-6 db
35
A heavy 20/40 radian
feedback filter
49
Rad/Sec
2
Gain
0 db
-12 db
20
166
40
Rad/Sec
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Speed Reference
Speed Reference
Operation
The output frequency of the drive is controlled, in part, by the speed command
or speed reference given to it. This reference can come from a variety of sources
including:
•
•
•
•
•
•
•
HIM (local or remote)
Analog Input
Preset Speed Parameter
Jog Speed Parameter
Communications Adapter
Process PI Loop
Digital Input MOP
Selection
Binary Logic
Some references can be selected by binary logic, through digital inputs to the
terminal block or bit manipulation of the Logic Command Word in a
communications adapter. These sources are used when the drive is in “Auto”
mode. The default reference is from the source selected in [Speed Ref A Sel],
parameter 90. This parameter can be set to any one of the 22 choices. If the
binary logic selection is zero, this will be the active speed reference.
Auto/Manual
Many applications require a “manual mode” where adjustments can be made and
setup can be done by taking local control of the drive speed. Typically, these
adjustments would be made via a “local” HIM mounted on the drive. When all
setup is complete, control of the drive frequency command is turned over to
automatic control from a remote source such as a PLC, analog input etc.
The source of the speed reference is switched to one of two “manual” sources
when the drive is put into manual mode:
1. Local HIM
2. Analog Input to terminal block
If the selection is the HIM, then the digital or analog speed control on the HIM
provides the reference.
If the switch to manual mode was made via a digital input, (parameters 361-366
set to “18, Auto/Manual”) then the source for the reference is defined in [TB
Man Ref Sel], parameter 96. This can be either of the 2 analog inputs or the
digital MOP.
When the drive is returned to automatic mode, the speed reference returns to the
source selected by the binary logic. Also see Auto/Manual on page 36.
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167
Speed Reference
DPI
See the DPI on page 92 for a description of DPI. One of the DPI ports can be
selected as the source of the speed reference.
In the PowerFlex 70, 700, and 700VC the speed reference from DPI is scaled so
that [Maximum Freq] = 32767. [Maximum Freq] is the largest output frequency
that the drive will deliver to the motor.
Additionally, the PowerFlex 70 and 700 drives have a parameter called
[Maximum Speed]. [Maximum Speed] limits the drive speed reference, such as
from a communication network or analog input.
PowerFlex drives contain the following necessary rule:
[Maximum Speed] + [Overspeed Limit] = [Maximum Freq]
[Overspeed Limit] allows the drive to operate above [Maximum Speed] for
certain functions such as bus regulation, current limit (during regeneration), PI
control, and slip compensation. It is important that [Overspeed Limit] is set to
allow enough headroom for the application. For example, let’s assume we have an
application where [Speed Mode] = “Slip Comp”. Slip compensation adds some
frequency to the commanded speed in order to compensate for slip in a loaded
motor. In this case, [Overspeed Limit] should not be set to 0. Otherwise, if the
drive is running with a commanded frequency of 60 Hz and the motor is loaded
at all, slip compensation will add some frequency and we would get a nuisance
“Overspeed” fault.
Defaults are as follows:
• [Maximum Speed] = 60 Hz
• [Overspeed Limit] = 10 Hz
• [Maximum Freq] = 130 Hz (this is default so that users who want to go twice
base speed don't have to change it).
To send out a speed reference to the drive from a controller over RIO, you can
perform the following calculation:
SpeedRef =
CommandFreq
[Maximum Freq]
x 32767
For example, to send out a command frequency of 60 Hz on a PowerFlex 70 or
700 with default settings we would calculate the following:
SpeedRef =
60 Hz
130 Hz
x 32767 = 15123
The following example illustrates how a change in P55 [Maximum Freq] in the
PowerFlex 70 or 700 affects the speed reference scaling:
[Overspeed Limit] = 10 Hz (this is factory default)
[Maximum Speed] = 60 Hz (this is factory default).
[Maximum Freq] = [Maximum Speed] + [Overspeed Limit] = 60 Hz + 10 Hz = 70 Hz.
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Speed Reference
Using the above formula, calculate the Speed Reference sent from a network
using a DPI adapter.
For example, to send out a command frequency of 60 Hz with [Maximum Freq]
= 70 Hz, we would calculate the following:
SpeedRef =
60 Hz
70 Hz
x 32767 = 28086
Jog
When the drive is not running, pressing the HIM Jog button or a programmed
Jog digital input will cause the drive to jog at a separately programmed jog
reference. This speed reference value is entered in [ Jog Speed], parameter 100.
Figure 35 Speed Reference Selection
= Default
Auto Speed Ref Options
Trim
Speed Ref A Sel, Parameter 090
Speed Ref B Sel, Parameter 093
Preset Speed 2, Parameter 102
Preset Speed 3, Parameter 103
Preset Speed 4, Parameter 104
Preset Speed 5, Parameter 105
Preset Speed 6, Parameter 106
Preset Speed 7, Parameter 107
DPI Port Ref 1-6, See Parameter 209
[Digital Inx Select]:
Speed Sel 3 2 1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
PI Exclusive Mode
[PI Configuration]:
Bit 0, Excl Mode = 0
Auto
Speed Adders
PI Output
Slip Compensation
None
Pure Reference
to follower drive for
Frequency Reference
Mod Functions
(Skip, Clamp,
Direction, etc.)
Min/Max Speed
Commanded
Frequency
DPI Command
Manual Speed Ref Options
HIM Requesting Auto/Manual
TB Man Ref Sel, Parameter 096
Jog Speed, Parameter 100
Drive Ref Rslt
Man
Digital Input
Jog Command
Acc/Dec Ramp
and
S Curve
Post Ramp
to follower drive for
Frequency Reference
[Speed Mode]:
2 "Process Pi"
1 "Slip Comp"
0 "Open Loop"
Output Frequency
Scaling
Scaling applies only to references from analog inputs and reference sources
selected in [Speed Ref x Sel], parameters 90/93.
Each analog input has its own set of scale parameters:
• [Analog In x Hi] sets the maximum level on input to be seen (i.e. 10 Volts).
• [Analog In x Lo] sets the minimum level on input to be seen (i.e. 0 Volts).
Each [Speed Ref x Sel] parameter has an additional set of scale parameters:
• [Speed Ref x Hi] selects the reference value for the maximum input specified
in [Analog In x Hi].
• [Speed Ref x Lo] selects the reference value for the minimum input specified
in [Analog In x Lo].
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Speed Reference
For example, if the following parameters are set:
[Analog In x Hi] = 10 V
[Analog In x Lo] = 0 V
[Speed Ref A Hi] = 45 Hz
[Speed Ref x Lo] = 5 Hz
then the speed command for the drive will be linearly scaled between 45 Hz at
maximum analog signal and 5 Hz at minimum analog signal. See additional
examples under Analog Inputs on page 22.
Polarity
The reference can be selected as either unipolar or bipolar. Unipolar is limited to
positive values and supplies only the speed reference. Bipolar supplies both the
speed reference AND the direction command: + signals = forward direction and
– signals = reverse direction.
Trim
If the speed reference is coming from the source specified in [Speed Ref A Sel] or
[Speed Ref B Sel], the a trim signal can be applied to adjust the speed reference by
a programmable amount. The source of the trim signal is made via [Trim In Sel],
parameter 117 and can be any of the sources that are also used as references.
[Trim Out Select], parameter 118 selects which of the references, A/B will be
trimmed.
If the trim source is an analog input, two additional scale parameters are provide
to scale the trim signal.
Figure 36 Trim
Trim Enable Select
A
Trim
B
Both
None
Reference A
Reference B
+
+
Trimmed
Reference A
+
+
Trimmed
Reference B
Min/Max Speed
[Max Speed]
Maximum and minimum speed limits are applied to the reference. These limits
apply to the positive and negative references. The minimum speed limits will
create a band that the drive will not run continuously within, but will ramp
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Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Speed Regulator
through. This is due to the positive and negative minimum speeds. If the
reference is positive and less than the positive minimum, it is set to the positive
minimum. If the reference is negative and greater than negative minimum, it is set
to the negative minimum. If the minimum is not 0, hysteresis is applied at 0 to
prevent bouncing between positive and negative minimums. See below.
Max Spd
Max Spd
Min Spd
Band
Min Spd
– Min Spd
– Max Spd
– Max Spd
Maximum frequency
The maximum frequency defines the maximum reference frequency. The actual
output frequency may be greater as a result of slip compensation and other types
of regulation. This parameter also defines scaling for frequency reference. This is
the frequency that corresponds to 32767 counts when the frequency reference is
provided by a network.
Speed Regulator
Vector FV 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 to adjust the torque reference that
is sent to the motor. This torque reference attempts to operate the motor at the
specified speed. This regulator also produces a high bandwidth response to speed
command and load changes.
Vector
FV
Integral Gain
The integral gain block outputs a torque command relative to the error
integrated over a period of time.
[Ki Speed Loop] sets the integral gain of the speed regulator. Its value is
automatically calculated based on the bandwidth setting in [Speed Desired BW].
Integral gain may be manually adjusted by setting [Speed Desired BW] to a value
of zero. Units are (per unit torque/sec) / (per unit speed). For example, when [Ki
Speed Loop] is 50 and the speed error is 1%, the integral output will integrate
from 0 to 50% motor rated torque in 1 second.
Vector
FV
Proportional Gain
The proportional gain determines how much of a speed error occurs during a
load transient.
[Kp Speed Loop] sets the proportional gain of the speed regulator. Its value is
automatically calculated based on the bandwidth setting in [Speed Desired BW].
Proportional gain may be manually adjusted by setting [Speed Desired BW] to a
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
171
Speed/Torque Select
value of zero. Units are (per unit torque) / (per unit speed). For example, when
[Kp Speed Loop] is 20, the proportional gain block will output 20% motor rated
torque for every 1% error of motor rated speed.
Vector
FV
Feed Forward Gain
The first section of the PI regulator is the feed forward block. [Kf Speed Loop]
allows the speed regulator to be dampened during speed changes. To reduce
speed overshoot, reduce the value of [Kf Speed Loop]. During auto-tune, the
feed forward is left open (no dampening).
Vector
FV
Speed Desired BW
[Speed Desired BW] 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. Adjusting this
parameter will cause the drive to calculate and change [Ki Speed Loop] and [Kp
Speed Loop] gains.
Vector
FV
Total Inertia
[Total Inertia] represents the time in seconds, for a motor coupled to a load to
accelerate from zero to base speed, at rated motor torque. The drive calculates
Total Inertia during the autotune inertia procedure. Adjusting this parameter will
cause the drive to calculate and change [Ki Speed Loop] and [Kp Speed Loop]
gains.
Speed/Torque Select
[Speed/Torque Mod] is used to choose the operating mode for the
drive. The drive can be programmed to operate as a velocity regulator, a torque
regulator, or a combination of the two. Refer to Figure 37.
Vector
FV
Figure 37
Speed/Torque Mod
0
1
Spd Reg PI Out
Scale
428
Ref A Hi
429
Ref A Lo
2
Min
Torque Ref A Sel 427
Torq Ref A Div 430
Torque Ref B Sel 431
Scale
432
Ref B Hi
433
Ref B Lo
3
Max
/
x
Torq Ref B Mult 434
172
88
0
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
4
5
+
+
abs
Min
6
Speed/Torque Select
As shown, [Speed/Torque Mod] (parameter 88) is used to select the mode of
operation. Zero torque current is allowed when set to “0.”
When set to a “1,” the drive/motor is operated in speed mode. The torque
command changes as needed to maintain the desired speed.
A value of “2” selects torque mode. In torque regulation mode, the drive controls
the desired motor torque. The motor speed will be a result of the torque
command and load present at the motor shaft.
Min and Max mode are selected by values 3 and 4, respectively. These two modes
offer a combination of speed and torque operation. The algebraic minimum or
maximum of speed/torque will be the operating point for the Min and Max
modes. The drive will automatically switch from speed to torque mode (or from
torque to speed) based on the dynamics of the motor/load.
The Min mode is typically used with positive torque and forward speed
operation, the minimum of the two being closest to zero. The Max mode is
opposite, typically used with reverse speed and negative torque, the maximum
being the least negative (closest to zero).
Sum mode is selected when set to “5.” This mode allows an external torque
command to be added to the speed regulator output when desired.
Speed Regulation Mode
Operating as a speed regulator is the most common and therefore simplest mode
to setup. Examples of speed regulated applications are blowers, conveyors,
feeders, pumps, saws, and tools.
In a speed regulated application, the torque reference is generated by the speed
regulator output. 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. At transient state, the torque reference will change
dramatically to compensate for a speed change. A short duration change in speed
is the result of increasing or decreasing the load very rapidly.
Torque Regulation Mode
A torque regulated application can be described as any process that requires some
tension control. An example of this is a winder or unwind where material is being
“drawn” or pulled with a specific tension required. The process requires another
element setting the speed. Configuring the drive for torque regulation requires
[Speed/Torque Mod] to be set to “2.” In addition, a reference signal must be
selected (Torque Ref A or Torque Ref B). If an analog signal is used for the
reference, select that from the Torque Ref A or Torque Ref B selections.
When operating in a torque mode, the motor current will be adjusted to achieve
the desired torque. If the material being wound/unwound breaks, the load will
decrease dramatically and the motor can potentially go into a “runaway”
condition.
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173
Speed/Torque Select
Figure 38
Scale
428
Ref A Hi
429
Ref A Lo
Torque Ref A Sel 427
Torq Ref A Div 430
Torque Ref B Sel 431
Scale
432
Ref B Hi
433
Ref B Lo
/
x
+
Torq Ref B Mult 434
Torque Reference:
[Torque Ref A Sel], parameter 427 is scaled by [Torque Ref A Hi] and [Torque
Ref A Lo]. Then divided by [Torq Ref A Div].
[Torque Ref B Sel], parameter 431 is scaled by [Torque Ref B Hi] and [Torque
Ref B Lo]. Then multiplied by [Torq Ref B Mult].
The final torque reference, in the Torque Mode, is the sum of scaled Torque Ref
A and scaled Torque Ref B.
Min Mode/Max Mode
This operating mode compares the speed and torque commands. The
algebraically minimum value is used. This mode can be thought of as a Speed
Limited Adjustable Torque operation. Instead of operating the drive as a pure
torque regulator, the “runaway” condition can be avoided by limiting the speed.
A winder is a good example for the application of the Min Spd/Trq operating
mode. Max mode would be used if both speed and torque are negative.
Figure 39 illustrates how min mode operates. The drive starts out operating as a
torque regulator. The torque reference causes the motor to operate at 308rpm.
The speed reference is 468rpm, so the minimum is to operate as a torque
regulator. While operating in torque regulation, the load decreases and the motor
speeds up. Notice the torque command has not changed. When the speed
regulator comes out of saturation, it clamps the speed and now the drive operates
as a speed regulator. The At Speed Relay then closes.
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Speed/Torque Select
Figure 39
Internal Torque Command
At Speed Relay
Load Step (Decrease)
Speed Feedback
308
RPM
Sum Mode
Configuring the drive in this mode allows an external torque input to be summed
with the torque command generated by the speed regulator. The drive requires
both a speed reference and a torque reference to be linked. This mode can be used
for applications that have precise speed changes with critical time constraints. If
the torque requirement and timing is known for a given speed change, then the
external torque input can be used to preload the integrator. The timing of the
speed change and the application of an external torque command change must be
coordinated for this mode to be useful. The sum mode will then work as a feed
forward to the torque regulator.
Zero Torque Mode
Operation in zero torque mode allows the motor to be fully fluxed and ready to
rotate when a speed command or torque command is given. For a cyclical
application where through put is a high priority this mode can be used. 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 regulate mode can be selected. The drive will then
immediately accelerate the motor without the need for “flux up” time.
Important: Zero Torque may excessively heat the motor if operated in this mode
for extended periods of time. No 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) may be
required.
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175
Speed Units
Speed Units
Vector
[Speed Units] selects the units to be used for all speed related
parameters. The options for [Speed Units] are:
• “Hz” – converts status parameters only to Hz.
• “RPM” – converts status parameters only to RPM.
• “Convert Hz” - converts all speed based parameters to Hz, and changes the
value proportionately (i.e. 1800 RPM = 60 Hz).
• “Convert RPM” - converts all speed based parameters to RPM, and changes
the value proportionately.
Start Inhibits
The [Start Inhibits] parameter indicates the inverted state of all start permissive
conditions. If the bit is on (HI or 1), the corresponding permissive requirement
has not been met and the drive is inhibited from starting. It will be updated
continually, not only when a start attempt is made. See also Start Permissives on
page 176.
Start Permissives
Start permissives are conditions required to permit the drive to start in any mode
– run, jog, auto-tune, etc. When all permissive conditions are met the drive is
considered ready to start. The ready condition is available as the drive ready
status.
Permissive Conditions
1. No faults can be active.
2. No type2 alarms can be active.
3. The TB Enable input (if configured) must be closed.
4. The DC bus precharge logic must indicate it is a start permissive.
5. All Stop inputs must be negated (See special Digital Inputs Stops
Configuration issues below).
6. No configuration changes (parameters being modified) can be in-progress.
If all permissive conditions are met, a valid start, run or jog command will start
the drive. The status of all inhibit conditions, except for item 6 above, are
reflected in the output parameter Start Inhibits. The configuration change
condition is a transient (short-term) condition and not directly user controlled. It
is therefore not reflected in the Start Inhibits parameter.
Note that the Start Inhibits conditions do not include any of the functionality
imposed by the DPI logic such as owners, masks, local control, etc.
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Start-Up
Start-Up
Start-Up Routines
PowerFlex drives offer a variety of Start Up routines to help the user commission
the drive in the easiest manner and the quickest possible time. PowerFlex 70
Drives have the S.M.A.R.T Start routine and a Basic assisted routine for more
complex setups. PowerFlex 700 drives have both of the above plus an advanced
startup routine.
S.M.A.R.T. Start
During a Start Up, the majority of applications require changes to only a few
parameters. The LCD HIM on a PowerFlex 70 drive offers S.M.A.R.T. start,
which displays the most commonly changed parameters. With these parameters,
you can set the following functions:
S - Start Mode and Stop Mode
M - Minimum and Maximum Speed
A - Accel Time 1 and Decel Time 1
R - Reference Source
T - Thermal Motor Overload
To run a S.M.A.R.T. start routine:
Step
1. Press ALT and then Esc (S.M.A.R.T). The S.M.A.R.T.
start screen appears.
2. View and change parameter values as desired. For
HIM information, see Appendix B.
3. Press ALT and then Sel (Exit) to exit the S.M.A.R.T.
start.
Key(s)
Example LCD Displays
ALT
Esc
ALT
Sel
S.M.A.R.T. List
Start Mode
Stop Mode
Minimum Speed
Basic Start Up
The Basic Start Up routine leads the user through the necessary information in a
simple question and answer format. The user can make the choice to execute or
skip any section of the routine. Below is a complete flow chart of the routine.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
177
Start-Up
Figure 40 PowerFlex 70 & 700 Standard Control Option Startup
HIM
Basic Start Up (Top Level)
Main Menu:
<Diagnostics>
Parameter
Device Select
Memory Storage
StartUp
Preferences
Esc
0-2
Startup
Drive active?
Abort
PowerFlex 70
StartUp
.
The drive must
be stopped to
proceed. Press
Esc to cancel.
Yes
Any state
'Esc' key
No
Stop
0-3
Startup
previously
aborted?
7. Done
/Exit
Yes
PowerFlex 70
StartUp
.
Make a selection
Abort
<Backup>
Resume
StartUp Menu
Resume
Backup
Go to previous
state
Go to Backup
screen for previous
state
No
0-0
PowerFlex 70
StartUp
.
This routine is
to help setup a
drive for basic
applications.
Parameter access
through other
menus may be
necessary to
setup advanced
features.
Enter
0-1
PowerFlex 70
StartUp
.
Complete these
steps in order:
1. Input Voltage
2. Motr Dat/Ramp
3. Motor Tests
4. Speed Limits
5. Speed Control
6. Strt,Stop,I/O
7. Done / Exit
Go to 1-0
Backup
Startup Menu
Go to 2-0
1. Input
Voltage
2. Motor
Dat/Ramps
Go to 3-0
3. Motor
Tests
Go to 4-0
4. Speed
Limits
5. Speed
Control
Go to 5-0
6. Strt,Stop,
I/O
Go to 6-0
178
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Start-Up
Figure 41 PowerFlex 70 & 700 Standard Control Option Startup (1)
Basic Start Up (Input Voltage)
1-0
StartUp
1. Input Voltage
This step should
be done only
when "alternate
voltage" is
needed (see user
manual). It will
reset all drive
parameters with
specific choice
of Volts and Hz.
Enter
Backup
Backup
Rated Volts
>300?
Yes
Backup
No
1-2
1-1
StartUp
1. Input Voltage
Enter choice for
Input Supply
400V, 50 Hz
<480V, 60 Hz>
StartUp
1. Input Voltage
Enter choice for
Input Supply
208V, 60 Hz
<240V, 60 Hz>
Enter
Enter
1-3
StartUp
1. Input Voltage
Reset all
parameters to
their defaults?
<Yes>
No
No
Yes
1-4
StartUp
1. Input Voltage
Clear fault to
continue.
Fault Clear
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Go to 0-1 (2)
179
Start-Up
Figure 42 PowerFlex 70 & 700 Standard Control Option Startup (2)
2-0
Basic Start Up (Motor Data/Ramp)
StartUp
2. Motr Dat/Ramp
Use motor nameplate data and
required ramp
times for the
following steps.
Enter
2-1
StartUp
2. Motr Dat/Ramp
Enter choice for
Mtr NP Pwr Units
Enter
2-2
2-7
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Power
123.4 kW
xxx.x <> yyy.y
StartUp
2. Motr Dat/Ramp
Enter choice for
Stop Mode A
Backup
Enter
Enter
2-3
2-10
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP FLA
+456.78 Amps
xxx.xx <> yyy.yy
Backup
Stop Mode A
= "DC Brake" or
"Ramp to
Hold"?
No
Enter
2-4
Yes
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Volts
123.4 Volt
xxx.x <> yyy.y
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
DC Brake Level
1.0 Amps
0.0 < 30.0 Amps
Enter
None - Bus Reg Mode A = Adj Freq.
Intenal - Bus Reg Mode A = Both, DB 1st.
External - Bus Reg Mode A = Both, DB 1st.
Enter
2-8
2-11
StartUp
2. Motr Dat/Ramp
Enter value for
Accel Time 1
6.0 Secs
0.0 < 60.0 secs
No
Enter
2-5
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Hertz
60.0 Hz
x.x <> y.y
Enter
Backup
Stop Mode A
= "DC
Brake"?
Enter
2-6
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP RPM
+456 RPM
xxx <> yyy
180
StartUp
2. Motr Dat/Ramp
Enter choice for
DB Resistor Type
None
Internal
External
2-9
2-12
StartUp
2. Motr Dat/Ramp
Enter value for
Decel Time 1
6.0 Secs
0.0 < 60.0 secs
Yes
StartUp
2. Motr Dat/Ramp
Enter value for
DC BrakeTime
1.0 Secs
0.0 < 90.0 Secs
2-13
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
S Curve %
0%
0 < 100 %
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Enter
Go to 0-1 (3)
Start-Up
Figure 43 PowerFlex 70 & 700 Standard Control Option Startup (3)
3-0
Basic Start Up (Motor Tests)
Startup
3. Motor Tests
This section
optimizes torque
performance and
tests for proper
direction.
Enter
3-1
Startup
3. Motor Tests
Complete these
steps in order:
<A. Auto Tune>
B. Directn Test
C. Done
Go to 0-1 (4)
Done
Auto Tune
3-2
Startup
A. AutoTune
Rotate Tune only
with no load and
low friction.
Static Tune when
load or friction
are present.
Direction
Test
3-3
Fault Clear
Enter/
Backup
Enter
Startup
A. AutoTune
Make a selectioon
<Rotate Tune>
Static Tune
Static
Tune
3-4
Startup
B. Directn Test
Press Jog or Start
to begin.
Enter/
Backup
3-8
3-9
Startup
A. Auto Tune.
Static Tune will
energize motor
with no shaft
rotation. Press
Start to begin.
Start
Start
Enter/
Backup
3-5
Startup
B. Directn Test
Is direction of
motor forward?
<Yes>
No
Yes
(stops drive)
Rotate
Tune
Start
3-10
Startup
A. Auto Tune
Executing test.
Please wait....
No
(stops drive)
3-12
Startup
A. Auto Tune
Rotate Tune will
energize motor,
then cause shaft
rotation. Press
Start to begin.
Startup
3. Motor Tests
Test aborted due
to user stop.
Clear fault to
continue.
Stop or Esc
(stops drive)
Fault
3-13
Startup
3. Motor Tests
Test aborted!
Clear the fault.
Check motor data
settings. Verify
load is removed.
Rotate/Static
Tune complete
(stops drive)
3-6
3-7
3-11
Startup
B. Directn Test
Test complete.
Startup
B. Directn Test
Press Enter.
Then power down
and swap 2 output
wires to motor.
Startup
A. Auto Tune
Test complete.
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181
Start-Up
Figure 44 PowerFlex 70 & 700 Standard Control Option Startup (4)
4-0
Basic Start Up (Speed Limits)
StartUp
4. Speed Limits
This section
defines min/max
speeds, and
direction method
Enter
4-1
4-2
StartUp
4. Speed Limits
Disable reverse
operation?
Yes
<No>
StartUp
4. Speed Limits
Enter choice for
Direction Method
<Fwd/Rev Command>
+/- Speed Ref
No
Yes
Enter
4-3
Backup
StartUp
4. Speed Limits
Enter value for
Maximum Speed
+60.00 Hz
xxx.xx <> yyy.yy
Backup
4-4
Enter
MaxSpd + OSL
> MaxFreq?
Backup
4-5
No
StartUp
4. Speed Limits
Enter value for
Minimum Speed
+5.78 Hz
xxx.xx <> yyy.yy
Enter
Yes
StartUp
4. Speed Limits
Maximum Freq and
Overspeed Limit
will be changed
to support your
Maximum Speed.
Enter
4-6
StartUp
4. Speed Limits
Rejecting this
change will
prevent starting
Accept
Reject
OS Limit =
MaxFreq - MaxSpd
Reject
MaxFreq = MaxSpd
+ OS Limit
MaxFreq = 400Hz
Accept
MaxSpd + OS
Lmt > 400Hz?
No
Yes
182
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Go to 0-1 (5)
Start-Up
Figure 45 PowerFlex 70 & 700 Standard Control Option Startup (5)
Basic Start Up (Speed Control)
5-0
StartUp
5. Speed Control
This section
defines a source
from which to control
speed.
Adapter
5-2
StartUp
5. Speed Control
Enter choice for
Input Signal
Analog Input 1
Analog Input 2
5-1
StartUp
5. Speed Control
Enter choice for
Speed Control
<Analog Input>
Comm Adapter
Local HIM-Port 1
Remote HIM
Preset Speeds
MOP
StartUp
5. Speed Control
Enter choice for
Comm Adapter
Port 5-internal
Port 2-external
Port 3-external
Enter
5-13
Enter
Analog Input
MOP
Local HIMPort 1
Go to 0-1 (6)
5-18
StartUp
5. Speed Control
Digital Inputs
5 & 6 will be
set to MOP Inc &
MOP Dec.
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
5-15
Preset
Speeds
Enter
5-19
StartUp
5. Speed Control
Save MOP speed
at power down ?
<Yes>
No
Remote
HIM
Go to 0-1 (6)
StartUp
5. Speed Control
Note: Factory default
settings
provide preset
speed operation
from the digital
inputs, unless
you change
their function.
5-3
StartUp
5. Speed Control
Enter choice for
Remote HIM
Port 2 (common)
Port 3
5-16
5-21
Enter
StartUp
5. Speed Control
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
PF70 StartUp
5. Speed Control
Enter value for
MOP Rate
5.0 Hz
xx.x < yy.y
Preset
Speed 1
5-5
StartUp
5. Speed Control
Enter value for
Preset Speed 2
10.0 Hz
xxx.x < yyy.y
Preset
Speed 2
5-6
StartUp
5. Speed Control
Enter value for
Preset Speed 3
15.0 Hz
xxx.x < yyy.y
Enter
5-12
StartUp
5. Speed Control
Make a selection .
<Preset Speed 1>
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
Done
Preset
Speed 5
Enter
Preset
Speed 6
Go to 0-1 (6)
Preset
Speed 7
5-23
5-8
5-9
5-10
StartUp
5. Speed Control
Enter value for
Preset Speed 4
20.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 5
25.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 6
30.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 7
35.0 Hz
xxx.x < yyy.y
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Lo
0.0 V
xxx.x < yyy.y
Enter
5-7
Enter
StartUp
5. Speed Control
The next two
parameters link
a low speed
with a low
analog value.
Preset
Speed 3
Preset
Speed 4
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
5-22
Done
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Hi
10.0 V
xxx.x < yyy.y
StartUp
5. Speed Control
Save MOP speed
at stop ?
<Yes>
No
5-17
Enter/
Backup
5-20
Enter
5-4
Enter
StartUp
5. Speed Control
The next two
parameters link
a high speed
with a high
analog value.
5-11
Enter
Analog
Input 1
5-14
5-24
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
Analog
Input 2
5-24
5-25
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
5-26
Enter
StartUp
5. Speed Control
The next two
parameters link
a high speed
with a high
analog value.
5-27
Enter
StartUp
5. Speed Control
Enter value for
Analog In 2 Hi
10.0 V
xxx.x < yyy.y
5-28
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
5-29
Enter
StartUp
5. Speed Control
The next two
parameters link
a low speed
with a low
analog value.
5-30
Enter
StartUp
5. Speed Control
Enter value for
Analog In 2 Lo
0.0 V
xxx.x < yyy.y
5-31
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
183
Start-Up
Figure 46 PowerFlex 70 & 700 Standard Control Option Startup (6)
6-0
6-1
StartUp
6. Strt,Stop,I/O
This section
defines I/O functions including
start and stop
from digital ins
StartUp
6. Strt,Stop,I/O
Complete these
steps in order:
<A. Dig Inputs>
B. Dig Outputs
C. Anlg Outputs
D. Done
Enter
Basic Start Up (Start,Stop,I/O)
D. Done
Go to 6-24
C. Anlg
Outputs
A. Dig Inputs
6-2
Go to 0-1 (7)
B. Dig
Outputs
6-18
Enter/
Backup
Go to 6-29
StartUp
A. Dig Inputs
Enter choice for
Digital In1 Sel
Go to 6-1 (B)
StartUp
A. Dig Inputs
Make a selection
<Easy Configure>
Custom Configure
Done
Digital In 1
6-19
Digital In 2
StartUp
A. Dig Inputs
Enter choice for
Digital In2 Sel
6-17
Custom Configure
StartUp
A. Dig Inputs
Make a selection
<Digital Input 1>
Digital Input 2
Digital Input 3
Digital Input 4
Digital Input 5
Digital Input 6
Done
Easy Configure
Backup
DigIn 5,6 = MOP
Inc, Dec?
Backup
6-3
Yes
No
StartUp
A. Dig Inputs
Digital Inputs
1-4 will be set
to defaults.
6-4
6-20
StartUp
A. Dig Inputs
Enter choice for
Digital In3 Sel
Digital In 3
Digital In 4
StartUp
A. Dig Inputs
Digital Inputs
1-6 will be set
to defaults.
6-21
StartUp
A. Dig Inputs
Enter choice for
Digital In4 Sel
Digital In 5
6-22
Digital In 6
Backup
Enter
Dir Mode =
Reverse
Disable?
Dir Mode =
Bipolar?
No
Yes
No
StartUp
A. Dig Inputs
Is reverse
required from
digital inputs?
<Yes>
No
Yes
No
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
2-wire
6-7
3-wire
6-12
6-10
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Run/Stop.
Enter
Go to 6-1 (B)
184
6-13
Enter
6-14
3-wire
StartUp
A. Dig Inputs
Digital Input 3
will be set to Fwd/
Reverse.
Enter
2-wire
6-15
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Stop.
Enter
6-16
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Run Reverse.
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Start.
Enter
6-11
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Run Forward.
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Stop.
Enter
StartUp
A. Dig Inputs
Enter choice for
Digital In6 Sel
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
6-9
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Not Used.
6-23
Yes
6-6
6-8
StartUp
A. Dig Inputs
Enter choice for
Digital In5 Sel
6-5
Enter
Enter
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Start.
Enter
Enter
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Start-Up
Figure 47 PowerFlex 70 & 700 Standard Control Option Startup (7)
Basic Start Up (Start,Stop,I/O [2])
6-24
Go to 6-1 (C)
Done
StartUp
B . Dig Outputs
Make a selection
<Digital Out 1>
Digital Out 2
Done
Digital
Out 1
6-29
StartUp
C. Anlg Outpts
Enter choice for
Analog Out 1 Sel
Digital
Out 2
Enter
6-25
6-30
6-27
StartUp
B. Dig Outputs
Enter choice for
Digital Out 1 Sel
StartUp
B. Dig Outputs
Enter choice for
Digital Out 2 Sel
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Hi
Enter
No
Enter
Enter
Digital Out 1 Sel
= ENUM choice
that uses
"Level"?
Digital Out 2 Sel
= ENUM choice
that uses
"Level"?
6-26
Enter
Yes
StartUp
B. Dig Outputs
Enter value for
Dig Out 1 Level
Backup
Backup
6-31
No
Enter
Yes
StartUp
B. Dig Outputs
Enter value for
Dig Out 2 Level
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Lo
Go to 6-1 (D)
Enter
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
185
Start-Up
Figure 48 PowerFlex 700 Vector Control Option Startup
For first time powerup...
HIM
Select:
<English>
Francais
Espanol
Deustch
Italiano
Main Menu:
<Diagnostics>
Parameter
Device Select
Memory Storage
Start-Up
Preferences
Flux Vector Start Up (Top Level)
Start-Up/Continue
(disallow Start/Jog)
Abort
(allow Start/Jog)
Esc
(allow Start/Jog)
Drive
active?
0-0
PowerFlex 700
Start-Up
.
Startup consists
of several steps
to configure a
drive for basic
applications.
0-3
PowerFlex 700
Start-Up
.
Make a selection
Abort
<Backup>
Resume
Start-Up Menu
No
Yes
0-2
Go to AbortResume state
PowerFlex 700
Start-Up
.
The drive must
be stopped to
proceed. Press
ESC to cancel.
Yes
Drive
active?
STOP
(Stops the Drive)
0-4
0-5
No
PowerFlex 700
Start-Up
.
SMART startup
programs 11 key
drive parameters
for fast setup .
Basic startup
programs basic
drive functions
and options. .
Detailed startup
programs motor
data, reference;
ramps; limits; &
analog/digital
I/O.
PowerFlex 700
Start-Up
.
Make a selection
<1.SMART>
2.Basic
3.Detailed
4.More Info
Done/Exit
(allow Start/Jog)
Basic/
Detailed
Backup
SMART
Go to 8-1 (SMART
Start)
First time
into
Startup??
Yes
Startup
Menu
Yes
Drive
active?
Go to 1-1 (Motor
Control)
No
No
Basic
Detailed
0-1
PowerFlex 700
Start-Up
.
Complete these
steps in order:
<1.Motor Control>
2.Motr Data/Ramp
3.Motor Tests
4.Speed Limits
5.Speed/Trq Cntl
6.Start/Stop/I/O
7.Done/Exit
Go to 1-0
0-1
PowerFlex 700
Start-Up
.
Complete these
steps in order:
<1.Motor Control>
2.Motr Data/Ramp
3.Motor Tests
4.Speed Limits
5.Speed/Trq Cntl
6.Start/Stop/I/O
7.Appl Features
8.Done/Exit
Motor Control
Go to 2-0
Motor Dat/Ramp
Go to 3-0
Motor Tests
Speed Limits
Speed/Torque Control
Go to 4-0
Go to 5-0
Strt/Stop/ I/O
Appl Features
Done/Exit
Go to 6-0
Go to 7-0
Go to HIM
Main Menu
186
Any state
(except 0-2)
'Esc' key
Start-Up/Restart
(disallow Start/Jog)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Resume/Esc
Backup
Go to previous
state
Go to Backup
screen for previous
state
Start-Up
Figure 49 PowerFlex 700 Vector Control Option Startup (1)
Flux Vector Start Up (Motor Control Select)
1-31
1-1 B
1-0
Start-Up
1. Motor Control
This section
selects the type
of Motor Control
the drive will
use.
1-2 B
B = Basic mode
Start-Up
1. Motor Control
Make a selection
<1.SVC>
2.V/Hz
3.Flux Vector
4.More info
SVC- Set
#53= 0
Flux
Vector
Start-Up
SVC
Enter choice of
Speed Units
<Hz>
RPM
Frequency
More
info
1-18
1-17
Start-Up
V/Hz
Select a V/Hz
control option:
<1.V/Hz-Fan/Pump>
2.V/Hz-Cust/Std.
3.More info
Start-Up
1.Motor Control
Use SVC
for applications
requiring speed
regulation.
Use V/Hz control
for Fan/Pump and
other V/Hz
applications.
Use Flux Vector
for applications
requiring Torque
control or tight
speed regulation.
More
info
1-6 B
Start-Up
Flux Vector
NOTE! An Encoder
is required for
the Flux Vector
Control option.
1-19
Start-Up
V/Hz
Enter choice for
Slip Comp
<Enable>
Disable
Start-Up
Flux Vector
Enter value for
Encoder PPR
1024
SVC
Enter choice for
Slip Comp
<Enable>
Disable
1-32
1-23
Start-Up
V/Hz
Define Custom
V/Hz curve?
<Yes>
No
Fan/Pump-Set #53=3
1-7 B
1-3 Start-Up
V/Hz
Custom/Std.
Start-Up
V/Hz
The Fan/Pump
option selects a
predefined V/Hz
curve.
The Custom/Std.
option allows
you to define a
V/Hz curve or
select a default
V/Hz curve.
Yes
Standardset params #54
& 69-72 to
default values
Disable
Set #80=0
Set #80 to
selection made
1-24
1-20
B
Start-Up
V/Hz
Enter choice for
Slip Comp
<Enable>
Disable
Start-Up
V\Hz
Control selected
is Standard V/Hz
Start-Up
V/Hz
Enter value for
Run Boost
10V
xx.x < yy.y
1-8 B
Disable
Enable
Set #80=0 Set #80=1
1-5 B
1-4
Start-Up
SVC
Control selected
is SVC with
no Slip Comp
Start-Up
SVC
Control selected
is SVC with
Slip Comp
Enable
Set #80=1
Start-Up
Flux Vector
Enter choice of
Speed Units
<Hz>
RPM
Speed pathSet #88 to 1
1-10
Start-Up
Flux Vector
Select Torque
Regulate option:
<1.Torque Regul.>
2.Min Torque/Spd
3.Max Torque/Spd
4.Sum Torque/Spd
Min Torque/ 5.Absolute
Speed Set #88 =3
1-11
1-13
Start-Up
V/Hz
Enter value for
Break Voltage
10.0 Hz
x.x < y.y
B
1-27
Start-Up
Flux V ector
Control selected
is FOC Speed
Regulate.
Start-Up
V/Hz
Enter value for
Break Frequency
10.0 Hz
x.xxxx < y.yyyy
1-16
AbsoluteSet #88
=6
1-12
Start-Up
Flux Vector
Control selected
is Torque/FOC
Max Torque/Speed
1-26
Start-Up
V/Hz
Control selected
is Fan/Pump
with Slip Comp
Torque path
Start-Up
Flux Vector
Control selected
is Torque/FOC
Min Torque/Speed
Start-Up
V/Hz
Control selected
is Fan/Pump
no Slip Comp
Trq
Regulate
Set #88
=2
1-25
Start-Up
V/Hz
Enter value for
Start Boost
10.0 V
x.xxxx < y.yyyy
1-21
1-9
Start-Up
Flux Vector
Enter choice of
Regulation
<Speed>
Torque
Max
Trq/Speed Set #88 = 4
1-22
1-28
Start-Up
Flux Vector
Control selected
is Torque/FOC
Absolute
Start-Up
V/Hz
Enter value for
Max Voltage
10.0 V
x.x < y.y
Sum Trq/SpeedSet #88 = 5
1-15
1-14
Start-Up
Flux Vector
Control selected
is Torque/FOC
Torque Regulate
1-30
Start-Up
Flux Vector
Control selected
is Torque/FOC
Sum Torque/Speed
Start-Up
V/Hz
Control selected
is V/Hz/Custom
no Slip Comp.
1-29
Start-Up
V/Hz
Control selected
is V/Hz/Custom
with Slip Comp.
Go to 0-1
2. Motr Dat/Ramp
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
187
Start-Up
Figure 50 PowerFlex 700 Vector Control Option Startup (2)
Flux Vector Start Up (Motor Dat/Ramp)
2-0
B
Start-Up
2. Motr Dat/Ramp
Use motor nameplate data and
required ramp
times for the
following steps.
2-1
B
Enter
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Volts
123.4 Volt
xxx.x <> yyy.y
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Hertz
60.0 Hz
x.x <> y.y
2-6
B
Start-Up
2. Motr Dat/Ramp
Enter Stop Mode:
1.Coast
<2.Ramp>
3.Ramp to Hold
4.DC Brake
Enter
2-5
B
2-7
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP FLA
+456.78 Amps
xxx.xx <> yyy.yy
2-4
B
2-14
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor Poles
12
xx <> yy
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Power
123.4 kW
xxx.x <> yyy.y
2-3
B
Enter
Start-Up
2. Motr Dat/Ramp
Enter choice for
Power Units
<HP>
Killowatt
2-2
B
B = Basic mode
Enter
Use formula:
Poles= 120 * NP Hz
NP RPM
No
as Motor Poles
parameter value.
Start-Up
2. Motr Dat/Ramp
Enter choice for
DB Resistor type
<None>
Internal
External
Start-Up
2. Motr Dat/Ramp
Enter value for
DC Brake Level
1.0 Amps
0.0 < 30.0 Amps
Enter
2-11
2-9
Yes
Start-Up
2. Motr Dat/Ramp
Enter value for
DC BrakeTime
1.0 Secs
0.0 < 90.0 Secs
Note: If Stop Mode A = COAST, then
skip 2-10.
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Accel Time 1
6.0 Secs
0.0 < 60.0 secs
No
Enter
2-12
Stop Mode A =
"DC Brake"?
Note: Depending on selection, set parameter
#161 (Bus Reg Mode A):
None - Bus Reg Mode A = Adj Freq.
Intenal - Bus Reg Mode A = Both, DB 1st.
External - Bus Reg Mode A = Both, DB 1st.
Note: Default should be NONE.
Yes
2-8
Note:
- For V/Hz mode, only states 2-0 thru 2-6 & 2-14 are displayed.
- For V/Hz mode, configure Stop Mode A as Coast to Stop.
- Going from state 2-7 to 2-10 directly sets the DC Brake Level/Time
parameters to their default value.
188
2-10
Stop Mode A =
"DC Brake" or
"Ramp to Hold"?
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP RPM
+456 RPM
xxx <> yyy
Backup
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Decel Time 1
6.0 Secs
0.0 < 60.0 secs
2-13
B
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
S Curve %
0%
0 < 100 %
Enter
Go to 0-1 (3. Motor
Tests)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Note: If Stop Mode A = COAST, then
skip 2-12. If in Quick/Basic mode, then
exit Motor Data/Ramp.
B
Start-Up
Figure 51 PowerFlex 700 Vector Control Option Startup (3)
3-0
3-22
Start-Up
3. Motor Tests
This section
optimizes motor
performance and
tests for proper
direction.
Flux Vector Start Up (Motor Tests)
Start-Up
3. Motor Tests
Select source of
Start/Stop
<Digital Inputs>
Local HIM-Port1
Remote HIM-Port2
3-21
If Digital Inputs:- Set
#361/2 to START/STOP resp.
If Local HIM:- Set
#361/2 to Not Used &
#90 to 18
3-1
Enter
Start Inhibit
param != 0
Note:
- Fix Jog/Reference to
5 Hz.
- State 3-4 allows
Start/Jog 3-4
Yes
No
Start-Up
A. Directn Test
Press Jog or Start
to begin.
Enter/
Backup
3-18
Start-Up
A. Directn Test
Test complete.
Press <ENTER>
3-2 Start-Up
3-14
B. AutoTune
IMPORTANT!!
Use Rotate Tune
if no load/low
friction/Flux
Vector mode.
Else use Static
Tune. For
special applications, see reference maual.
Start Inhibit
param != 0
Start-Up
3. Motor Tests
Cannot start due
to open Stop
input or other
[Start Inhibits]
Press Enter.
Yes
No
Static
Tune
3-19
Start-Up
C. Inertia Test
Caution:Inertia
Test causes
shaft rotation.
<START> to begin
3-20
Note: States 3-8
& 3-9 allow Start.
If NO..
(stops
drive)
3-8
3-7
3-17
Start-Up
A. Directn Test
Power down and
swap encoder
leads.
Go to State 3-4
No
FOC?
Yes
Start-Up
B. Auto Tune
Caution: Rotate
Tune will cause
shaft rotation.
Press START to
begin.
3-10
3-16
Start-Up
B. Auto Tune
Enter value for
Autotune Torque
6.0 %
xxx.x <> yyy.y
3-15
Start (disallow
Start/Jog)
Start-Up
C. Inertia Test
Enter value for
Speed Desired BW
60.0 RPM
xxx.x <> yyy.y
Start-Up
B. Auto Tune
Executing test.
Please wait...
FOC
Mode?
Yes
3-11
Note:
- The Motor Tests are NOT executed while in V/Hz mode.
Stop or ESC
(stops drive)
Start-Up
C. Inertia Test
Test complete.
Press <ENTER>
Stop or Esc
(stops drive)
Fault
(stops drive)
Go to 3-1
3-13
No
Start-Up
B. Auto Tune
Test complete.
Press <ENTER>
Fault
(stops drive)
3-23
Rotate/Static Tune
complete
(stops drive)
3-24
Start-Up
B. Auto Tune
Rotate Tune
done. Press
ENTER to continue with
Inertia Test.
Rotate Tune
3-9
Start-Up
B. Auto Tune.
Static Tune will
energize motor
with no shaft
rotation. Press
START to begin.
Start-Up
A. Directn Test
Startup will
automatically
reverse the
MotorLeads.
Start-Up
C. Inertia Test
Executing test.
Please wait...
Start-Up
B. AutoTune
Make a selectioon
Static Tune
<Rotate Tune>
Note: Set #61
(Autotune) to '2' or
'1' depending on
selection
Start (disallow
Start/Jog)
Go to State 3-18
Start-Up
C. Inertia Test
Connect load to
motor for
Inertia Test.
B. Auto Tune
Enter
If YES &
negative
encoder
counts..
(stops
drive)
Go to 3-1
C. Inertia Test
A. Directn Test
Motor rotation
correct for
application?
<Yes>
No
3-6
SV
Motor
Cntl
Sel?
3-3
3-5 Start-Up
If YES & positive
encoder counts..
(stops drive)
V/Hz
FOC
Start/Jog
(disallow Start/Jog)
Backup
3-25
Start-Up
C.Inertia Test
Sensrls Vector
does not require
an Inertia Test.
Go to 0-1 (4.Speed
Limits)
D. Done
Start-Up
3. Motor Tests
Complete these
steps in order:
<A. Directn Test>
B. Auto Tune
C. Inertia Test
D. Done
Direction
Test
Start-Up
C.Inertia Test
V/Hz Control
does not require
an Inertia Test.
3-12
Start-Up
3. Motor Tests
Test aborted due
to user stop.
Clear fault to
continue.
Start-Up
3. Motor Tests
Test aborted!
Clear the fault.
Check motor data
settings. Verify
load is removed.
Go to 3-1
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
189
Start-Up
Figure 52 PowerFlex 700 Vector Control Option Startup (4)
Flux Vector Start Up (Speed Limits)
4-0
Start-Up
4. Speed Limits
This section
defines min/max
speeds and
direction method
B
4-1
Start-Up
4. Speed Limits
Enter value for
Maximum Speed
+60.00 Hz
xxx.xx <> yyy.yy
B
4-2
Start-Up
4. Speed Limits
Enter value for
Minimum Speed
+5.78 Hz
xxx.xx <> yyy.yy
B
FOC
Mode?
Yes
4-3
No
Go to 0-1 (5.
Speed Control)
190
Start-Up
4. Speed Limits
Enter value for
Rev Speed Lim
+5.78 Hz
xxx.xx <> yyy.yy
B
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Start-Up
Figure 53 PowerFlex 700 Vector Control Option Startup (5)
5-0 Start-Up
Flux
Vector
Mode?
5. Speed Control
This section
selects the
speed/torque
control source.
Note:
- Only Analog and Local HIM
are displayed in 5-1 for Basic
mode.
Comm Adapter write to #90 (Ref A
Sel) selection
5-2
Start-Up
Comm Adapter
Make a selection
<Port 5-internal>
Port 2-common
Port 3-external
Port 4-external
Go to 0-1 (6.Strt/
Stop/I/O)
Yes
No
5-1
Speed
Start-Up
5. Speed Control
Choose source
of Reference:
<1.Analog Input>
2.Preset Speed 1
3.Digital Inputs
4.Comm Adapter
5.Local HIM
6.Remote HIM
7.MOP
Local HIM- Port 1Set param #90
(Ref A Sel) to '18'
5-3
5-11
Start-Up
5. Speed Control
Note: Factory
default settings
provide preset
speed operation
from the digital
inputs.
5. Speed Control
Enter value for
Preset Speed 2
10.0 Hz
xxx.x < yyy.y
5-6 Start-Up
5. Speed Control
Enter value for
Preset Speed 3
15.0 Hz
xxx.x < yyy.y
5-35
5-8 Start-Up
5. Speed Control
Enter value for
Preset Speed 5
25.0 Hz
xxx.x < yyy.y
5-9 Start-Up
Start-Up
5. Speed Control
Digital Inputs
5 & 6 will be
set to MOP Inc &
MOP Dec.
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
Set params: #90 (Ref A
Sel) to Anlg In 1; #93 (Ref
B Sel) to Preset Spd 1;
#364-66 (Digital In 4-6)
to Speed Sel 1, 2, 3.
Start-Up
5. Speed Control
Save MOP speed
at Stop ?
<Yes>
No
Start-Up
5. Speed Control
Select a Preset
Speed:
<1.Preset Speed 1>
2.Preset Speed 2
3.Preset Speed 3
4.Preset Speed 4
5.Preset Speed 5
6.Preset Speed 6
7.Preset Speed 7
8.Done
Preset
Speed 3
Preset
Speed 4
Upon "Enter", write to
bit '1' of param #194
(Save MOP Ref)
Start-Up
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
x.x < y.y
PF70 Start-Up
5. Speed Control
Enter value for
MOP Rate
5.0 Hz
xx.x < yy.y
Done
Enter
Enter
Enter
Go to 0-1
(6. Strt/Stop/I/O)
Note :
- For V/Hz mode, the MOP option in 5-1 is NOT displayed, screens 5-14
thru 5-17 and 5-18 thru 5-31 are also NOT displayed.
Go to 5-1
5-27
Start-Up
5. Speed Control
Enter value for
Analog In 2 Hi
10.0 V
x.xxxx < y.yyyy
5-28
Yes
Start-Up
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
x.x < y.y
5-29
Start-Up
5. Speed Control
The next two
steps scale a
low speed with
a low analog
value.
5-24
5-10 Start-Up
Yes
Start-Up
5. Speed Control
The next two
steps scale a
high speed to
a high analog
value.
Start-Up
5. Speed Control
The next two
steps scale a
low speed with
a low analog
value.
Start-Up
5. Speed Control
Enter value for
Analog In 1 Lo
0.0 V
x.xxxx < y.yyyy
Start-Up
5. Speed Control
Configure other
Spd References?
<Yes>
No
No
5-26
5-22
5-23
5-33
5. Speed Control
Enter value for
Preset Speed 7
35.0 Hz
xxx.x < yyy.y
No-If AIn 2 Hi/Lo
value out of range,
set to min of Signal
type selected.
5-21
5-17
Preset
Speed 6
5. Speed Control
Enter value for
Preset Speed 6
30.0 Hz
xxx.x < yyy.y
No-If AIn 1 Hi/Lo
value out of range,
set to min of Signal
type selected
Start-Up
5. Speed Control
Enter value for
Analog In 1 Hi
10.0 V
x.xxxx < y.yyyy
Preset
Speed 5
Preset
Speed 7
V/Hz
Mode?
5-20
5-12
Preset
Speed 2
V/Hz
Mode?
Start-Up
5. Speed Control
The next two
steps scale a
high speed to
a high analog
value.
5-16
Enter/
Backup
Preset
Speed 1
Set bit 1 of #320 to '0'
(for Volts) & '1' (for Amps)
5-19
Upon "Enter", write to
bit '0' of param #194
(Save MOP Ref)
5-25
Start-Up
5. Speed Control
Enter choice for
Signal Type
<Voltage>
Current
Set bit 0 of #320 to '0'
(for Volts) & '1' (for Amps)
Start-Up
5. Speed Control
Save MOP speed
at power down ?
<Yes>
No
5. Speed Control
Set #90 to
Set #90 to
Analog Input 1 Analog Input 2
Start-Up
5. Speed Control
Enter choice for
Signal Type
<Voltage>
Current
5-15
Start-Up
5-7 Start-Up
5. Speed Control
Enter value for
Preset Speed 4
20.0 Hz
xxx.x < yyy.y
5-18
5-14
Digital
Inputs
5. Speed Control
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
Start-Up
5. Speed Control
Enter choice for
Input Signal
<Analog Input 1>
Analog Input 2
MOP - Set
Param #90
(Ref A Sel)
to '9'
Preset
Speed - Set
param #90
(Ref A Sel)
to '11'
5-4 Start-Up
5-13
Go to 6-49
Analog Input
Start-Up
Remote HIM
Make a selection
<Port 2 (common)>
Port 3
Port 4
5-5 Start-Up
Torque
Go to 0-1 (6. Strt/
Stop/I/O)
Remote
HIM -write
to #90 (Ref
A Sel)
selection
Flux Vector Start Up (Speed/Torque Control)
5-34
Start-Up
C. Anlg Inputs
Enter choice for
Reference::
<Speed>
Torque
Start-Up
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
x.x < y.y
5-30
Start-Up
5. Speed Control
Enter value for
Analog In 2 Lo
0.0 V
x.xxxx < y.yyyy
5-31
Start-Up
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
x.x < y.y
5-32
Start-Up
5. Speed Control
Verify high/low
speeds with
high/low analog
signals.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
191
Start-Up
Figure 54 PowerFlex 700 Vector Control Option Startup (6)
Flux Vector Start Up (Strt,Stop,I/O)
B
6-0
Start-Up
6. Strt,Stop,I/O
This section
defines I/O
functions
including Start
and Stop.
B = Basic mode
6-1
Start-Up
6. Strt,Stop,I/O
Complete these
steps in order:
<A.Dig Inputs>
B.Dig Outputs
C.Analog Outputs
D.Done
A. Dig Inputs
6-2
B. Dig
Outputs
Go to 6-27
C.Analog
Output
Go to 6-49
Enter/
Backup
D. Done
6-19
More
info
Start-Up
A. Dig Inputs
Easy Configure
asks questions
before writing
to digital ins.
Custom Configure
allows you to
program each
digital input(s)
6-26
DigIn 5,6 = MOP
Inc, Dec?
No
B
6-4
Start-Up
A. Dig Inputs
Digital Inputs
1-4 will be set
to defaults.
6-5
Digital In 5
B
6-8
2-wire
B
Start-Up
A. Dig Inputs
Digital In1 set
to Not Used.
Digital In2 set
to Run/Stop.
B
Start-Up
A. Dig Inputs
Enter choice for
Control Method
<3 wire>
2 wire
More info
3-wire
B 6-11
Start-Up
A. Dig Inputs
Digital In1 set
to Stop.
Digital In2 set
to Start.
B
B 6-12
Start-Up
A. Dig Inputs
Digital Inputs
configured for
3-wire control
no reversing.
Note:
- For V/Hz mode, states 6-3 - 6-5, & 6-11 - 6-16 are not displayed.
6-7
Start-Up
A. Dig Inputs
2 wire control
uses a contact
that acts as
both STOP (Open)
& Run (Closed).
3 wire control
uses 2 contacts;
one for START
& one for STOP.
Yes
6-13
6-14
2-wire
More
Info..
3-wire
Start-Up
A. Dig Inputs
Digital Inputs
configured for
2-wire control
with reversing.
B
6-16
Start-Up
A. Dig Inputs
Digital Input 3
will be set to Fwd/
Reverse.
B
Start-Up
A. Dig Inputs
Digital In1 set
to Run Forward.
Digital In2 set
to Run Reverse.
6-15
Start-Up
A. Dig Inputs
Enter choice for
Digital In4 Sel
6-24
Start-Up
A. Dig Inputs
Enter choice for
Digital In6 Sel
B
B
More
Info..
Start-Up
A. Dig Inputs
Enter choice for
Digital In3 Sel
6-25
B 6-6
Start-Up
A. Dig Inputs
Enter choice for
Control Method
<3 wire>
2 wire
More info
6-22
Start-Up
A. Dig Inputs
Enter choice for
Digital In5 Sel
Start-Up
A. Dig Inputs
Is REVERSE
required from
digital inputs?
<Yes>
No
No
Start-Up
A. Dig Inputs
Enter choice for
Digital In2 Sel
6-23
Start-Up
A. Dig Inputs
2 wire control
uses a contact
that acts as
both STOP (Open)
& Run (Closed).
3 wire control
uses 2 contacts;
one for START
& one for STOP.
192
Digital In 4
Digital In 6
Backup
Start-Up
A. Dig Inputs
Digital Inputs
configured for
2-wire control
no reversing
Digital In 3
Done
Backup
6-10
Digital In 2
Go to 6-1 (B.Dig
Outputs)
Start-Up
A. Dig Inputs
Digital Inputs
1-6 will be set
to defaults.
6-9
Start-Up
A. Dig Inputs
Select a Digital
Input:
<1.Digital In 1>
2.Digital In 2
3.Digital In 3
4.Digital In 4
5.Digital In 5
6.Digital In 6
7.Done
Custom Configure
Easy Configure
6-3
Digital In 1
6-21
Start-Up
A. Dig Inputs
Digital Input
Config options:
<Easy Configure>
Custom Configure
More info
Yes
Start-Up
A. Dig Inputs
Enter choice for
Digital In1 Sel
Go to 0-1 (7. Application
Features)
B
6-20
B
6-17
Start-Up
A. Dig Inputs
Digital In1 set
to Stop.
Digital In2 set
to Start.
B
B
Start-Up
A. Dig Inputs
Digital Inputs
configured for
3-wire control
with reversing.
Go to 6-1 (B. Dig
Outputs)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
6-18
Start-Up
Figure 55 PowerFlex 700 Vector Control Option Startup (7)
6-27
Digital Out 1
6-28
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 1 Sel
No
Flux Vector Start Up (Start,Stop,I/O [2])
Start-Up
B. Dig Outputs
Make a selection
<Digital Out 1>
Digital Out 2
Digital Out 3
Done
Go to 6-1 (C.Anlg
Inputs)
Done
6-34
Digital Out 3
6-32
Start-Up
C. Anlg Inputs
Enter choice for
Input Signal
<Analog Input 1>
Analog Input 2
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 3 Sel
6-30 Digital Out 2
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 2 Sel
Anlg 1
6-35
Digital Out 1
Sel = ENUM
choice that
uses "Level"?
Start-Up
Digital Out 3
Sel = ENUM
choice that
uses "Level"?
Digital Out 2
Sel = ENUM
choice that
uses "Level"?
6-29 Yes
Start-Up
B. Dig Outputs
Enter value for
Dig Out 1 Level
Yes
6-31
6-33
Start-Up
B. Dig Outputs
Enter value for
Dig Out 3 Level
Yes
Start-Up
B. Dig Outputs
Enter value for
Dig Out 2 Level
No
No
Anlg 2
Enter choice for
Signal type:
<Voltage>
Current
Torque RefAnlg 1
Torque RefAnlg 2
Start-Up
C. Anlg Inputs
The next two
steps scale a
high torque with
a high analog
value.
Start-Up
C. Anlg Inputs
The next two
steps scale a
high torque with
a high analog
value.
6-36
6-37
6-49
Start-Up
C.Analog Outputs
Make a selection
<Anlgl Out 1>
Anlg Out 2
Done
Go to 6-1 (D.
Done)
6-42
Start-Up
C. Anlg Inputs
Enter choice for
Signal type:
<Voltage>
Current
6-44
Start-Up
C. Anlg Inputs
Enter value for
Analog In 1 Hi
10.0 V
x.xxxx < y.yyyy
Start-Up
C. Anlg Inputs
Enter value for
Analog In 2 Hi
10.0 V
x.xxxx < y.yyyy
6-38
6-50
Analog 1
Start-Up
C.Analog Outputs
Enter choice for
Analog Out 1 Sel
Output Freq
6-51
Start-Up
C.Analog Outputs
Enter choice for
Signal Type
<Voltage>
Current
6-52
Analog 2
6-54
Start-Up
C.Analog Outputs
Enter choice for
Analog Out 2 Sel
Output Amps
6-55
Start-Up
C.Analog Outputs
Enter choice for
Signal Type
<Voltage>
Current
6-56
Start-Up
C.Analog Outputs
Enter value for
Start-Up
C.Analog Outputs
Enter value for
Analog Out 1 Hi
10.000 Volt
x.xxxx < y.yyyy
Analog Out 2 Hi
10.000 Volt
x.xxxx < y.yyyy
6-53
6-57
Start-Up
C.Analog Outputs
Enter value for
Start-Up
C.Analog Outputs
Enter value for
Analog Out 1 Lo
0.0 Volt
x.xxxx < y.yyyy
Analog Out 2 Lo
0.0 Volt
x.xxxx < y.yyyy
6-43
6-45
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
6-39
6-46
Start-Up
C. Anlg Inputs
The next two
steps scale a
low torque with
a low analog
value.
Start-Up
C. Anlg Inputs
The next two
steps scale a
low torque with
a low analog
value.
6-47
6-40
Start-Up
C. Anlg Inputs
Enter value for
Analog In 1 Lo
10.0 V
x.xxxx < y.yyyy
6-41
Start-Up
C. Anlg Inputs
Enter value for
Analog In 2 Lo
10.0 V
x.xxxx < y.yyyy
6-48
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Go to 6-1 (D.Anlg
Outputs)
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
193
Start-Up
Figure 56 PowerFlex 700 Vector Control Option Startup (8)
7-0 Start-Up
Flux Vector Start Up (Application Functions)
7.Appl. Features
This allows
programming of
additional drive
features.
7-1 Start-Up
7.Appl Features
Make a Selection
<Flying Start>
Auto Restart
Done
7-2
No
Start-Up
7.Appl Features
Enter choice for
PI Reference
1
Analog In 1
7-3 Start-Up
7.Appl Features
Enter choice for
PI Feedback
1
Analog In 1
7-4 Start-Up
7.Appl Features
Enter value for
PI Setpoint
50.0%
xx.x < yy.y
7-5
7-6
7-4
Start-Up
7.Appl Features
Enable Flying
Start?
<Yes>
No
Process PI
7-2
Auto
Restart
Flying
Start
7-3
Start-Up
7.Appl Features
Set Auto Restart
Tries to Zero to
disable the
function.
Yes
7-5
Start-Up
7.Appl Features
Enter value for
Flying StartGain
4000
xxx < yyyy
Start-Up
7.Appl Features
Enter value for
Auto Rstrt Tries
0
xxx < yyyy
Go to 7-1 (Auto
Restart)
Auto Restart
tries = 0?
Yes
Go to 7-1 (Done)
7-6
Start-Up
7.Appl Features
Enter value for
Auto Rstrt Delay
1.0 Secs
xx.x < yy.y
Start-Up
7.Appl Features
Enter value for
PI Upper Limit
60.0 Hz
xx.x < yy.y
Start-Up
8.Appl Features
Enter value for
PI Lower Limit
-60.0 Hz
xx.x < yy.y
7-7 Start-Up
8.Appl Features
Enter value for
PI Integral Time
2.0 Secs
x.x < y.y
7-8 Start-Up
8.Appl Features
Select other PI
options in
parameter #124.
Go to 0-1 (8. Done/
Exit)
194
No
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Start-Up
Figure 57 PowerFlex 700 Vector Control Option Startup (9)
8-0
Start-Up
SMART
Enter choice of
Speed units:
<Hz>
RPM
Flux Vector Start Up (S.M.A.R.T.)
8-1
Start-Up
SMART
Enter value for
Digital In 2 Sel
5
Start
8-2
Start-Up
2. Motr Dat/Ramp
Enter choice for
Stop Mode A
Coast
<Ramp>
Ramp to Hold
DC Brake
8-3
8-4
8-5
Start-Up
SMART
Enter value for
Minimum Speed
0.0 Hz
Start-Up
SMART
Enter value for
Maximum Speed
60.0 Hz
Start-Up
SMART
Enter value for
Accel Time 1
10.0 Secs
8-6
Start-Up
SMART
Enter value for
Decel Time 1
10.0 Secs
8-7
Start-Up
SMART
Enter value for
Speed Ref A Sel
Analog In 2
8-8
Start-Up
SMART
Enter value for
Motor NP FLA
0.8 Amps
8-9
Start-Up
SMART
Enter value for
Motor OL Hertz
10.0 Hz
8-10
Start-Up
SMART
Enter value for
Motor OL Factor
1.0
8-11
Start-Up
SMART
SMART Startup
is now complete.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
195
Start-Up
Figure 58 PowerFlex 700 Vector Control Option Startup (10)
1-0
Flux Vector Start Up (Motor Control Select)
1-1
Start-Up
1. Motor Control
This section
selects the type
of Motor Control
the drive will
use.
Start-Up
1. Motor Control
Enter choice of
Control:
<Speed>
Torque
More info
Torque
Speed
1-11
1-2
Start-Up
Torque
Is an encoder
present?
<Yes>
No
Torque- No
Start-Up
Speed
Is an encoder
present?
<Yes>
No
TorqueYes
1-3
1-12
1-4
Start-Up
Torque-FOC
An Encoder is
required for the
Torque Control
option. Select
another Motor
Control option
or install an
encoder.
1-6
Start-Up
Speed-SVC
Enter value for
Encoder PPR
1024
1-5
Min Torque/
Speed Set #88 to 3
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Min Torque/Speed
YES-Speed pathSet #88 to 1
Start-Up
Speed-SVC
Control selected
is FOC Speed
Regulate.
Start-Up
Torque-FOC
Select Torque
Regulate option:
<Torque Regulate>
Min Torque/Speed
Max Torque/Speed
Sum Torque/Speed
Absolute
1-7
V/Hz
Custom/Multi
Motor - Set
param #53 to '2'
& #80 to '0'
1-15
Start-Up
Frequency-V/Hz
Select V/Hz
Parameters.
<Standard V/Hz>
Custom V/Hz
V/Hz
1-13
Sensorless
Vector - set param #53
to '0' & #80 to '0'
Fan/Pump Set param
#53 to '3' &
#80 to '0'
Start-Up
Frequency-V/Hz
Control selected
is Frequency/SV
no Slip Comp
1-10
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Absolute
Sum Trq/SpeedSet #88 to 5
Trq
Regulate
1-9
Set #88
Start-Up
to 2
Torque-FOC
Control selected
is Torque/FOC
Sum Torque/Speed
1-8
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Torque Regulate
Start-Up
Speed-SVC
Control selected
is Speed/SVC
with Slip Comp
1-21
Standard
Start-Up
Frequency-V/Hz
Control selected
is Freq/Fan/Pump
no Slip Comp
1-22
1-18
1-23
Start-Up
Frequency-V/Hz
Enter value for
Max Voltage
10.0 V
x.x < y.y
1-24
Go to 1-1
Start-Up
Speed-SVC
Use Speed-SVC
for applications
requiring speed
regulation.
Start-Up
Frequency-V/Hz
Control selected
is Freq/Custom.
Start-Up
Speed-SVC
Enter choice of
Speed Units
<V/Hz>
RPM
Go to 0-1
2. Motr Dat/Ramp
196
Start-Up
Frequency-V/Hz
Enter value for
Break Voltage
10.0 Hz
x.x < y.y
Start-Up
Frequency-V/Hz
Enter value for
Break Frequency
10.0 Hz
x.xxxx < y.yyyy
Start-Up
Frequency-V/Hz
Control selected
is Freq/V/Hz.
Start-Up
Speed-SVC
Enter value for
Max Voltage
10.0 V
x.x < y.y
1-19
Start-Up
Frequency-V/Hz
Enter value for
Run Boost
10V
xx.x < yy.y
1-20
1-17
1-25
Custom
Start-Up
Frequency-V/Hz
Enter value for
Start Boost
10.0 V
x.xxxx < y.yyyy
1-16
AbsoluteSet #88
to 6
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Max Torque/Speed
NO
Start-Up
Frequency-V/Hz
Select Motor
Control Mode
<SVC-common>
V/Hz
More info
Torque path
Max
Trq/Speed Set #88 to 4
1-14
Start-Up
Frequency-V/Hz
Select Motor
Control Mode
<V/Hz-Fan/Pump>
V/Hz-Custom
V/Hz-Multi Motor
SV-No regulation
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Stop Modes
Stop Modes
[Stop Mode A, B]
[DC Brake Lvl Sel]
[DC Brake Level]
[DC Brake Time]
1. Coast to Stop - When in 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.
Output Voltage
Output Current
Motor Speed
Time
Stop
Command
Coast Time is load dependent
2. Dynamic Braking is explained in detail in the PowerFlex Dynamic Braking
Selection Guide, publication PFLEX-AT001.
3. DC Brake is selected by setting [Stop Mode A] to a value of “3.” The user can
also select the amount of time the braking will be applied and the magnitude
of the current used for braking with [DC Brake Time] and [DC Brake Level].
This mode of braking will generate up to 40% of rated motor torque for
braking and is typically used for low inertia loads.
When in Brake to Stop, the drive acknowledges the Stop command by
immediately stopping the output and then applying a programmable DC
voltage [DC Brake Level] to 1 phase of the motor.
The voltage is applied for the time programmed in [DC Brake Time]. After
this time has expired, all output ceases. If the load is not stopped, it will
continue to coast until all energy is depleted (A on the diagram below). If the
time programmed exceeds the needed time to stop, the drive will continue to
apply the DC hold voltage to the non-rotating motor (B on the diagram
below). Excess motor current could cause motor damage. The user is also
cautioned that 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 (C on the diagram below).
Output Voltage
Output Current
Motor Speed
DC
Hold Level
Time
Stop
Command
(B)
(C)
(A)
DC Hold Time
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
197
Stop Modes
4. Ramp To Stop is selected by setting [Stop Mode x]. The drive will ramp the
frequency to zero based on the deceleration time programmed into [Decel
Time 1/2]. The “normal” mode of machine operation can utilize [Decel Time
1]. If the “Machine Stop” mode requires a faster deceleration than desired for
normal mode, the “Machine Stop” can activate [Decel Time 2] with a faster
rate selected. When in Ramp to Stop, the drive acknowledges the Stop
command by decreasing or “ramping” the output voltage and frequency to
zero in a programmed period (Decel Time), maintaining control of the motor
until the drive output reaches zero. The output transistors are then shut off.
The load/motor should follow the decel ramp. Other factors such as bus
regulation and current limit can alter the decel time and modify the ramp
function.
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 [DC Hold Time]
and [DC Hold Level] are not zero, the drive applies DC to the motor
producing current at the DC Hold Level for the DC Hold Time.
Output Voltage
Output Current
Motor Speed
Output Current
Output Voltage
DC
Hold
Level
Time
Stop
Command
Zero
Command
Speed
DC Hold Time
Motor speed during and after the application of DC depends upon the
combination of the these two parameter settings, and the mechanical system.
The drive output voltage will be zero when the hold time is finished.
The level and uniformity of the DC braking offered at zero speed may not be
suitably smooth for many applications. If this is an application requirement, a
vector control drive, motion control drive or mechanical brake should be
used.
The drive output voltage will be zero when the hold time is finished
198
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Stop Modes
5. Ramp To Hold is selected by setting [Stop Select x]. The drive will ramp the
frequency to zero based on the deceleration time programmed into [Decel
Time 1/2]. Once the drive reaches zero hertz, a DC Injection holding current
is applied to the motor. The level of current is set in [DC Brake Level].
In this mode, the braking is applied Continuously. [DC Hold Time] has no
effect in this mode. Braking will continue until one of the following events
occur:
– The Enable Input is opened, or . . .
– A Start command is re-issued.
Again, caution must be exercised to not overheat the motor by applying excess
voltage and/or for excess time, particularly if the motor is not rotating.
Output Voltage
Output Voltage
Output Current
Output Current
Motor Speed
Motor Speed
Output Current
Output Voltage
DC
Hold Level
Time
Stop
Command
Zero
Command
Speed
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Re-issuing a
Start Command
199
Test Points
Test Points
Diagnostics
UTILITY (File E)
234 [Testpoint 1 Sel]
236 [Testpoint 2 Sel]
Default:
Min/Max:
Selects the function whose value is displayed value in Display:
[Testpoint x Data].
These are internal values that are not accessible through
parameters.
See Testpoint Codes and Functions for a listing of
available codes and functions.
Default:
235 [Testpoint 1 Data]
237 [Testpoint 2 Data]
Min/Max:
32
The present value of the function selected in [Testpoint Display:
x Sel].
499
0/999
1
Read Only
0/65535
1
Table 17 Testpoint Codes and Functions
Code Selected in
[Testpoint x Sel]
0
1
2
3
4
5
6
7
8-99
Function Whose Value is Displayed in
[Testpoint x Data]
DPI Error Status
Heatsink Temperature
Active Current Limit
Active PWM Frequency
Lifetime MegaWatt Hours
Lifetime Run Time
Lifetime Powered Up Time
Lifetime Power Cycles
Reserved for Factory Use
Thermal Regulator
See Drive Overload on page 94.
Torque Limits
Vector FV The bus regulator, when enabled, generates a regenerative power
limit to prevent the DC bus voltage from rising. The maximum (value closest to
zero) of the bus regulator regen power limit and [Regen Power Limit] is
converted into a positive and negative torque limit. The positive limit is used
when the motor is regenerating in the reverse direction. The negative limit is used
when the motor is motoring in the reverse direction. Finally, the drive’s torque
reference is limited by the minimum (value closest to zero) of the positive torque
limit from the power limit section and [Pos Torque Limit]. The drive’s torque
reference is also limited by the maximum (value closest to zero) of the negative
torque limit from the power limit section and [Neg Torque Limit].
Motor Torque Ref
from Torque Notch Filter
24
440
4-7
Control Status
Torque Pos Limit
200
435
Speed Feedback
25
Rated Volts
27
DC Bus Memory
13
Bus Reg Mode A
161
Bus Reg Mode B
162
DC Bus Voltage
12
Regen Power Lim
153
Torque Neg Limit
436
Bus
Voltage
Regulator
Min
Power
Limit
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Max
Torque
Limit
Torque Performance Modes
Torque Performance
Modes
[Torque Perf Mode] or [Motor Cntl Sel] (Vector) selects the output mode of the
drive. The choices are:
• Custom Volts/Hertz
Used in multi-motor or synchronous motor applications.
• Fan/Pump Volts/Hertz
Used for centrifugal fan/pump (variable torque) installations for additional
energy savings.
• Sensorless Vector
Used for most general constant torque applications. Provides excellent
starting, acceleration and running torque.
• Sensorless Vector w/Economizer
Used in constant torque applications that have significant “idle” time (time
spent at greatly reduced load) to offer additional energy conservation.
The following table shows the performance differences between V/Hz and
Sensorless Vector.
Torque Mode
Speed Regulation
(% of base speed)
Operating Speed Range
Speed Bandwidth
Fan/Pump and
Custom V/Hz with SVC with Slip SVC with
Slip Comp
Comp
Feedback
0.5%
0.5%
0.1%
Flux Vector
without
Feedback
0.1%
Flux Vector with
Feedback
0.001%
40:1
10 rad/sec
120:1
50 rad/sec
1000:1
250 rad/sec
80:1
20 rad/sec
80:1
20 rad/sec
Volts/Hertz
Volts/Hertz operation creates a fixed relationship between output voltage and
output frequency. The relationship can be defined in two ways.
1. Fan/Pump
When this option is chosen, the relationship is 1/X2. Therefore;
for full frequency, full voltage is supplied and for ½1/2 rated frequency,
1/4 voltage is applied, etc. 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
Base Frequency
(Nameplate)
Maximum
Frequency
2. Custom
Custom Volts/Hertz allows 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 would see if it
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
201
Torque Performance Modes
were started across the line. As seen in the diagram below, the volts/hertz ratio
can be changed to provide increased torque performance when required. The
shaping takes place by programming 5 distinct points on the curve:
– Start Boost - Used to create additional torque for breakaway from zero
speed and acceleration of heavy loads at lower speeds
– 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.
– Break Voltage/Frequency - Used to increase the slope of the lower
portion of the Volts / hertz curve, providing additional torque.
– Motor Nameplate Voltage/Frequency - sets the upper portion of the
curve to match the motor design. Marks the beginning of the constant
horsepower region
– Maximum Voltage/Frequency - Slopes that portion of the curve used
above base speed.
Maximum Voltage
Base Voltage
(Nameplate) Voltage
Break Voltage
Start/Accel Boost
Run Boost
Break
Frequency
Base Frequency
(Nameplate)
Maximum
Frequency
Sensorless Vector
Sensorless Vector technology consists of a basic V/Hz core surrounded by
excellent current resolution (the ability to differentiate flux producing current
from torque producing current), a slip estimator, a high performance current
limiter (or regulator) and the vector algorithms.
CURRENT FEEDBACK - TOTAL
Current
Resolver
TORQUE I EST.
CURRENT FEEDBACK
V/Hz Control
SPEED REF.
+
FREQUENCY REF.
+
Current
Limit
ELEC. FREQ.
V/Hz
V VECTOR
SLIP FREQUENCY
202
Voltage
Control
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
GATE
SIGNALS
Inverter
Motor
TORQUE I EST.
TORQUE I EST.
Flux
Vector
Control
V REF.
Slip
Estimator
Torque Performance Modes
The algorithms operate on the knowledge that motor current is the vector sum of
the torque and flux producing components. Values can be entered to identify the
motor values or an autotune routine can be run to interrogate and identify the
motor values (see Autotune on page 40). Early versions required feedback, but
today, performance is sensorless. It offers high breakaway torque, exceptional
running torque, a wider speed range than V/Hz, higher dynamic response and a
fast accel “feed forward” selectable for low inertia loads (adaptive current limit).
Sensorless vector is not a torque regulating technology. It does NOT
independently control the flux and torque producing currents. Therefore, it
cannot be used to regulate torque (torque follower).
In sensorless vector control, the drive maintains a constant flux current up to base
speed, allowing the balance of the drive available current to develop maximum
motor torque. By manipulating output voltage as a function of load, excellent
motor torque can be generated.
Maximum Voltage
Base Voltage
(Nameplate)
ve
Cur
oad
L
ll
e Fu
t
ima
prox
App
te
ima
urve
dC
Loa
No
prox
Ir Voltage
App
Base Frequency
(Nameplate)
Vector
FV
Maximum
Frequency
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. This type of speed regulator produces a high bandwidth response to
speed command and load changes.
In flux vector control, the flux and torque producing currents are independently
controlled. Therefore, we can send a torque reference directly instead of a speed
reference. The independent flux control also allows us to reduce the flux in order
to run above base motor speed.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
203
Torque Reference
Figure 59 Flux Vector
High Bandwidth Current Regulator
CURRENT FEEDBACK
Flux
Reg.
SPEED REF.
V mag
Current
Reg.
Speed
Reg.
TORQUE REF.
Voltage
Control
Inverter
Motor
V ang
Encoder
SLIP
Adaptive
Controller
AUTOTUNE PARAMETERS
SPEED FEEDBACK
Torque Reference
Vector FV When the PowerFlex 700 Vector Control drive is operated in
Torque mode, an external signal is used for a Torque reference. Refer to Figure 60.
Figure 60
Scale
428
Ref A Hi
429
Ref A Lo
Torque Ref A Sel 427
Torq Ref A Div 430
Torque Ref B Sel 431
Scale
432
Ref B Hi
433
Ref B Lo
/
x
+
Torq Ref B Mult 434
Torque Reference Input
[Torque Ref A], parameter 427 is used to supply an external reference for how
much torque is desired. The scaling of this parameter is from –800 to +800, via
[Torq Ref A Hi] and [Torq Ref A Lo].
Torque Ref 1 is then divided by [Torq Ref A Div], parameter 430. This defines
the scaled Torque Ref A.
[Torque Ref B], parameter 431 is used to supply an external reference for how
much torque is desired. The scaling of this parameter is from –800 to +800, via
[Torq Ref B Hi] and [Torq Ref B Lo].
The Torque Ref B is then multiplied by [Torq Ref B Mul], parameter 434. This
defines the scaled Torque Ref B.
Once the scaling is complete on both Torque Ref A and Torque Ref B, the output
is summed to create the external torque reference
This can be utilized when a master/slave multi-drive system is configured. The
torque reference into the “slave” can be scaled to create the proper torque output.
Keep in mind that the motors may be different ratings and this function is used
to help the “system” share the load.
204
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Troubleshooting
PowerFlex 700 Firmware 3.001 (& later) Enhancements
Extra selections have been added to [Torque Ref A Sel] and [Torque Ref B Sel] in
firmware version 3.001 (and later) for the PowerFlex 700 Vector Control drive:
• Scale Block Output available as a selection
• Torque Setpoint 2 is new and available as a selection
Default:
1
1
Selects the source of the external torque reference to Options:
the drive. How this reference is used is dependent
FV
upon [Speed/Torque Mod].
(1) See User Manual for DPI port locations.
(2) Vector firmware 3.001 and later.
0
427
431
438
Vector
Vector
Vector v3
[Torque Ref A Sel]
[Torque Ref B Sel]
[Torque Setpoint2]
FV Provides an internal fixed value for Torque Setpoint
when [Torque Ref Sel] is set to “Torque Setpt 2.”
Default:
“Torque Setpt”
“Disabled”
053
“Torque Setpt”
“Torque Stpt1”(2)
1
“Analog In 1”
2
“Analog In 2”
3-17 “Reserved”
18-2 “DPI Port 1-5” (1)
2
“Reserved”
23 “Disabled”
24 “Scale Block1-4”(2)
25-2 “Torque Stpt2”(2)
8
29
0.0%
Min/Max: –/+800.0%
0.1%
Units:
Troubleshooting
See Faults on page 101 and Advanced Tuning on page 12.
Unbalanced or
Ungrounded Distribution
Systems
Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives,” publication DRIVES-IN001 for detailed information on
Unbalanced or Ungrounded Distribution Systems.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
205
User Sets
User Sets
After a drive has been configured for a given application the user can store a copy
of all of the parameter settings in a specific EEPROM area known as a “User Set.”
Up to 3 User Sets can be stored in the drives memory to be used for backup, batch
“switching” or other needs. All parameter information is stored. The user can
then recall this data to the active drive operating memory as needed. Each User
Set can also be identified with a programmable name, selected by the user for
clarity.
Two operations are available to manage User Sets, “Save To User Set” and
“Restore From User Set.” The user selects 1, 2, or 3 as the area in which to store
data. After data is successfully transferred, “Save User Set” returns to a value of 0.
To copy a given area back into the active EEprom memory, the user selects Set 1,
2, or 3 for “Restore User Set.” After data is successfully transferred, “Restore User
Set” returns to a value of 0. When shipped from the factory all user sets have the
same factory default values. Reset Defaults does not effect the contents of User
Sets.
Important: User Sets can only be transferred via the HIM. No provisions exist
for control via digital I/O or communications module.
Figure 61 User Sets
PowerBoard
EEprom
Factory
Default Data
Reset Defaults
Drive Rating & Motor
Parameters
1
Reset
Active EE
Non Drive Rating & Motor
Parameters
Flash Memory
SaveUserSet
400V
Default Data
480V
Default Data
2
1
User Set 1
2
User Set 2
3
User Set 3
Save
User set
3
Active EE
Restore
User set
RestoreUserSet
Load
Application
Set
Application Set
206
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Flash Memory
Voltage Class
Voltage Class
PowerFlex drives are sometimes referred to by voltage “class.” This class identifies
the general input voltage to the drive. This general voltage includes a range of
actual voltages. For example, a 400 Volt Class drive will have an input voltage
range of 380-480VAC. While the hardware remains the same for each class,
other variables, such as factory defaults, catalog number and power unit ratings
will change. In most cases, all drives within a voltage class can be reprogrammed
to another drive in the class by resetting the defaults to something other than
“factory” settings. The [Voltage Class] parameter can be used to reset a drive to a
different setup within the voltage class.
As an example, consider a 480 volt drive. This drive comes with factory default
values for 480V, 60 Hz with motor data defaulted for U.S. motors (HP rated,
1750 RPM, etc.) By setting the [Voltage Class] parameter to “low Voltage” (this
represents 400V in this case) the defaults are changed to 400V, 50 Hz settings
with motor data for European motors (kW rated, 1500 RPM, etc.). Refer to
Figure 61.
Voltage Tolerance
Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or
PowerFlex 700 Technical Data (publication 20B-TD001) for details.
Watts Loss
Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or
PowerFlex 700 Technical Data (publication 20B-TD001) for Watts Loss
information.
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
207
Watts Loss
Notes:
208
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Index
A
Accel Mask 113
Accel Owner 126
Accel Time 11
Accel Time 1/2 11
Advanced Tuning 70
Alarm Queue 18
Alarm x Code 18
Alarms 15
Analog I/O 18
Analog I/O Cable Selection 28
Analog In Lo 22
Analog In1 Value 28
Analog In2 Value 28
Analog Inputs 18
Analog Out Scale 35
Analog Out1 Sel 31
Analog Out2 Sel 31
Analog Outputs 31
Analog Scaling 22
Anlg In 1, 2 Loss 26
Anlg In Config 16, 19
Anlg In Loss 17
Anlg In Sqr Root 26
Anlg Out Setpt 36
Auto / Manual 36, 167
Auto Restart 38
Auto Rstrt Delay 38
Auto Rstrt Tries 38
Auto-Economizer 99
Autotune 40
B
Block Diagrams 44
Bus Capacitors, Discharging 10
Bus Memory 69
Bus Reg Gain 56
Bus Reg Mode A, B 56
Bus Regulation 56
Bypass Contactor 120
C
Cable
I/O, Analog 28
I/O, Digital 70
Motor, Length 61
Cable Termination 123
Cable Trays 61
Capacitors - Bus, Discharging 10
Carrier (PWM) Frequency 62
CE
Conformity 63
Requirements 63
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
Circuit Breakers 106
Clear Fault Owner 126
Coast 197
Compensation 149
Conduit 61
Contactor, Output 123
Contactors
Bypass 120
Input 120
Output 120
Copy Cat 65
Current Limit 66
Current Lmt Gain 66
Current Lmt Sel 19, 66, 157
Current Lmt Val 66
D
Datalinks 67
DC Brake Level 197
DC Brake Lvl Sel 197
DC Brake Time 197
DC Braking 197
DC Bus Voltage 69
Decel Mask 113
Decel Owner 126
Decel Time 69
Decel Time 1/2 69
Dig Out Setpt 91
Dig Outx Level 89
Dig Outx OffTime 90
Dig Outx OnTime 90
Digital Input Conflicts 83
Digital Inputs 70
Digital Inputs Group 71, 72
Digital Inx Sel 71, 72
Digital Output Timers 90
Digital Outputs 87
Digital Outputs Group 71, 88
Digital Outx Sel 17, 87, 88
Direction Control 91
Direction Mask 113
Direction Owner 126
DPI 92
Drive Output Contactor 123
Drive Overload 94
Drive Ratings 99
Drive Thermal Manager Protection 97
Droop 99
Dynamic Braking 197
E
Economizer 99
Efficiency Derates 100
209
Index
EMC
Directive 63
EMC Instructions 63
Encoder 165
ESD, Static Discharge 10
Exclusive Ownership 125
F
Fan Curve 100
Fault Clr Mask 113
Fault Configuration 103, 157
Fault Queue 101
Faults 101
Feedback Select 162
Flux Up 104
Flux Up Mode 104
Flying Start En 106
Flying Start Gain 106
Flying StartGain 106
Fuses 106
G
General Precautions 10
Group
Digital Inputs 71, 72
Digital Outputs 71, 88
Power Loss 130
Speed References 16
L
Language 111
Language Parameter 111
Language Select, HIM 107
Linking Parameters 111
Local Mask 113
Local Owner 126
Logic Mask 113
Low Voltage Directive 63
M
Manual Preload 36
Masks 113
Max Speed 170
Maximum frequency 171
Min Mode/Max Mode 174
MOP Mask 113
MOP Owner 126
Motor Cable Lengths 61
Motor Nameplate 116
Motor NP FLA 116
Motor NP Hz 116
Motor NP Power 116
Motor NP Pwr Units 116
Motor NP RPM 116
Motor NP Volts 116
Motor Overload 117
Motor Overload Protection 119
Motor Start/Stop 120
H
HIM Memory 107
HIM Operations 107
Human Interface Module
Language 107
Password 107
User Display 108
I
I/O Wiring
Analog 28
Digital 70
Input Contactor
Start/Stop 120
Input Devices 108
Input Modes 109
Input Power Conditioning 110
J
Jog 110
Jog Mask 113
Jog Owner 126
210
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
N
Notch Filter 121
O
Output Contactor
Start/Stop 120
Output Current 123
Output Devices
Contactors 120, 123
Output Reactor 123
Output Frequency 124
Output Power 124
Output Reactor 123
Output Voltage 124
Overspeed 124
Owners 125
P
Parameter access level 127
Index
Parameters
Accel Mask 113
Accel Owner 126
Alarm x Code 18
Analog In Hi 22
Analog In Lo 22
Analog In1 Value 28
Analog In2 Value 28
Analog Out Scale 35
Analog Out1 Sel 31
Analog Out2 Sel 31
Anlg In Config 16, 19
Anlg In Loss 17
Anlg In Sqr Root 26
Anlg Out Setpt 36
Auto Rstrt Delay 38
Auto Rstrt Tries 38
Bus Reg Gain 56
Bus Reg Mode A, B 56
Clear Fault Owner 126
Compensation 149
Current Lmt Sel 19, 157
Decel Mask 113
Decel Owner 126
Dig Out Setpt 91
Dig Outx Level 89
Dig Outx OffTime 90
Dig Outx OnTime 90
Digital Inx Sel 71, 72
Digital Outx Sel 17, 87, 88
Direction Mask 113
Direction Owner 126
Fault Clr Mask 113
Fault Config x 157
Feedback Select 162
Flying Start En 106
Flying Start Gain 106
Flying StartGain 106
Jog Mask 113
Jog Owner 126
Language 111
Local Mask 113
Local Owner 126
Logic Mask 113
MOP Mask 113
MOP Owner 126
PI Configuration 148
PI Deriv Time 147
PI Reference Sel 148
Power Loss Mode 130
Reference Mask 113
Reference Owner 126
Reset Meters 151
Speed Mode 162
Speed Ref A Sel 16
Start Mask 113
Start Owner 126
Stop Owner 126
Testpoint 1 Sel 200
Testpoint x Data 200
Torque Perf Mode 201
Torque Ref x Sel 205
Torque Setpoint2 205
Trim Out Select 149
Password, HIM 107
PET Ref Wave 128
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
PI Config 135
PI Configuration 148
PI Control 135
PI Deriv Time 147
PI Error Meter 135
PI Feedback Meter 135
PI Feedback Sel 135
PI Integral Time 135
PI Output Meter 135
PI Preload 135
PI Prop Gain 135
PI Ref Meter 135
PI Reference Sel 135, 148
PI Setpoint 135
PI Status 135
PI Upper/Lower Limit 135
Power Loss 128
Power Loss Group 130
Power Loss Mode 130
Power Up Marker 103
Precautions, General 10
Preset Frequency 135
Process PI Loop 135
PWM Frequency 62, 98
R
Reference Mask 113
Reference Owner 126
Reference, Speed 72, 77, 167
Reflected Wave 149
Repeated Start/Stop 120
Reset Meters 151
Reset Run 151
RFI Filter 151
S
S Curve 151
Scale Blocks 154
Sensorless Vector 202
Shear Pin 157
Signal Loss 26
Skip Frequency 158
Sleep Mode 160
Slip Compensation 162
Speed
Control 162
Regulation 162
Speed Feedback Filter 166
Speed Mode 162
Speed Ref A Sel 16
Speed Reference 72, 77, 167
Speed Reference Trim 28, 170
Speed References Group 16
Speed Regulation Mode 173
211
Index
Speed Units 176
Speed/Torque Select 172
Start Inhibits 176
Start Mask 113
Start Owner 126
Start Permissives 176
Start/Stop, Repeated 120
Start-Up 177
Static Discharge, ESD 10
Stop Mode A, B 197
Stop Modes 197
Stop Owner 126
Sum Mode 175
T
Terminal Designations 29
Test Points 200
Testpoint 1 Sel 200
Testpoint x Data 200
Thermal Manager Protection 97
Thermal Regulator 200
Torque Performance Modes 201
Torque Ref x Sel 205
Torque Reference 204
Torque Regulation Mode 173
Torque Setpoint2 205
Trim 28
Trim Out Select 149
Troubleshooting 205
U
User Display, HIM 108
User Sets 206
V
Vector Control 203
Vector Feedback 162
Vector Speed Feedback 162
Voltage class 207
Voltage Tolerance 207
Volts/Hertz 201
W
Watts Loss 207
Wiring Examples 29
Z
Zero Torque Mode 175
212
Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013
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At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample
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Installation Assistance
If you experience a problem within the first 24 hours of installation, review the information that is contained in this
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Publication PFLEX-RM001H-EN-P - June 2013
Supersedes Publication PFLEX-RM001G-EN-P - August 2004
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