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Adjustable
Frequency AC Drive
www.abpowerflex.com
Reference Manual
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls” (Publication SGI-1.1
available from your local Allen-Bradley Sales Office or online at
http:// www.ab.com/manuals/gi
) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will the Allen-Bradley Company 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, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
!
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 the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful application and understanding of the product.
Shock Hazard labels may be located on or inside the drive to alert people that dangerous voltage may be present.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
COLOR-KEYED is a registered trademark of Thomas & Betts Corporation.
Chapter 1
Chapter 2
Table of Contents
Specifications & Dimensions
Detailed Drive Operation
ii
Table of Contents
Appendix A
Section 1
Section 2
Section 3
Section 4
Index
Chapter
1
Specifications & Dimensions
PowerFlex 70/700
Specifications
Category
Protection
Agency
Certification
Specification
PowerFlex 70 Drive
AC Input Overvoltage Trip:
AC Input Undervoltage Trip:
Bus Overvoltage Trip:
Bus Undervoltage Trip:
Nominal Bus Voltage:
PowerFlex 700
AC Input Overvoltage Trip:
AC Input Undervoltage Trip:
Bus Overvoltage Trip:
Bus Undervoltage Trip:
Nominal Bus Voltage:
All Drives
Heat Sink Thermistor:
Drive Overcurrent Trip
Software Current Limit:
Hardware Current Limit:
Instantaneous Current Limit:
Line transients:
Control Logic Noise Immunity:
Power Ride-Thru:
Logic Control Ride-Thru:
Ground Fault Trip:
Short Circuit Trip:
200-208V
Drive
240V
Drive
380/400
Drive
480V
Drive
600V
Drive
247VAC 285VAC 475VAC 570VAC 690VAC
120VAC 138VAC 233VAC 280VAC 345VAC
350VDC 405VDC 675VDC 810VDC 1013VDC
176VDC 204VDC 339VDC 407VDC 998VDC
281VDC 324VDC 540VDC 648VDC 810VDC
See PowerFlex 70 above
Adjustable
See PowerFlex 70 above
Monitored by microprocessor overtemp trip
20-160% of rated current
200% of rated current (typical)
220-300% of rated current (dependent on drive rating) up to 6000 volts peak per IEEE C62.41-1991
Showering arc transients up to 1500V peak
15 milliseconds at full load
0.5 seconds minimum, 2 seconds typical
Phase-to-ground on drive output
Phase-to-phase on drive output
690V
Drive
The drive is designed to meet the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection,
Installation and Operation of Adjustable Speed Drive Systems.
NEMA 250 - Enclosures for Electrical Equipment
IEC 146 - International Electrical Code.
UL and cUL Listed to UL508C and CAN/CSA-C2.2 No. 14-M91
c
U
L
US
Marked for all applicable European Directives
(1)
EMC Directive (89/336/EEC)
Emissions
EN 61800-3 Adjustable Speed electrical power drive systems Part 3
Immunity
EN 61800-3 Second Environment, Restricted Distribution
Low Voltage Directive (73/23/EEC)
EN 60204-1 Safety of Machinery –Electrical Equipment of Machines
EN 50178 Electronic Equipment for use in Power Installations
1-2
Input/Output Ratings
Category Specification
Environment Altitude: 1000 m (3300 ft) max. without derating
Ambient Operating Temperature without derating:
Open Type:
IP20:
NEMA Type 1:
IP56, NEMA Type 4X
0 to 50 degrees C (32 to 122 degrees F)
0 to 50 degrees C (32 to 122 degrees F)
0 to 40 degrees C (32 to 104 degrees F)
0 to 40 degrees C (32 to 104 degrees F)
Storage Temperature (all const.): –40 to 70 degrees C (–40 to 158 degrees F)
Relative Humidity:
Shock:
Vibration:
5 to 95% non-condensing
15G peak for 11ms duration (
±
1.0 ms)
0.152 mm (0.006 in.) displacement, 1G peak
Electrical
Voltage Tolerance:
Frequency Tolerance:
Input Phases:
–10% of minimum, +10% of maximum.
47-63 Hz.
Three-phase input provides full rating for all drives. Single-phase operation provides 50% of rated current.
Displacement Power Factor
PF70 - C & D Frame Drives:
PF70 - A & B Frame Drives:
PF700
Efficiency:
Max. Short Circuit Current Rating:
Using Recommended Fuse or
Circuit Breaker Type
Method:
0.92 lagging (entire speed range)
0.64 lagging
TBD
97.5% at rated amps, nominal line volts.
Maximum short circuit current rating to match specified fuse/circuit breaker capability.
Control
(1)
Sine coded PWM with programmable carrier frequency. Ratings apply to all drives (refer to the Derating Guidelines on
). The drive can be supplied as 6 pulse or 12 pulse in a configured package.
Carrier Frequency
PF70 - A-D Frame Drives:
PF700 - 0-3 Frames:
Output Voltage Range:
Output Frequency Range:
Frequency Accuracy
Digital Input:
Analog Input:
Speed Regulation - Open Loop with Slip Compensation:
Selectable Motor Control:
2-10 kHz. Drive rating based on 4 kHz
2-10 kHz. Drive rating based on 4 kHz
0 to rated motor voltage
0 to 400 Hz.
Within
Within
±
±
±
0.01% of set output frequency.
0.4% of maximum output frequency.
0.5% of base speed across a 40:1 speed range.
Stop Modes:
Accel/Decel:
Intermittent Overload:
Sensorless Vector with full tuning. Standard V/Hz with full custom capability. PF700 adds flux vector.
Multiple programmable stop modes including - Ramp, Coast, DC-Brake,
Ramp-to-Hold and S-curve.
Two independently programmable accel and decel times. Each time may be programmed from 0 - 3600 seconds in 0.1 second increments
110% Overload capability for up to 1 minute
150% Overload capability for up to 3 seconds
Current Limit Capability: Proactive Current Limit programmable from 20 to 160% of rated output current. Independently programmable proportional and integral gain.
Electronic Motor Overload
Protection
Class 10 protection with speed sensitive response. Investigated by U.L.
to comply with N.E.C. Article 430. U.L. File E59272, volume 12.
Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high [Pulse Freq] readings.
Input/Output Ratings
Each PowerFlex Drive has normal and heavy duty torque capabilities. The listings can be found in Tables
Heat Dissipation
See
Derating Guidelines
1-3
Derating Guidelines
PowerFlex 70 Ambient Temperature/Load
PowerFlex70, A Frame 400V Class. Derating, Ambient Temperature and Load. Open, NEMA1, IP20.
62
60
58
56
54
52
50
10kHz
8kHz
6kHz
4kHz
2kHz
48
40 50 60 70
% of Full Load, Amps
80 90
PowerFlex70, B Frame 400V Class. Derating, Ambient Temperature and Load. Open, NEMA1, IP20
100
65
60
55
50
10kHz
8kHz
6kHz
4kHz
2kHz
55
50
60
58
45
40 50 60 70
% of Full Load Amps
80 90 100
PowerFlex70, C Frame 400V Class, Derating, Ambient Temperature and Load. Open, NEMA1 and IP20
62
56
54
52
50
10kHz
8kHz
6kHz
4kHz
2kHz
48
40 50 60 70
% of Output FLA
80 90
PowerFlex70, D Frame 400V Class. Derating, Ambient Temperature and Load. Open, NEMA1, IP20
60
100
10kHz
8kHz
6kHz
4kHz
2kHz
45
40
40 50 60 70
% of Full Load Amps
80 90 100
1-4
Derating Guidelines
Altitude
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 1000
PowerFlex 70 Altitude Derating Factor - All Frames.
2000 3000
Altitude (m)
4000 5000 6000
Efficiency
1
0.9
0.8
0.7
0.6
0.5
25 50 75 100
1 HP
0.5 HP
PowerFlex 70 Dimensions
1-5
PowerFlex 70
Dimensions
A
B
Figure 1.1 PowerFlex 70 Frames A-D
F
C D
E
Dimensions are in millimeters and (inches)
C
D
A
B
Frame
(see
)
A B C D E F Weight
121.9 (4.80) 94.2 (3.71) 211.6 (8.33) 225.8 (8.89) 5.8 (0.23) 179.8 (7.08) 3.56 kg (7.85 lb)
171.2 (6.74) 122.7 (4.83) 220.2 (8.67) 234.6 (9.24) 5.8 (0.23) 179.8 (7.08) 4.49 kg (9.9 lb)
185.9 (7.32) 137.6 (5.42) 285.6 (11.25) 300.0 (11.81) 5.8 (0.23) 179.8 (7.08) 7.60 kg (16.75 lb)
220.4 (8.68) 169.0 (6.65) 335.7 (13.21) 350.0 (13.78) 5.8 (0.23) 180.4 (7.10) 9.75 kg (21.5 lb)
Table 1.A PowerFlex 70 Frames
Frame
A
B
C
D
–
3
–
2
240/208V AC Input 400V AC Input
ND HP HD HP ND kW HD kW
480V AC Input
ND HP HD HP
600V AC Input
ND HP HD HP
0.5
1
0.33
0.75
0.37
0.75
0.25
0.55
0.5
1
0.33
0.75
0.5
1
0.33
0.75
–
1.5
–
2
1.5
2.2
4
5.5
1.1
1.5
3
4
2
3
5
7.5
1.5
2
3
5
2
3
5
7.5
1.5
2
3
5
5
7.5
10
3
5
7.5
7.5
11
15
5.5
7.5
11
10
15
20
7.5
10
15
10
15
20
7.5
10
15
1-6
PowerFlex 70 Dimensions
Figure 1.2 PowerFlex 70 Bottom View Dimensions - Frame A
41.9
(1.65)
35.6
(1.40)
80.0
(3.15)
86.4
(3.40)
∅
22.2
(0.88)
99.3
(3.91)
137.4
(5.41)
Dimensions are in millimeters and (inches)
Figure 1.3 PowerFlex 70 Bottom View Dimensions - Frame B
66.5
(2.62)
45.5
(1.87)
104.6
(3.40)
85.6
(3.37)
123.7
(4.87)
∅
22.2
(0.88)
99.3
(3.91)
137.4
(5.41)
Dimensions are in millimeters and (inches)
PowerFlex 70 Dimensions
1-7
Figure 1.4 PowerFlex 70 Bottom View Dimensions - Frame C
34.5
(1.36)
65.5
(2.58)
96.5
(3.80)
∅
22.2
(0.88)
96.0
(3.78)
118.3
(4.65)
140.5
(5.53)
Number of fans will vary depending on drive size.
Dimensions are in millimeters and (inches)
Figure 1.5 PowerFlex 70 Bottom View Dimensions - Frame D
52.2
(2.06)
80.3
(3.16)
106.8
(4.20)
123.4
(4.86)
37.2
(1.46)
∅
22.2
(0.88)
22.2
∅
(0.88)
F G
102.6
(4.04)
140.3
(5.52)
Dimensions are in millimeters and (inches)
1-8
PowerFlex 70 Flange Mount Dimensions
PowerFlex 70 Flange
Mount Dimensions
Drive Catalog Number
20AB2P2F
20AB4P2F
20AC1P3F / 20AD1P1F
20AC2P1F / 20AD2P1F
20AC3P5F / 20AD3P4F
20AE0P9F
20AE1P7F
20AE2P7F
20AB6P8F
20AC5P0F / 20AD5P0F
20AC8P7F / 20AD8P0F
20AE3P9F
20AE6P1F
20AB9P6F
20AB015F
20AC011F / 20AD011F
20AC015F / 20AD014F
20AE9P0F
20AE011F
20AB9P6F
20AB015F
20AC011F / 20AD011F
20AC015F / 20AD014F
20AE9P0F
20AE011F
Figure
Knockout Dimensions
Figure 1.6 Overall Dimensions
A
Cutout Dimensions
C
B
Dimensions are in millimeters and (inches)
B
C
Frame
A
D
A
156.0 (6.14)
205.2 (8.08)
219.0 (8.62)
248.4 (9.78)
B
225.8 (8.89)
234.6 (9.24)
300.0 (11.81)
350.0 (13.78)
C
178.6 (7.03)
178.6 (7.03)
178.6 (7.03)
178.6 (7.03)
Figure 1.7 A Frame Knockout Dimensions
96.1
72.4
59.6
(2.35)
(2.85)
(3.78)
101.9
(4.01)
PowerFlex 70 Flange Mount Dimensions
1-9
22.2 dia.
(0.87 dia.)
43.2
(1.70)
70.5
(2.78)
76.6
(3.02)
Dimensions are in millimeters and (inches)
Figure 1.8 B Frame Knockout Dimensions
92.4
70.9
(2.79)
(3.64)
102.7
(4.04)
130.5
(5.14)
140.6
(5.54)
22.2 dia.
(0.87 dia.)
41.4
(1.63)
65.9
(2.59)
76.6
(3.02)
Dimensions are in millimeters and (inches)
1-10
PowerFlex 70 Flange Mount Dimensions
Figure 1.9 C Frame Knockout Dimensions
92.2
111.2
(4.38)
73.0
(3.63)
53.1
(2.87)
(2.09)
22.2 dia.
(0.87 dia.)
40.6
(1.60)
68.7
(2.70)
Dimensions are in millimeters and (inches)
Figure 1.10 D Frame Knockout Dimensions
107.3
135.5
(5.33)
78.3
(4.22)
51.9
(3.08)
(2.04)
2x 22.2 dia.
(0.87 dia.)
2x 28.5 dia.
(1.12 dia.)
74.1
42.3
(1.67)
(2.92)
Dimensions are in millimeters and (inches)
Figure 1.11 A Frame Cutout Dimensions
156.0
(6.14)
140.7
(5.54)
70.4
(2.77)
6.9
(0.27)
PowerFlex 70 Flange Mount Dimensions
1-11
127.0
(5.00)
195.1
(7.68)
210.6
(8.29)
225.8
(8.89)
105.3
(4.15)
8x 4.0 +0.13 -0.03 dia.
(0.16 +.005 -.001 dia.)
4x 3.0R
(0.12R)
7.7
(0.31)
58.8
(2.31)
Dimensions are in millimeters and (inches)
1-12
PowerFlex 70 Flange Mount Dimensions
6.9
(0.27)
Figure 1.12 B Frame Cutout Dimensions
205.2
(8.08)
190.0
(7.48)
95.0
(3.74)
176.3
(6.94)
205.5
(8.09)
109.7
(4.32)
219.3
(8.64)
234.6
(9.24)
8x 4.0 +0.13 -0.03 dia.
(0.16 +.005 -.001 dia.)
4x 3.0R
(0.12R)
6.9
(0.27)
58.8
(2.31)
Dimensions are in millimeters and (inches)
6.3
(0.25)
Figure 1.13 C Frame Cutout Dimensions
219.0
(8.62)
202.0
(7.95)
101.0
(3.98)
PowerFlex 70 Flange Mount Dimensions
1-13
271.8
(10.70)
12x 4.0
±
0.13 dia.
(0.16
±
.005 dia.)
189.4
(7.46)
4x 3.0R
(0.12R)
41.5
(1.63)
5.6
(0.22)
141.5
(5.57)
241.5
(9.51)
283.0
(11.14)
300.0
(11.81)
58.8
(2.31)
Dimensions are in millimeters and (inches)
1-14
PowerFlex 70 Flange Mount Dimensions
4.5
(0.18)
40.7
(1.60)
Figure 1.14 D Frame Cutout Dimensions
248.4
(9.78)
231.4
(9.11)
190.7
(7.51)
115.7
(4.56)
319.8
(12.59)
222.4
(8.75)
14x 4.0
±
0.13 dia.
(0.16
±
.005 dia.)
4x: 3.0R
(0.12R)
61.5
(2.42)
131.5
(5.18)
201.5
(7.93)
271.5
(10.69)
333.0
(13.11)
350.0
(13.78)
6.0
(0.24)
58.8
(2.31)
Dimensions are in millimeters and (inches)
Figure 1.15 Flange Mounting
PowerFlex 70 Flange Mount Dimensions
1-15
1
M4 x 8 x 25
(#10-24 x .75)
2
3
Dimensions are in millimeters and (inches)
1-16
PowerFlex 700 Dimensions
PowerFlex 700
Dimensions
Figure 1.16 PowerFlex 700 Frames 0-3
(0 Frame Shown)
15.0 (0.59)
5.8 (0.23) dia.
A
D
5.5 (0.22)
C
B
E
CAUTION
HOT surfaces can cause severe burns
5.5 (0.22)
8.0
(0.31)
Dimensions are in millimeters and (inches).
2
3
5
0
1
Frame
(see
Weight
(1)
kg (lbs.)
A B C D E Drive
Drive &
Packaging
110.0 (4.33) 336.0 (13.23) 200.0 (7.87) 80.0 (3.15) 320.0 (12.60) 5.22 (11.5) 8.16 (18)
135.0 (5.31) 336.0 (13.23) 200.0 (7.87) 105.0 (4.13) 320.0 (12.60) 7.03 (15.5) 9.98 (22)
222.0 (8.74) 342.5 (13.48) 200.0 (7.87) 192.0 (7.56) 320.0 (12.60) 12.52 (27.6) 15.20 (33.5)
222.0 (8.74) 517.5 (20.37) 200.0 (7.87) 192.0 (7.56) 500.0 (19.69) 18.55 (40.9) 22.68 (50)
300.0 (11.81) 583.0 (22.95) 270.3 (10.64) 225.0 (8.86) 625.0 (24.61)
(2)
(1)
(2)
Weights include HIM and Standard I/O.
Not available at time of publication
Table 1.B PowerFlex 700 Frames
Frame
0
1
2
3
5
–
–
15
20
5
7.5
10
–
–
–
2
3
208/240V AC Input 400V AC Input 480V AC Input
ND HP HD HP ND kW HD kW ND HP HD HP
0.5
1
0.33
0.75
0.37
0.75
0.25
0.55
0.5
1
0.33
0.75
1.5
2
–
–
1.5
2.2
4
5.5
0.75
1.5
2.2
4
2
3
5
7.5
1.5
2
3
5
3
5
7.5
–
10
15
–
–
7.5
11
15
18.5
22
30
–
55
5.5
7.5
11
15
18.5
22
45
–
10
15
20
25
30
40
–
75
25
30
60
–
7.5
10
15
20
PowerFlex 700 Dimensions
1-17
Figure 1.17 PowerFlex 700 Bottom View Dimensions – Frame 0
96.0 (3.78)
75.0 (2.95)
55.0 (2.17)
35.0 (1.38)
22.2 (0.87) Dia. – 4 Places
30.2
(1.19)
187.5
(7.38)
132.9
(5.23)
185.0
(7.28)
41.9 (1.65)
56.1 (2.21)
75.9 (2.99)
96.0 (3.78)
Dimensions are in millimeters and (inches)
Figure 1.18 PowerFlex 700 Bottom View Dimensions – Frame 1
108.5 (4.27)
87.5 (3.44)
67.5 (2.66)
47.5 (1.87)
28.6 (1.13) Dia.
22.2 (0.87) Dia.
3 Places
25.5
(1.00)
187.6
(7.39)
133.3
(5.25)
185.1
(7.29)
43.0 (1.69)
70.0 (2.76)
75.9 (2.99)
96.0 (3.78)
Dimensions are in millimeters and (inches)
1-18
PowerFlex 700 Dimensions
Figure 1.19 PowerFlex 700 Bottom View Dimensions – Frame 2
167.5 (6.59)
156.9 (6.18)
22.4 (0.88) Dia.
2 Places
28.7 (1.13) Dia.
3 Places
184.8
(7.28)
157.5
(6.20)
150.9
(5.94)
112.1
(4.41)
39.3 (1.55)
57.2 (2.25)
72.7 (2.86)
106.0 (4.17)
139.4 (5.49)
177.4 (6.98)
Dimensions are in millimeters and (inches)
Figure 1.20 PowerFlex 700 Bottom View Dimensions – Frame 3
105.3 (4.15)
94.7 (3.73)
22.2 (0.87) Dia.
28.6 (1.13) Dia.
2 Places
37.3 (1.47) Dia.
2 Places
165.1
(6.50)
160.1
(6.30)
151.1
(5.95)
127.7
(5.03)
184.5
(7.26)
22.7 (0.89)
29.0 (1.14)
66.0 (2.60)
97.0 (3.82)
137.2 (5.40)
187.0 (7.36)
Dimensions are in millimeters and (inches)
Chapter
2
Detailed Drive Operation
Accel Time
AC Supply Source
Considerations
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 Frequency – Minimum Frequency
Accel Time
= Accel Rate
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 using the 1st
/ 2nd Accel inputs shown below or a similar pattern of Accel Time select bits in the Logic Control word used via PLC communications.
Times are adjustable in.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.
PowerFlex 700 drives are suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes, 600V.
!
ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in
Tables
through
.
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
2-2
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
Alarm Config
1 0 0
X X
Active
Alarm
Inactive
Alarm
Inactive
Alarm
Alarms
2-3
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]
Selects the mode for the analog inputs.
322
325
323
326 x
15 x
14 x
13 x
12 x
11 x
10 x
9
Bit #
Factory Default Bit Values x
8 x
7 x
6 x
5 x
4 x
3 x
2
0
1
A nalo
0
0
2 g In
A na log
In 1
1 =Current
0 =Voltage x =Reserved
Analog In Config
0 1
Speed Ref A Sel
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.
Default:
Options:
(1)
See Appendix B for DPI port locations.
2
18
19
20
21
14
15
16
17
22
23
10
11
12
13
1
2
3-8
9
“Analog In 2”
“Analog In 1”
“Analog In 2”
“Reserved”
“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)
“DPI Port 6”
(1)
117 thru
120
192 thru
194
213
272
273
320
361 thru
366
002
091 thru
093
101 thru
107
2-4
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
P325
4mA
P091
60 Hz
P092
0 HZ
The input is configured to recognize a loss of signal and react accordingly to the programming.
324
327
[Analog In 1 Loss]
[Analog In 2 Loss]
Selects drive action when an analog signal loss is 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.
Default:
Options:
5
6
3
4
0
1
2
0
0
“Disabled”
“Disabled”
“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
384
[Digital Out1 Sel]
[Digital Out2 Sel]
Selects the drive status that will energize a (CRx) output relay.
Default:
Options:
(1)
Contacts shown on page 1-12 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.
1
4
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
21
22
23
24
17
18
19
20
25
26
“Fault”
“Run”
“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
382
386
383
002
001
003
004
218
012
137
157
147
053
048
184
Alarms
2-5
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)
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]
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.
Default:
Min/Max:
Display:
Read Only
0/256
1
261
2-6
Analog Inputs
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
.
•
Provide an external and adjustable value for the current limit and DC braking level
•
Enter and exit sleep mode.
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
for details on this mode of operation.
Analog In 1 Lo
Analog In 1 Hi
Analog In 2 Lo
Analog In 2 Hi
Analog Input
1 Scale
Volts or mA
Cal Analog 1
Analog Input
2 Scale
Volts or mA
Cal Analog 2
Input/Output
Parameter
Processing
Selection/Control
Speed Ref A Sel Speed Ref B Sel Trim In Select TB Man Ref Sel PI Reference Sel PI Feedback Sel Current Lmt Sel DC Brk Levl Sel Sleep-Wake Ref
Ref A
Scale/Limit
Speed Ref A Lo
Speed Ref A Hi
Speed Ref B Lo
Speed Ref B Hi
Ref B
Scale/Limit
Trim
Scale/Limit
Trim Lo
Trim Hi
TB Manual
Scale/Limit
Trim Out Sel
Hz
+
Hz
Reference A
+
Hz
Reference B
Brake Level
Scale/Limit
Sleep Level
Compare
Hz
TB Manual
PI
Reference
Scale/Limit
%
PI Reference
PI Feedback
Scale/Limit
%
PI Feedback
Current Limit
Scale/Limit
% Rated
Current
Current Limit
% Rated
Current
DC Brake
Sleep/
Wake
Sleep/Wake
Sleep Level
Wake Level
Analog 1
Voltage
Analog 1
Current
ADC
Input/Output
Parameter
Processing
Selection/Control
Anlg In Config
0-10v
0-20mA
Unipolar
Cal 1
Current
Cal 1
Anlg In 1 Loss
Loss
Detect
Limit
0-10V
Anlg In Sqr Root
Loss
Detect
Limit
4-20mA
Square
Root
Cal Analog 1
Analog 2
Unipolar
Analog 2
Bipolar
Analog 2
Current
ADC
Anlg In Config
(voltage)
(current)
Analog In1 Value
Analog In 2 Lo
Analog In 2 Hi
0-10v
Note: If either of these parameters is < 0, input will go into bipolar mode, otherwise unipolar.
Unipolar
Cal 2
-10v - +10v
0-20mA
Bipolar
Cal 2
Current
Cal 2
Anlg In 2 Loss
Loss
Detect
Limit
0-10V
Loss
Detect
Limit
-10V to
10V
Limit
4-20mA
Anlg In Sqr Root
Square
Root
Cal Analog 2
Analog In2 Value
Analog Inputs
2-9
Scaling Blocks
[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 or current limit. 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]
2-10
Analog Inputs
Configuration #1:
•
[Speed Ref A Sel] = “Analog In 1”
•
[Minimum Speed] = 0 Hz
•
[Maximum Speed] = 60 Hz
•
[Analog In 1 Lo] = 0%
•
[Analog In 1 Hi] = 100%
This is the default setting, where minimum input (0 volts) represents
[Minimum Speed] of 0 Hz and maximum input (10 volts) represents
[Maximum Speed] of 60 Hz.
8
6
4
2
12
10
Config 1
0 6 12 18 24 30 36 42 48 54 60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Lo]
0V
[Analog In 1 Hi]
10V
[Minimum Speed]
0 Hz
[Maximum Speed]
60 Hz
Configuration #2:
•
[Speed Ref A Sel] = “Analog In 1”
•
[Minimum Speed] = 0 Hz
•
[Maximum Speed] = 30 Hz
•
[Analog In 1 Lo] = 0%
•
[Analog In 1 Hi] = 100%
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).
Analog Inputs
2-11
8
6
4
2
12
10
0 6 12 18 24 30 36 42 48 54 60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Lo]
0V
[Analog In 1 Hi]
10V
[Minimum Speed]
0 Hz
[Maximum Speed]
30 Hz
Config 2
Configuration #3:
•
[Speed Ref A Sel] = “Ana In 1”
•
[Minimum Speed] = 0 Hz.
•
[Maximum Speed] = 60 Hz.
•
[Analog In 1 Lo] = 20%
•
[Analog In 1 Hi] = 100%
This configuration is referred to as offset. In this case, a 2-10 volt input signal provides 0-60 Hz output, providing a 2 volt offset in the speed command.
12
10
8
6
4
2
Config 3
0 6 12 18 24 30 36 42 48 54 60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Lo]
2V
[Analog In 1 Hi]
10V
[Minimum Speed]
0 Hz
[Maximum Speed]
60Hz
2-12
Analog Inputs
Configuration #4:
•
[Minimum Speed] = 0 Hz.
•
[Maximum Speed] = 60 Hz.
•
[Analog In 1 Lo] = 100%
•
[Analog In 1 Hi] = 0%
This configuration is used to invert the operation of the input signal. Here, maximum input (100% of 10 Volts = 10 Volts) represents [Minimum Speed] of 0 Hz and minimum input (0% of 10 Volts = 0 Volts) represents
[Maximum Speed] of 60 Hz.
8
6
4
2
12
10
Config 4
0 6 12 18 24 30 36 42 48 54 60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Lo]
10V
[Analog In 1 Hi]
0V
[Minimum Speed]
0 Hz
[Maximum Speed]
60Hz
Configuration #5:
•
[Minimum Speed] = 0 Hz.
•
[Maximum Speed] = 60 Hz.
•
[Analog In 1 Lo] = 0%
•
[Analog In 1 Hi] = 50%
This configuration is used when the input signal is 0-5 volts. Here, minimum input (0% of 10 Volts = 0 Volts) represents [Minimum Speed] of
0 Hz and maximum input (50% of 10 Volts = 5 Volts) represents [Maximum
Speed] of 60 Hz. This allows full scale operation from a 0-5 volt source.
Analog Inputs
2-13
4
3
2
1
6
5
0 6 12 18 24 30 36 42 48 54 60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Lo]
0V
[Analog In 1 Hi]
5V
[Minimum Speed]
0 Hz
[Maximum Speed]
60Hz
Config 5
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.
10
8
6
4
2
0 2 4 6
Input (Volts)
8 10
2-14
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.
5
6
3
4
1
2
Value
0
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
Action on Signal Loss
Disabled
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.
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.
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.
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
.
•
[Trim In Select]
•
[Trim Out Select]
•
[Trim Hi]
•
[Trim Lo]
Analog Inputs
2-15
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.
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
017
[Analog In1 Value]
[Analog In2 Value]
Value of the signal at the analog inputs.
Default:
Min/Max:
Display:
Read Only
0.000/20.000 mA
–/+10.000V
0.001 mA or 0.001 Volt
Cable Selection
Important points to remember:
•
Always use copper wire.
•
Wire with an insulation rating of 600V or greater is recommended.
•
Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
Important: I/O terminals labeled “–” or “Common” are not referenced to ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.
!
!
ATTENTION: Configuring an analog input for 0-20mA operation and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.
ATTENTION: Hazard of personal injury or equipment damage exists when using bipolar input sources. Noise and drift in sensitive input circuits can cause unpredictable changes in motor speed and direction. Use speed command parameters to help reduce input source sensitivity.
Table 2.A Recommended Signal Wire
Signal
Type
Standard
Analog I/O
Encoder/
Pulse I/O
EMC
Compliance
Wire Type(s)
Belden 8760/9460(or equiv.)
Belden 8770(or equiv.)
Less than or equal to 30 m (98 ft.)
– Belden 9730 (or equiv.)
Greater than 30 m (98 ft.) –
Belden 9773(or equiv.)
Description
0.750 mm
2
(18AWG), twisted pair, 100% shield with drain
(1)
.
0.750 mm
2
(18AWG), 3 cond., shielded for remote pot only.
0.196 mm
2
(24AWG), individually shielded.
0.750 mm
2
(18AWG), twisted pair, shielded.
Refer to
EMC Instructions on page 2-37 for details.
Minimum
Insulation Rating
300V,
60 degrees C
(140 degrees F)
(1)
If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.
2-16
Analog Inputs
Refer to
Table 2.J on page 2-46 for recommended digital I/O control wire.
Figure 2.1 PowerFlex 700 Standard I/O Terminal Designations
1
16
32
No. Signal
1
2
3
4
Anlg Volts In 1 (–)
Anlg Volts In 1 (+)
Anlg Volts In 2 (–)
Anlg Volts In 2 (+)
(1)
Description
Isolated
(2)
, bipolar, differential,
±
10V,
11 bit & sign, 100k ohm input impedance.
Isolated
(3)
, bipolar, differential,
±
10V,
11 bit & sign, 100k ohm input impedance.
For (+) and (–) 10V pot references.
Bipolar, differential,
±
10V, 11 bit & sign, 2k ohm minimum load.
5 Pot Common
6 Anlg Volts Out 1 (–)
7 Anlg Volts Out 1 (+)
8 Anlg Current Out 1 (–)
–
9 Anlg Current Out 1 (+)
10 Reserved for Future Use
11 Digital Out 1 – N.C.
Fault
12 Digital Out 1 Common
4-20mA, 11 bit & sign, 500 ohm maximum load.
13 Digital Out 1 – N.O.
14 Digital Out 2 – N.C.
Alarm
15 Digital Out 2 Common
16 Digital Out 2 – N.O.
17 Anlg Current In 1 (–)
18 Anlg Current In 1 (+)
19 Anlg Current In 2 (–)
20 Anlg Current In 2 (+)
Resistive Load
Rating: 8A at 250V AC/30V DC
Min. Load: 10mA
Inductive Load
Rating: 2A at 250V AC/30V DC
Min. Load: 10mA
Isolated ohm input impedance.
Isolated
, 4-20mA, 11 bit & sign, 100
, 4-20mA, 11 bit & sign, 100 ohm input impedance.
21 –10V Pot Reference –
22 +10V Pot Reference –
23 Reserved for Future Use
24 +24VDC –
2k ohm minimum, 15mA maximum load.
25 Digital In Common –
26 24V Common –
27
28
29
30
31
32
Digital In 1
Digital In 2
Digital In 3
Digital In 4
Digital In 5
Digital In 6
Drive supplied power for logic inputs.
150mA maximum Load.
Stop - CF 115V AC, 50/60 Hz
Start
Opto isolated (250V)
Jog
Low State: less than 30V AC
High State: greater than 100V AC
Speed Sel 1
24V AC/DC, 50/60 Hz
Speed Sel 2
Opto isolated (250V)
Speed Sel 3 Low State: less than 5V AC
High State: greater than 20V AC
320 -
329
338 -
346
380 -
387
320 -
329
361 -
366
(1)
(2)
(3)
These inputs/outputs are dependant on a number of parameters. See “Related Parameters.”
Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.
Differential Isolation - External source must be less than 10V with respect to PE.
Refer to the PowerFlex 70 User Manual for terminal designations and wiring examples.
Analog Inputs
2-17
I/O Wiring Examples (PowerFlex 700 shown)
Input/Output
Potentiometer
(1)
10k Ohm Pot.
Recommended
(2k Ohm Minimum)
Joystick
±
10V Input - 100k ohm input impedance.
Connection Example
Potentiometer
Analog Input
±
10V Input - 100k ohm input impedance.
4-20 mA Input - 100 ohm input impedance
Voltage - Bipolar
3
4
(3)
5
1
2
22
Joystick
3
5
17
18
21
22
Current - Unipolar
–
+
Analog/Digital
Output
±
10V Output - Can drive a 10k ohm load (25 mA short circuit current limit).
Voltage
+ –
6
7
2 Wire Control
(2)
Non-Reversing
-
Requires 2-wire functions only ([Digital In1 Sel]). Using
3-wire selections will cause a type 2 alarm.
3 Wire Control
24VDC Internal Supply
(4)
24
25
26
27
Stop-Run
24VDC Internal Supply
Requires only
3-wire functions
([Digital In1 Sel]).
Including 2-wire selections will cause a type 2 alarm.
24
25
26
27
28
Stop
Start
Current
+ –
8
9
24VDC External Supply
Common
25
+24V
Logic
Power Source or
11
12
13
14
15
16
115V External Source
25
Neutral 115V
27
Stop-Run
24VDC External Supply 115V External Source
Common
25
27
28
27
Stop-Run
Stop
Start
+24V
25
Neutral
Stop
27
28
115V
Start
(1)
(2)
(3)
(4)
Refer to the Attention statement on
for important bipolar wiring information.
Important: Programming inputs for 2 wire control deactivates all HIM Start buttons.
Examples show hardware wiring only. Refer to
page 2-16 for parameters that must be adjusted.
If desired, a User Supplied 24V DC power source can be used. Refer to the “External” example.
2-18
Analog Outputs
Analog Outputs
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 source for the analog output by setting [Analog Outx
Sel].
342 [Analog Out1 Sel]
Selects the source of the value that drives the analog output.
Default:
Options:
0 “Output Freq”
See Table
001
002
003
004
005
007
006
012
135
136
137
138
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.
Absolute
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, as described in
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 Outputs
2-19
Table 2.B Analog Output Scaling Ranges
Quantity
Output Frequency
Commanded
Frequency
[Analog Outx Lo]
Corresponds to:
(Absolute Value Disabled)
-[Maximum Freq]
-[Maximum Freq]
[Analog Outx Lo]
Corresponds to:
(Absolute Value Enabled)
0 Hz
0 Hz
Output Current 0 Amps 0 Amps
Output Torque Current -200% of drive rated current 0 Amps
Output Flux Current 0 Amps
Output Power 0 kW
0 Amps
0 kW
[Analog Outx Hi]
Corresponds to:
[Maximum Freq]
[Maximum Freq]
200% of drive rated current
200% of drive rated current
200% of drive rated current
200% of drive rated power
Output Voltage
Dc Bus Voltage
PI Reference
PI Feedback
PI Error
PI Output
0 V
0 V
-100%
-100%
-100%
-100%
0 V
0 V
0%
0%
0%
0%
120% of drive rated voltage
200% of drive rated voltage
100%
100%
100%
100%
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]
Analog
Output Voltage
Output Current vs.
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], even if output current is beyond the range defined in
. 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
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.
2-20
Analog Outputs
10V
[Analog Out1 Lo]
Analog
Output Voltage
Output Current vs.
Analog Output Voltage
Marker Lines
[Analog Out1 Hi]
0V
0% 200%
Output Current
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]
Analog
Output Voltage
Output Torque Current vs.
Analog Output Voltage
Marker Lines
[Analog Out1 Lo]
200%
0V
0%
Output Torque Current
200%
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]
Analog
Output Voltage
[Analog Out1 Lo]
200%
0V
0%
Output Torque Current
200%
Output Torque Current vs.
Analog Output Voltage
Marker Lines
Filtering
Software filtering will be performed on the analog outputs for certain signal sources, as specified in
. “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.
Analog Outputs
2-21
Table 2.C Software Filters
Quantity
Output Frequency
Filter
No extra filtering
Commanded Frequency No extra filtering
Output Current Filter A
Output Torque Current
Output Flux Current
Output Power
Output Voltage
Filter A
Filter A
Filter A
No extra filtering
DC Bus Voltage
PI Reference
PI Feedback
PI Error
PI Output
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%.
2-22
Auto / Manual
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 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).
Auto / Manual
2-23
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
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.
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.
2-24
Auto Restart (Reset/Run)
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]
Sets the maximum number of times the drive attempts to reset a fault and restart.
Default:
Min/Max:
Display:
0
0/9
1
!
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:
Min/Max:
Display:
1.0 Secs
0.5/30.0 Secs
0.1 Secs
175
174
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.
The auto-reset/run feature provides 2 status bits in [Drive Status 2] – an active status, and a countdown status.
210 [Drive Status 2]
Present operating condition of the drive.
Read Only
Bit # x
15 x
14
0
13
D M oto r O verld req
R eg im
B us F it
C urr L
A uto ct
R st A
A uto
R st C td n
A
0
12
0
11
0
10
0
9
0
8 x
7
0
6
g g uto
Tu nin
D
C
B rakin
Sto pp in
Jo g gg in
R g un nin
A g ctive
R ead y
0
5
0
4
0
3
0
2
0
1
0
0
1 =Condition True
0 =Condition False x =Reserved
209
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.
Auto Restart (Reset/Run)
2-25
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
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.)
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.”
2-26
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
OV Fault @ V bus
Max
3
Drive Output Shut Off
2
1
Ch1
Ch3
100mV
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 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.
Bus Regulation
2-27
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.
Single Seq 2.50kS/s
DB Bus
3
Output
Motor
2
1
Ch1
Ch3
100mV
500mV
Ch2 100mV M 200ms Ch3 1.49 V
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
The bus voltage regulator is shown in the lower one-third of
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
move to the positions shown in
Table 2.D Switch Positions for Bus Regulator Active
SW 1
Bus Regulation Limit
SW 2
Bus Reg
SW 3
Open
SW 4
Closed
SW 5
Don’t Care
2-28
Bus Regulation
Current Limit Level
Figure 2.2 Bus Voltage Regulator, Current Limit and Frequency Ramp.
Current Limit
PI Gain Block
Derivative Gain
Block
SW 3
I Limit,
No Bus Reg
Magnitude
Calculator
U Phase Motor Current
W Phase Motor Current
0
Limit
SW 1
No Limit
Acc/Dec Rate
I Limit,
No Bus Reg
Jerk
Ramp
Jerk
Clamp
No Limit
SW 2
Bus Reg
Frequency Set Point
Maximum Frequency, Minimum Speed, Maximum Speed, Overspeed Limit
Frequency
Ramp
(Integrator)
+
+
+
Frequency Reference (to Ramp Control, Speed Ref, etc.)
Speed Control (Slip Comp, Process PI, etc)
Frequency
Reference
+
+
SW 5
Speed
Control
Mode
Frequency
Limits
Output Frequency
Bus Voltage Regulation Point, V reg
SW 4
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 Regulation
2-29
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.
!
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.
2-30
Cable, Control
Cable, Control
Cable Entry Plate
Removal
PowerFlex 70
In PowerFlex 70, the user selects the bus voltage regulator using the [Bus
Reg Mode A] and [Bus Reg Mode B] parameters. The available modes include “Disabled,” “Adjust Freq,” and “Dynamic brak.” The bus voltage regulator is never active with the internal dynamic braking function.
The bus voltage regulation set point Vreg in PowerFlex 70 is fixed for each voltage class of drive. The bus voltage regulation set points are identical to the internal dynamic brake regulation set points V
DB’s
and are shown in
Table 2.E PowerFlex 70 Bus Voltage Regulation Set Points (Vreg)
200/240 V Class Drive 400 V Class Drive 480 V Class Drive 600 V Class
V reg
377 VDC 750 VDC 750 VDC –
The nature of this control is to increase the magnitude of the drive’s output frequency to reduce or eliminate regeneration and avoid an over-voltage fault. The increase in output frequency may increase the operating voltage.
The magnitude increase in frequency when bus regulation is active is limited to the sum of [Maximum Speed] and [Overspeed Limit]. When this frequency limit is met, the output frequency will be clamped and an over-voltage fault occurs if regeneration continues to increase the bus voltage.
PowerFlex 700
PowerFlex 700 allows the user to simultaneously enable both internal dynamic braking and the bus voltage regulator. There are two bus voltage regulation set point parameters, [Bus Reg Mode A] and [Bus Reg Mode B] in the PowerFlex 700 (See
). The user can select which bus
regulation set point is active by configuring one of the digital inputs as a selector.
Table 2.F PowerFlex 700 Dynamic Braking and Bus Voltage Limit References
V db
Bus Reg 1
Bus Reg 2
200/240 V Class Drive 400 V Class Drive 480 V Class Drive 600 V Class
377 VDC 750 VDC 750 VDC –
358 – 392 VDC 715 – 785 VDC 715 – 785 VDC –
The nature of this control, like PowerFlex 70, is to increase the magnitude of the drive’s output frequency to reduce or eliminate regeneration and avoid a bus over-voltage fault. The increase in the output frequency may increase the operating voltage. PowerFlex 700 internally limits the magnitude of output frequency to the sum of Maximum Speed and
Overspeed Limit.
See
Cable Selection on page 2-15 and
.
If additional wiring access is needed, the Cable Entry Plate on 0-3 Frame drives can be removed. Simply loosen the screws securing the plate to the chassis. The slotted mounting holes assure easy removal.
Cable, Motor Lengths
2-31
Cable, Motor Lengths
The length of cable between the drive and motor may be limited by various application parameters. The 2 primary areas of concern are Reflected Wave and Cable charging.
The Reflected Wave phenomenon, also known as transmission line effect, produces very high peak voltages on the motor due to voltage reflection.
While Allen-Bradley drives have patented software that limits the voltage peak to 2 times the DC bus voltage and reduce the number of occurrences, many motors have inadequate insulation systems to tolerate these peaks.
See
Reflected Wave on page 2-127 for more details.
Refer to
for measuring cable lengths when concerned about
Reflected Wave. Each individual motor must be considered based on the lead length for that motor only. Diagram A shows 2 motors, each 300 feet from the drive. Motor protection decisions are based on 300 feet cable length (not 600 ft). If the motors need protection at this distance, then both motors must be dealt with individually. Diagram B shows 1 motor at 50 feet and one at 550 feet. It is likely that the motor that is close to the drive (50
Ft) will not need protection, but the motor farther from the drive (550 Ft) may. Again, each motor must be considered individually based on its distance from the drive.
Cable charging occurs because of the capacitance, phase-to-phase or phase-to-ground, inherent in the length of cable. The current that is used to charge the cable capacitance detracts from the overall current capability of the drive and reduces the availability of torque producing current for the motor. This can result in poor motor performance, motor stalls under full load and nuisance drive overcurrent tripping.
Refer to
for measuring cable lengths when concerned about
cable charging. In this case, it is the total amount of cable connected to the drive that must be considered. Diagram A shows 2 motors, each 300 feet from the drive. The drive must be capable of supplying enough current to charge the total length (600 ft) plus the needed current to produce necessary torque in the motors. If the motors will not receive the desired current due to cable charging, then the drive size should be increased to supply needed current. Diagram B shows 1 motor at 50 feet and one at 550 feet. Again, the drive must be capable of supplying enough current to charge the total length
(600 ft), plus the needed current to produce necessary torque in the motors.
In fact, diagrams A, B, C and D will all require the same cable charging installation guidelines because they all have total cable lengths of 600 feet.
2-32
Cable, Motor Lengths
A
Figure 2.3 How to Measure Motor Cable Lengths Limited by Capacitance
B C D
91.4 (300)
91.4 (300)
15.2 (50)
167.6 (550) 182.9 (600)
15.2 (50)
152.4 (500)
15.2 (50)
All examples represent motor cable length of 182.9 meters (600 feet).
Cable, Power
Cable, Power
2-33
!
ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4 mm/0.015 in.).
Shielded/Armored
Shielded cable is recommended if sensitive circuits or devices are connected or mounted to the machinery driven by the motor.
Figure 2.4 Recommended Power Wire
Location
Standard
(Option 1)
Standard
(Option 2)
Class I & II;
Division I & II
Rating/Type
600V, 90
°
C (194
°
F)
XHHW2/RHW-2
Anixter
B209500-B209507,
Belden 29501-29507, or equivalent
Tray rated 600V, 90
°
C
(194
°
F) RHH/RHW-2
Anixter OLF-7xxxxx or equivalent
Tray rated 600V, 90
°
C
(194
°
F) RHH/RHW-2
Anixter 7V-7xxxx-3G or equivalent
Description
•
Four tinned copper conductors with XLP insulation.
•
Copper braid/aluminum foil combination shield and tinned copper drain wire.
•
PVC jacket.
•
Three tinned copper conductors with XLPE insulation.
•
5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield.
•
PVC jacket.
•
Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor.
•
Black sunlight resistant PVC jacket overall.
•
Three copper grounds on #10 AWG and smaller.
Based on field and internal testing, Rockwell Automation/Allen-Bradley has determined conductors manufactured with Poly Vinyl Chloride (PVC) wire insulation are subject to a variety of manufacturing inconsistencies which can lead to premature insulation degradation when used with IGBT drives that produce the reflected wave phenomena. Flame-retardant heat-resistant thermoplastic insulation is the type of insulation listed in the
NEC code for the THHN wire designation. This type of insulation is commonly referred to as PVC. In addition to manufacturing inconsistencies, the physical properties of the cable can change due to environment, installation and operation, which can also lead to premature insulation degradation. The following is a summary of our findings:
2-34
Cable, Power
Manufacturing Inconsistencies and their Effects on Cable Life
Due to manufacturing inconsistencies, the following conditions can exist:
•
PVC insulation material may have a dielectric constant ranging between
4 and 8 depending on the manufacturer. The higher the dielectric constant, the lower the dielectric strength (and voltage withstand to transients). A single IGBT drive output may have reflected wave transient voltage stresses of up to twice (2 per unit) the DC bus voltage between its own output wires. Multiple drive output wires in a single conduit or wire tray further increase output wire voltage stress between multi-drive output wires that are touching. Drive #1 may have a (+) 2 pu stress while drive #2 may simultaneously have a (–) 2 pu stress. Wires with dielectric constants (>4) cause the voltage stress to shift to the air gap between the wires that are barely touching. This electric field may be high enough to ionize the air surrounding the wire insulation and cause a partial discharge mechanism (corona) to occur. The electric field distribution between wires increases the possibility for corona which further produces ozone. This attacks the PVC insulation and produces carbon tracking, leading to the susceptibility of insulation breakdown.
•
Due to inconsistencies in manufacturing processes or wire pulling, air voids can also occur in the THHN wire between the nylon jacket and
PVC insulation. Because the dielectric constant of air is much lower than the dielectric constant of the insulating material, the transient reflected wave voltage may appear across the small air void capacitance. The
Corona Inception Voltage (CIV) for the air void may be reached which further produces ozone, which attacks the PVC insulation and produces carbon tracking, leading to the susceptibility of insulation breakdown as in the above case.
•
Asymmetrical construction of the insulation has also been observed for some manufacturers of PVC wire. A wire with a 15 mil specification was observed to have an insulation thickness of 10 mil at some points. The smaller the insulation thickness, the less voltage the wire can withstand.
Cable, Power
2-35
Installation, Operation and Environmental Considerations
•
THHN jacket material has a relatively brittle nylon that lends itself to damage (i.e. nicks and cuts) when pulled through conduit on long wire runs. This issue is of even greater concern when the wire is being pulled through multiple 90 degree bends in the conduit. It is these nicks that may be a starting point for corona that leads to insulation degradation.
•
During operation, the conductor heats up and a “coldflow” condition may occur with PVC insulation at points where the unsupported weight of the wire may stretch the insulation. This has been observed at right angle bends where wire is dropped down to equipment from an above wireway. This “coldflow” condition produces thin spots in the insulation which lowers the cable’s voltage withstand capability.
•
The NEC 1996 code defines “dry, damp and wet” locations (7-31) and permits the use of heat-resistant thermoplastic wire in both dry and damp applications (Table 310-13). However, PVC insulation material is more susceptible to absorbing moisture than XLPE (Cross Linked
Polyethylene) insulation material (XHHN-2) identified for use in wet locations. Because the PVC insulating material absorbs moisture, the
Corona Inception Voltage insulation capability of the “damp” or “wet”
THHN was found to be less than 1/2 of the same wire when “dry”. For this reason, certain industries where water is prevalent in the environment have refrained from using THHN wire with IGBT drives.
Cable Recommendations for New & Existing Installations of IGBT Drives in Wet
Locations
•
Belden YR41709 cable is a PVC jacketed, shielded type TC with XLPE conductor insulation designed to meet NEC code designation XHHW-2
(wet locations per NEC 1996, Table 310-13). Based on Rockwell
Automation research, tests have determined the Belden YR41709 is notably superior to loose wires in dry, damp and wet applications and can significantly reduce capacitive coupling and common mode noise.
Other cable types for wet locations include those in the table above
summarizes the previous considerations and explanations.
Because applications can vary widely, the information in the flowchart is intended to be used only as a guideline in the decision-making process.
2-36
Cable, Standard I/O
Figure 2.5 Wire Selection Flowchart
Selecting Wire to Withstand Reflected Wave Voltage for New and Existing Wire Installations in Conduit or Cable Trays
PVC
Conductor
Insulation
DRY
(Per NEC 7-31)
Conductor
Environment
230V
Insulation
Thickness
15 mil
400/460V
20 mil or > (1)
RWR or
Terminator
Reflected Wave
Reducer?
No RWR or
Terminator
Cable
Length
< 50 ft.
Single Drive,
Single Conduit or Wire Tray
> 50 ft.
# of
Drives in Same
Conduit or Wire
Tray
Multiple Drives in Single Conduit or Wire Tray
15 mil PVC
Not
Recommended
USE XLPE or > 20 mil
XLPE
WET
(Per NEC code Table 7-31)
575V
Reflected Wave
Reducer?
No RWR or Terminator
15 mil PVC
Not
Recommended
USE XLPE or > 20 mil
RWR or
Terminator
OK for < 600V AC
System
No RWR or
Terminator required
XLPE (XHHW-2)
Insulation for
<600V AC
System
No RWR or
Terminator
Required
(1) The mimimum wire size for PVC cable with 20 mil or greater insulation is 10 gauge.
See NEC Guidelines
(70-196 Adjustment Factors) for
Maximum Conductor Derating &
Maximum Wires in Conduit or Tray
Cable, Standard I/O
Refer to
Cable Selection on page 2-15 and
Cable Selection on page 2-46 .
CabIe Trays and
Conduit
Important: Because of the nature of the drive PWM output and the reflected wave phenomenon, it is preferable to have each set of drive motor/power cables in an individual conduit. If this is not possible, it is important that the allowable fill rates specified in the applicable national or local codes NOT BE Exceeded.
!
ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from
“cross coupled” motor leads.
Carrier (PWM)
Frequency
This section is under construction. If further information is required, please contact factory.
CE Conformity
CE Conformity
2-37
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 Manual.
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.
•
EN60204-1 Safety of machinery – Electrical equipment of machines.
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.
Essential Requirements for CE Compliance
Conditions 1-4 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3.
1. Standard PowerFlex CE compatible Drive.
2. Grounding as described on
3. 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.
4. Conditions in the appropriate table (
).
2-38
CE Conformity
Table 2.G PowerFlex 70 – EN61800-3 First Environment Restricted Distribution
Frame Drive Description
A Drive Only
Drive with DeviceNet
Drive with Remote I/O
B
C
Drive Only
Drive with DeviceNet
Drive with Remote I/O
Drive Only
D
Drive with DeviceNet
Drive with Remote I/O
Drive Only
Drive with DeviceNet
Drive with Remote I/O
Restrict Motor
Cable to
12 m (40 ft.)
–
–
✔
✔
✔
✔
–
✔
✔
✔
✔
✔
Restrict Motor
Cable to
40 m (131 ft.)
✔
✔
✔
–
–
–
–
–
–
–
–
–
Internal
Filter
Option
–
–
–
✔
✔
✔
–
–
–
–
–
–
External
Filter
✔
✔
✔
–
–
–
–
–
–
–
–
–
–
✔
–
–
✔
–
–
✔
Comm
Cable
Ferrite
(1)
–
–
✔
–
Common
Mode
Core
(2)
–
–
–
–
✔
✔
✔
–
–
–
–
–
(1)
(2)
Two turns of the blue comm option cable through a Ferrite Core (Fair-Rite #2643102002 or equivalent).
Refer to the 1321 Reactor and Isolation Transformer Technical Data publication, 1321-TD001x for 1321-Mxxx selection information.
Table 2.H PowerFlex 70 – EN61800-3 Second Environment
Frame Drive Description
A Drive Only
Drive with DeviceNet
Drive with Remote I/O
B
C
Drive Only
Drive with DeviceNet
Drive with Remote I/O
Drive Only
D
Drive with DeviceNet
Drive with Remote I/O
Drive Only
Drive with DeviceNet
Drive with Remote I/O
Restrict Motor
Cable to
12 m (40 ft.)
–
–
–
–
–
–
–
–
–
–
–
–
Restrict Motor
Cable to
40 m (131 ft.)
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Internal
Filter
Option
–
–
–
✔
✔
✔
–
–
–
–
–
–
External
Filter
✔
✔
✔
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Comm
Cable
Ferrite
–
–
–
–
–
–
–
–
–
–
–
–
Common
Mode
Core
–
–
–
–
–
–
Table 2.I PowerFlex 700 EN61800-3 EMC Compatibility
1
2
Frame
0
3
Second Environment
Restrict Motor Cable to 30 m (98 ft.)
Any Drive and Option
✔
✔
✔
✔
First Environment Restricted Distribution
Restrict Motor Cable to 150 m (492 ft.)
Any Drive and Option External Filter Required
(1)
✔ ✔
✔
✔
✔
✔
✔
✔
(1)
Select the Roxburgh filter (or equivalent) that meets your specifications from the list below. Refer to: http://
www.deltron-emcon.com for detailed filter information.
Filter Part No.
Current
MIF306
MIF310
MIF316
MIF323
MIF330
6A
10A
16A
23A
30A
Filter Part No.
Current
MIF350 50A
MIF375
MIF3100
MIF3150
75A
100A
150A
Copy Cat
Copy Cat
2-39
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.
2-40
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
A. 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.
B. Software Instantaneous Trip - If it is determined that the hardware overcurrent levels are too high for certain drives (below certain output frequencies), an additional software overcurrent trip is invoked. When the drive is being operated below the given frequency (fixed and stored in drive memory) the software overcurrent trip level is set to a value less than the hardware overcurrent level. This offers additional protection to drives running at very low output frequencies, if needed. If the reduced current limit level is exceeded, an F36 “SW Overcurrent” fault is generated.
C. 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.
Current Limit
2-41
D. 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.
E. 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.
F. Thermal manager (see
Drive Overload on page 2-71 ).
2-42
Datalinks
Datalinks
Programmable
Controller
I/O Image Table
Output Image
Block Transfer
Logic Command
Analog Reference
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
Input Image
Block Transfer
Logic Status
Analog Feedback
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
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]
Remote I/O
Communication
Module
Adjustable Frequency
AC Drive
Datalink A
Datalink A
Parameter/Number
Data In A1
Data In A2
300
301
Data Out A1
Data Out A2
310
311
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.
Datalinks
2-43
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 Parameter
LSW 9
MSW 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.
Datalink
A1
A2
Most/Least Significant Word Parameter
LSW 242
-Not Used0
Data(decimal)
32573
0
Datalink
A1
A2
Most/Least Significant Word Parameter
-Not Used0
MSW 242
Data(decimal)
0
13
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 Parameter
MSW 242
LSW 242
Data(decimal)
13
32573
32-bit data is stored in binary as follows:
MSW 2
31
through 2
16
LSW 2
15
through 2
0
Example
Parameter 242 - [Power Up Marker] = 88.4541 hours
MSW = 13 decimal
= 1101 binary
= 2
16
+ 2
18
+ 2
19
= 851968
LSW = 32573
851968 + 32573 = 884541
2-44
DC Bus Voltage / Memory
DC Bus Voltage /
Memory
A measure of the instantaneous value or “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 approximately 2.4V DC per minute (for a
480V AC drive). An increase in DC Bus memory is blocked during deceleration to prevent a false high value due to the bus being pumped up by regeneration. Any change to DC Bus memory is blocked during inertia ride through.
Decel Time
Decel Time
2-45
[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 Frequency – Minimum Frequency
Decel Time
= Decel Rate
Two Decel times exist to allow the user to change rates “on the fly” via PLC command or Digital Input. The selection is made using the 1st/2nd Decel inputs shown below or a similar pattern of decel time select bits in the Logic
Control word used via PLC communications.
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.
2-46
Digital Inputs
Digital Inputs
Cable Selection
Important points to remember about I/O wiring:
•
Always use copper wire.
•
Wire with an insulation rating of 600V or greater is recommended.
•
Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
Table 2.J Recommended Control Wire for Digital I/O
Type
Shielded
Wire Type(s)
Unshielded Per US NEC or applicable national or local code
Multi-conductor shielded cable such as Belden 8770(or equiv.)
Description
–
0.750 mm
2
(18AWG), 3 conductor, shielded.
Minimum
Insulation Rating
300V, 60 degrees C
(140 degrees F)
Wiring Examples
See
There are 6 digital (discrete) inputs (numbered 1 through 6) available at the terminal block.
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.
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.
Digital Inputs
2-47
361
[Digital In1 Sel]
Default: 4
362
363
364
365
366
[Digital In2 Sel]
[Digital In3 Sel]
[Digital In4 Sel]
[Digital In5 Sel]
[Digital In6 Sel]
Selects the function for the digital inputs.
(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.
Default:
Default:
Default:
Default:
Default:
Options:
3 2 1 Auto Reference Source
1
1
0
1
1
0
0
0
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
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. For example, [Digital In1 Sel] set to 5 “Start” in 3-wire control and
[Digital In2 Sel] set to 7 “Run” in 2-wire control.
Refer to Alarm Descriptions on page 4-8 for information on resolving this type of conflict.
(5)
Auto/Manual - Refer to Figure 1.6 on page 1-13 for details.
27
28
29
30
23
24
25
26
19
20
21
22
15
16
17
18
11
12
13
14
7
8
9
10
5
6
3
4
0
1
2
5
10
15
16
17
“Stop – CF”
(CF = Clear Fault)
“Start”
“Jog”
“Speed Sel 1”
“Speed Sel 2”
“Speed Sel 3”
“Not Used”
“Enable”
“Clear Faults”
(1)
“Aux Fault’
“Stop – CF”
(2)
“Start”
(2)
“Fwd/ Reverse”
(2)
“Run”
(3)
“Run Forward”
(3)
(3)
“Run Reverse”
“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”
“Pwr Loss Lvl”
“Precharge En”
100
156
162
096
140
194
380
124
The available functions are defined in
.
2-48
Digital Inputs
Table 2.K 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
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.
Accel 2
Decel 2
Accel 2 & Decel 2
MOP Increment
MOP Decrement
Stop Mode B
Bus Regulation Mode B
PI Enable
PI Hold
PI Reset
Auxiliary Fault
Local Control
Allows terminal block to assume complete control of Speed
Reference.
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
Enable
Clear faults and return drive to ready status.
Open input causes drive to coast to stop, disallows start.
Exclusive Link Exclusive Link – digital input is routed through to digital output, no other use.
Power Loss Level (PowerFlex 700 only) Selects between using fixed value for power loss level and getting the level from a parameter
Precharge Enable (PowerFlex 700 only) If common bus configuration, denotes whether drive is disconnected from DC bus or not. Controls precharge sequence on reconnection to bus.
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.
Digital Inputs
2-49
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 Run Reverse Action
Open Open Drive stops, terminal block relinquishes direction ownership.
Open Closed
Closed Open
Drive runs in reverse direction, terminal block takes direction ownership.
Drive runs in forward direction, terminal block takes direction ownership.
Closed Closed Drive continues to run in current direction, but terminal block maintains direction ownership.
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.
2-50
Digital Inputs
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 causes a configuration alarm.
•
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
Digital Inputs
2-51
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.
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 Jog Reverse Action
Open Open Drive will stop if already jogging, but can be started by other means. Terminal block relinquishes direction ownership.
Open Closed
Closed Open
Drive jogs in reverse direction. Terminal block takes direction ownership.
Drive jogs in forward direction. Terminal block takes direction ownership.
Closed Closed Drive continues to jog in current direction, but terminal block maintains direction ownership.
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Digital Inputs
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] 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.
Digital Inputs
2-53
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 2-104 ). 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.
The table below describes the various reference sources that can be selected using all three of the Speed Select input functions.
Speed Select 3 Speed Select 2 Speed Select 1 Parameter that determines Reference
Open Open Open [Speed Ref A Sel]
Open
Open
Open
Closed
Closed
Open
[Speed Ref B Sel]
[Preset Speed 2]
Open
Closed
Closed
Closed
Closed
Closed
Open
Open
Closed
Closed
Closed
Open
Closed
Open
Closed
[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
2-54
Digital Inputs 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 Speed Select 2 Selected Parameter that determines reference
Open Open [Speed Ref A Sel]
Open
Closed
Closed
Closed
Open
Closed
[Preset Speed 2]
[Preset Speed 4]
[Preset Speed 6]
•
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.
Digital Inputs
2-55
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 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
2-56
Digital Inputs 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.”
•
Stop Mode B
This digital input function selects between two different drive stop modes. See also
.
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
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 2-116 .
•
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.
Digital Inputs
2-57
If this input function is open, the integrator for the Process PI loop will be allowed to increase. See
.
•
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
.
•
Auxiliary Fault
The “Auxiliary 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 Fault” fault code.
If the “Auxiliary Fault” input function is assigned to a physical digital input, that input will be active irrespective 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
If this input function is not configured, then the fault will not occur.
•
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.
2-58
Digital Inputs
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
.
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.
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 a parameter. 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.
Digital Inputs
2-59
•
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.
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.
2-60
Digital Inputs
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
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 2.L 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.
Table 2.M 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.
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.
Digital Inputs
2-61
“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
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.
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.
Examples
PowerFlex 70
Below is a typical digital input configuration that includes “3-wire” start.
The digital input configuration parameters should be set up as follows:
•
[Digital In1 Sel] set to “Start”
•
[Digital In2 Sel] set to “Stop - Clear Faults”
•
[Digital In3 Sel] set to “Forward/Reverse”
•
[Digital In4 Sel] set to “Jog”
•
[Digital In5 Sel] set to “Speed Select 1”
•
[Digital In6 Sel] set to “Enable”
2-62
Digital Inputs
Figure 2.6 Typical digital input configuration with “3-wire” start
Digital In1
Digital In2
Digital In3
Digital In4
Digital In5
Digital In6
Common
Start
Stop - CF
Forward/Reverse
Jog
Speed Select 2
Enable
represents a typical digital input configuration that includes “Run
Fwd/Rev” start. The digital input configuration parameters should be set up as follows:
•
[Digital In1 Sel] = “Run Forward”.
•
[Digital In2 Sel] = “Run Reverse”.
•
[Digital In3 Sel] = “Jog Forward”.
•
[Digital In4 Sel] = “Jog Reverse”
•
[Digital In5 Sel] = “Accel 2 & Decel 2”.
•
[Digital In6 Sel] = “Speed Select 1”.
Figure 2.7 Typical digital input configuration with “Run Fwd/Rev” start
Digital In1
Digital In2
Digital In3
Digital In4
Digital In5
Digital In6
Common
Run Forward
Run Reverse
Jog Forward
Jog Reverse
Accel 2/Decel 2
Speed Select 1
Digital Outputs
Digital Outputs
2-63
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 250 VAC or 220 VDC. The table below shows specifications and limits for each relay / contact.
PowerFlex 700
Rated Voltage
Maximum Current
Maximum Power
Minimum DC Current
Minimum DC Voltage
Switching Time
Initial State
Number of relays
(Standard I/O)
PowerFlex 70
Resistive Load Inductive Load
250 VAC
220 VDC
250 VAC
220 VDC
3 A
AC - 50 VA
DC - 60 W
10
µ
A
10 mV
1.5 A
AC - 25 VA
DC - 30 W
8ms
De-energized
2
250 VAC
220 VDC
8 A
8ms
De-energized
2
250 VAC
220 VDC
4 A
Configuration
The outputs may be independently configured via the following parameters to switch for various states of the drive.
380
384
[Digital Out1 Sel]
[Digital Out2 Sel]
Selects the drive status that will energize a (CRx) output relay.
Default:
Options:
(1)
Contacts shown on page 1-12 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.
1
4
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
21
22
23
24
17
18
19
20
25
26
“Fault”
“Run”
“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”
002
001
003
004
218
012
137
157
147
053
048
184
381
385
382
386
383
The selections can be divided into three types of annunciation.
1. The relay changes state due to a particular status condition in the drive.
2-64
Digital Outputs
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
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]
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.
380 381
385
[Dig Out1 Level]
[Dig Out2 Level]
Sets the relay activation level for options
10 – 15 in [Digital Outx Sel]. Units are assumed to match the above selection
(i.e. “At Freq” = Hz, “At Torque” = Amps).
Default:
Min/Max:
Display:
0.0
0.0
0.0/819.2
0.1
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
Digital Outputs
2-65
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.
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.
2-66
Digital Outputs
The user can disable either timer by setting the corresponding delay time to
0.
Important: Note that whether a particular type of transition (FALSE to
TRUE or TRUE TO 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.
382
386
[Dig Out1 OnTime]
[Dig Out2 OnTime]
Sets the “ON Delay” time for the digital outputs. This is the time between the occurrence of a condition and activation of the relay.
383
387
[Dig Out1 OffTime]
[Dig Out2 OffTime]
Sets the “OFF Delay” time for the digital outputs. This is the time between the disappearance of a condition and de-activation of the relay.
Default:
Min/Max:
Display:
0.0 Secs
0.0 Secs
0.0/600.0 Secs
0.1 Secs
Default:
Min/Max:
Display:
0.0 Secs
0.0 Secs
0.0/600.0 Secs
0.1 Secs
380
380
0
0
CR1 On Delay = 2 Seconds
Relay Activates
5
Current Limit Occurs
10
Relay Does Not Activate
CR1 On Delay = 2 Seconds
Cyclic Current Limit
(every other second)
5 10
Direction Control
Direction Control
2-67
Direction control of the drive is an exclusive ownership function. This means that 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, of the drive output, not he motor. Motor wiring and phasing determines its CW or CCW rotation The direction of the drive, is controlled in one of three ways:
1. 2-Wire digital input selection such as Run Forward or Run Reverse
2. 3-Wire digital input selection such as Forward/Reverse, Forward or
Reverse
3. Control Word bit manipulation from a DPI device such as a communications interface.
4. The sign (+ / -) of a bipolar analog input
Refer to
and
more detail on the configuration and operating rules for direction control.
2-68
DPI
DPI
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 drives support the existing
SCANport and Drive Peripheral Interface (DPI) communication protocols.
Multiple devices of each type (SCANport or DPI) can be attached to and communicate with the drive at the same time. This communication interface is the primary way to interact with, and control the drive.
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/
DPI
2-69
Consumer messages are of fixed size, 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.
2-70
DPI
Table 2.N Timing specifications contained in DPI and SCANport
DPI
SCANport 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.
DPI
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 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.
SCANport No MUT.
DPI 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.
SCANport 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.
DPI Peer messages requests cannot be sent any faster than 2x of MUT.
SCANport No Peer message support
DPI
SCANport 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.
DPI
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.
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.
SCANport Assume same 1 sec time-out. Maximum number of fragments is 16
DPI 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.
SCANport 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
Drive Overload
2-71
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.
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
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.
2-72
Drive Overload
Figure 2.8 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
Time (Seconds)
100.00
1,000.00
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
1.00
The lower curve in
shows the boundary of heavy duty operation.
In heavy duty, the drive is rated to produce 150% of rated current for 60 seconds, 200% of rated current for three seconds, and 220% of rated current 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 2.9 Heavy Duty Boundary of Operation
2.50
2.25
10.00
100.00
Time (Seconds)
1000.00
10000.00
Drive Overload
2-73
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 2.10 Thermal Manager Inputs/Outputs
DTO Select
(Off,PWM,ILmt,Both)
PWM Frequency
(2 - 12 kHz)
Current Limit
(0 - 200%)
Temperature Analog Input
(Volts)
I_total
(Amps)
V_dc
(Volts)
Output Frequency
(0-400 Hz)
Drive
Thermal
Overload
DTO Fault
(On,Off)
Active PWM Frequency
(2 - 12 kHz)
Active Current Limit
(0 - 200%)
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 T
J
is calculated based on the measured drive temperature T
Drive
, and a temperature rise that is a function of operating conditions. When the temperature device is inside the power module T
Drive
is the same as T
Case
. On larger size drives the temperature device will be mounted on the heat sink rather than inside the power module, and the thermal model becomes more complex.
P
J
as defined in the second equation is the power dissipated in one generalized IGBT.
R
J-Case
is the worst case thermal resistance from the junction to the case.
Boost[freq] is a term that increases the modeled temperature at low output frequencies.
kHz * SwitchLosses is a term that increases losses at higher PWM carrier frequencies.
T
J
= T
Case
+ P
J
R
J-Case
Boost{Freq]
P
J
= I
Peak
2
R
0
+ I
Peak
V
0
+ I
Peak
V
DC kHz * SwitchLosses
Without a temperature device on each IGBT the calculation of T
J must take into account the worst case conditions for heat transfer. A model that adds the heat dissipated in the rectifier is also under consideration. More detail will be included in the design specification.
2-74
Drive Overload
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 T
J
increases the thermal manager may reduce the PWM frequency. If T
J
continues to rise current limit may be reduced, and if T
J 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 kHz Alarm is turned on.
This alarm will be annunciated even if the reduced PWM frequency is not enabled.
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
ILmt 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.
Drive Ratings (kW, Amps, Volts)
2-75
DTO Fault
For all possible settings of [Drive OL Mode], the drive will always monitor the T j
and T
Drive
and generate a fault when either temperature becomes critical. If T
Drive
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 measured Drive temperature is displayed as a standard parameter. The calculated IGBT temperature may be displayed as a test point parameter.
Analysis of the possible source or error shows that the drive temperature should be within +/– 3
°
C of the actual temperature, over the full range of operation.
Low Speed Operation
When operation is below 4 Hz, the rating of the drive is reduced. At low output frequencies 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 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 2-83
.
2-76
Economizer
Economizer
Efficiency
Auto-Economizer (also see
Torque Performance Modes on page 2-162 )
Economize mode consists of the sensorless vector control voltage with an energy saving function (E-SVC).
The output voltage is automatically adjusted, in steady state frequency operation only, as the load is increased or decreased such that minimum current is supplied to the motor and its efficiency is optimized. Adjusting the flux producing current facilitates reduction of the output voltage. The flux current is reduced as long as the total drive output current does not exceed 75% of motor rated current. The flux current is not allowed to be less than 50% of the selected flux current parameter value.
Maximum Voltage
Motor Nameplate Voltage
Rated Flux Current
Increasing
Load
V total
Ir Voltage
0
0
Frequency
Reduced Flux Current, minimum of 50% of Rated Flux Current
Motor Nameplate
Frequency
Maximum
Frequency
0.6
0.5
0.8
0.7
The following chart is typical of the efficiency calculations for variable frequency drives. Efficiency generally decreases with increasing load on decreasing speed.
1
1 HP
0.5 HP
0.9
25 50 75 100
Fan Curve
Fan
Fan Curve
2-77
When torque performance is set to Fan Curve the relation ship between frequency and voltage is as shown in the following figure. The fan curve provides the option to generate 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 is offset by the run boost parameter to provide necessary starting torque. No extra parameters are needed for fan curve.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
See
above.
Base Frequency
(Nameplate)
Maximum
Frequency
2-78
Faults
Faults
Faults are events or conditions within the drive which constitute user notification and may warrant various responses. Some conditions are user configurable as to whether the drive will consider them a fault. Faults are indicated to the user via HIM fault codes and/or popup dialogs or status indications as well as a group of output parameters. Faults are latched, requiring the user or application to perform a fault reset action to clear the latched condition. If the fault condition still exists it will be latched again.
When a Fault Occurs
1. The faulted status is set causing a coast stop sequence to occur turning off output power to the motor.
2. If this is the first fault latched:
– An entry is made in the fault queue.
– The following fault context data will be recorded/updated. Note there is only a single copy of this information which is always related to the most recent fault queue entry (#1).
– Status 1 @ Fault and Status 2 @ Fault
State of Drive Status 1 and Drive Status 2.
– Alarm 1 @Fault and Alarm 2 @Fault
State of Alarm Status 1 and Alarm Status 2
– Fault Frequency: drive speed at time of fault (output frequency if in v/ hz or SVC operation).
– Fault Motor Amps: motor amps at time of fault.
– Fault Bus Volts: unfiltered DC Bus volts at time of fault.
A faulted status indicates whether one or more fault conditions have occurred. The state of the fault queue (empty or full) has no affect on the faulted status.
Fault Queue
Faults are also logged Into a fault queue such that a history of the most recent fault events Is retained.
A fault queue will record the occurrence of the first fault event - i.e. the 1st fault which occurs while no other fault is latched. A new fault event will not be logged to the fault queue if a previous fault is already latched (has occurred but not yet reset/cleared). This results in fault queue entry #1 always indicating the fault which last tripped the drive.
Each fault queue entry will include a fault code and a time stamp value. The fault queue will be a first-in first-out (FIFO) queue. This results in the most recent 'n' faults being retained in the fault queue. Entry 1 will always be the most-recent entry (newest). Entry 'n' will always be the oldest entry, where
'n' is the maximum number of queue entries supported by the drive. As a
Faults
2-79
new fault is logged into the queue 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
The fault code for each entry can be read via a corresponding output
(read-only) parameter. Viewed in this manner (i.e. as a parameter) a numeric fault code is presented - i.e. no text string. This was decided to provide consistent fault indication between the LED and LCD HIM peripherals.
A text string of up to 16 characters is presented when accessing the fault queue via a DPI peripheral, which can present the fault queue to the user rather than through parameters.
Time
[Fault 1-8 Time]
Time Stamp Value
The time stamp value recorded in the fault queue is the value of an internal drive-under-power-timer at the time of the fault. At drive power-up, this internal value is copied to [PowerUp Marker]. The fault queue time stamp can then be compared to determine when the fault occurred relative to the last drive power-up. The user has no control over the value of the internal drive under power timer, which will increment in value over the life of the power structure (saved in nonvolatile storage on the power structure, not the
Control Board).
The time stamp for each fault queue entry can be read via a corresponding parameter. The time stamp value will be presented in xxx.yyyy hours (4 decimal places). Each increment of 1 will represent 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. 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:
2-80
Faults
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.
Resetting faults will clear the faulted status indication. If any fault condition still exists, the fault will be latched and another entry made in the fault queue.
Note: Performing a fault reset does not inherently clear the fault queue.
Clearing the fault queue is a separate action.
Configuration
[Fault Config 1]
Bit-mapped 16 bit word enabling certain fault conditions. Disabling a fault removes the affect 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.
Flying Start
Flying Start
2-81
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. 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:
Options:
0
0
1
“Disabled”
“Disabled”
“Enabled”
170
The gain can be adjusted to increase responsiveness. Increasing the value in
[Flying StartGain] increases the responsiveness of the Flaying Start Feature
169 170 [Flying StartGain]
Sets the response of the flying start function.
Default:
Min/Max:
Display:
4000
20/32767
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.
2-82
Flying Start
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
Fuses and Circuit Breakers
2-83
Tables
through
provide drive ratings (including continuous, 1 minute and 3 second) and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 degree C and the U.S. N.E.C. Other country, state or local codes may require different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the recommended types listed below. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen.
•
IEC
– BS88 (British Standard) Parts 1 & 2
(1)
, EN60269-1, Parts 1 & 2, type gG or equivalent should be used.
•
UL – UL Class CC, T, RK1 or J must be used.
Circuit Breakers
The "non-fuse" listings in the following tables include both circuit breakers
(inverse time or instantaneous trip) and 140M Self-Protecting Motor
Starters. If one of these is chosen as the desired protection method, the following requirements apply.
•
IEC and UL
– Both types of devices are acceptable for IEC and UL installations.
(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED,
EFS, EF, FF, FG, GF, GG, GH.
2-84
Fuses and Circuit Breakers
Table 2.O PF70 208/240 Volt AC Input Recommended Protection Devices
Drive
Catalog
Number
HP
Rating
Input
Ratings Output Amps
Dual
Element Time
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min.
Max.
208 Volt AC Input
20AB2P2 A 0.5
0.33 2.9
20AB4P2 A 1 0.75 5.6
20AB6P8 B 2
20AB9P6 B 3
1.5
2
10.0
14.0
1.1
2
3.6
5.1
2.5
4.8
7.8
11.0
2.7
5.5
10.3
12.1
3.7
7.4
13.8
16.5
20AB015 C 5 3
20AB022 D 7.5
5
16.0
23.3
5.8
8.3
17.5
25.3
19.2
27.8
26.6
37.9
20AB028 D 10 7.5
29.8
10.7 32.2
37.9
50.6
240 Volt AC Input
20
25
35
6
10
15
20
35
50
70
6
10
15
25
20AB2P2 A 0.5
0.33 2.5
20AB4P2 A 1 0.75 4.8
1.1
2.2
2 4.2
2.4
4.8
3.3
6.4
20AB6P8 B 2
20AB9P6 C 3
20AB015 C 5 3
20AB022 D 7.5
5
1.5
8.7
2 12.2
3.6
5.1
6.8
9.6
13.9
19.9
5.8
8.3
15.3
22
9
10.6
17.4
24.2
12
14.4
23.2
33
20AB028 D 10 7.5
25.7
10.7 28 33 44
6
10
15
20
20
25
35
4.5
9
15
20
30
45
60
20
25
35
6
10
15
20
6
10
15
20
20
25
35
Non-Time
Delay Fuse
Min.
Max.
10
17.5
30
40
70
100
125
8
15
25
35
60
80
110
15
15
30
40
70
100
125
15
15
25
35
60
80
110
Circuit
Breaker
Motor
Circuit
Protector
Amps Amps
140M Motor Starter with Adjustable Current Range
Available Catalog Numbers
3
7
15
15
30
30
50
30
30
50
7
7
15
30
140M-C2E-B40 140M-D8E-B40 –
140M-C2E-B63 140M-D8E-B63 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
–
–
140M-C2E-C20 140M-D8E-C20 140M-F8E-C20 –
140M-C2E-C25 140M-D8E-C25 140M-F8E-C25 140M-CMN-2500
– – 140M-F8E-C32 140M-CMN-4000
140M-C2E-B25 140M-D8E-B25 –
140M-C2E-B63 140M-D8E-B63 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C20 140M-D8E-C20 140M-F8E-C20 –
– –
–
–
140M-F8E-C32 140M-CMN-4000
Table 2.P PF70 400/480 Volt AC Input Recommended Protection Devices
Drive
Catalog
Number
HP
Rating
Input
Ratings Output Amps
Dual
Element Time
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min.
Max.
400 Volt AC Input
20AC1P3 A 0.37 0.25 1.6
20AC2P1 A 0.75 0.55 2.5
1.1
1.3
1.8
2.1
1.4
2.4
20AC3P5 A 1.5
1.1
4.3
20AC5P0 B 2.2
1.5
6.5
20AC8P7 B 4 3
20AC011 C 5.5
4
11.3
11
3
4.5
7.8
7.6
3.5
5
8.7
11.5
4.5
5.5
9.9
13
20AC015 C 7.5
5.5
15.1
10.4 15.4
17.2
20AC022 D 11 7.5
21.9
15.2 22 24.2
20AC030 D 15 11 30.3
21 30 33
480 Volt AC Input
1.9
3.2
6
7.5
13.2
17.4
23.1
33
45
3
6
10
10
15
15
20
25
35
30
45
60
3
4
6
10
17.5
25
20AD1P1 A 0.5
0.33 1.3
20AD2P1 A 1 0.75 2.4
20AD3P4 A 2
20AC5P0 B 3
20AD8P0 B 5 3
20AD011 C 7.5
5
1.5
3.8
2 5.6
9.8
9.5
1.1
2
1.1
2.1
3.2
3.4
4.7
5
8.4
8
7.9
11
20AD015 C 10 7.5
12.5
10.4 14
20AD022 D 15 10 19.9
16.6 22
20AD027 D 20 15 24.8
20.6 27
1.2
2.4
4.5
5.5
8.8
12.1
16.5
24.2
33
22
33
44
1.6
3.2
6
7.5
12
16.5
3
6
10
10
15
15
20
25
35
3
6
10
10
15
20
30
45
60
3
6
10
10
15
15
20
25
35
3
6
10
10
15
15
20
25
35
Non-Time
Delay Fuse
Min.
Max.
Circuit
Breaker
Motor
Circuit
Protector
(4)
Amps Amps
4
8
12
20
30
40
50
80
100
5
8
12
20
30
45
60
80
120
15
15
15
20
30
40
50
80
100
15
15
15
20
30
40
60
80
120
3
3
7
15
15
15
20
30
50
3
7
7
15
15
15
20
30
50
140M Motor Starter with Adjustable Current Range
Available Catalog Numbers
140M-C2E-B16 – –
140M-C2E-B25 140M-D8E-B25 –
–
–
140M-C2E-B40 140M-D8E-B40 – –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C25 140M-D8E-C25 140M-F8E-C25 140-CMN-2500
– – 140M-F8E-C32 140M-CMN-4000
140M-C2E-B16 – –
140M-C2E-B25 140M-D8E-B25 –
–
–
140M-C2E-B40 140M-D8E-B40 –
140M-C2E-C63 140M-D8E-C63 –
–
–
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C20 140M-D8E-C20 140M-F8E-C20 –
– – 140M-F8E-C25 140M-CMN-2500
Table 2.Q PF70 600 Volt AC Input Recommended Protection Devices
Drive
Catalog
Number
HP
Rating
Input
Ratings Output Amps
Dual
Element Time
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min.
Max.
600 Volt AC Input
20AE0P3 A 0.5
0.33 1.3
20AE1P7 A 1 0.75 1.9
20AE2P7 A 2
20AE3P9 B 3
1.5
2
3.0
4.4
1.3
0.9
2.0
1.7
3.1
2.7
4.5
3.9
1.1
2.0
3.6
4.3
1.4
2.6
4.8
5.9
20AE6P1 B 5 3
20AE9P0 C 7.5
5
7.5
7.7
7.8
6.1
8.0
9.0
6.7
9.9
9.2
13.5
20AE011 C 10 7.5
9.8
10.1 11.0
13.5
18.0
20AE017 D 15 10 15.3
15.9 17.0
18.7
25.5
20AE022 D 20 15 20.0
20.8 22.0
25.5
34.0
10
10
15
20
4
6
3
3
25
12
20
20
35
6
8
3
3.5
45
10
10
15
20
4
6
3
3
25
Non-Time
Delay Fuse
Min.
Max.
20
35
40
60
3.5
6
10
15
80
Circuit
Breaker
Motor
Circuit
Protector
Amps Amps
20
35
40
60
15
15
15
15
80
15
15
15
30
7
7
3
3
30
140M Motor Starter with Adjustable Current Range
Available Catalog Numbers
Not Applicable
See
for Notes.
Fuses and Circuit Breakers
2-85
Table 2.R PF700 208/240 Volt AC Input Recommended Protection Devices
Drive
Catalog
Number
HP
Rating
Input
Ratings Output Amps
Dual
Element Time
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min.
Max.
208 Volt AC Input
20BB2P2 0 0.5
0.33 1.9
20BB4P2 0 1 0.75 3.7
20BB6P8 0 2
20BB9P6 0 3
1.5
2
6.8
9.5
0.7
2.5
1.3
4.8
2.4
7.8
3.4
11
2.7
5.5
3.7
7.4
10.3
13.8
12.1
16.5
20BB015 1 5 3
20BB022 1 7.5
5
15.7
5.7
17.5
19.2
26.2
23.0
8.3
25.3
27.8
37.9
20BB028 2 10 7.5
29.6
10.7 32.2
37.9
50.6
20BB042 3 15 10 44.5
16.0 48.3
53 72.5
20BB054 3 20 15 57.2
20.6 62.1
72.5
97
240 Volt AC Input
20
30
40
60
3
6
10
12
80
35
50
70
100
6
10
15
20
125
20BB2P2 0 0.5
0.33 1.7
20BB4P2 0 1 0.75 3.3
20AB6P8 0 2
20BB9P6 0 3
1.5
2
5.9
8.3
0.7
2.2
1.4
4.2
2.4
6.8
3.4
9.6
2.4
4.8
9
10.6
3.3
6.4
12
14.4
20BB015 1 5 3
20BB022 1 7.5
5
13.7
5.7
15.3
17.4
23.2
19.9
8.3
22 24.2
33
20BB028 2 10 7.5
25.7
10.7 28
20BB042 3 15 10 38.5
16.0 42
33
46.2
44
63
20BB054 3 20 15 49.5
20.6 54 63 84
20
25
35
50
3
5
10
12
70
30
50
60
90
6
8
15
20
100
20
30
40
60
3
6
10
12
80
20
25
35
50
3
5
10
12
70
Non-Time
Delay Fuse
Min.
Max.
70
100
125
175
10
17.5
30
40
225
60
80
100
150
10
15
25
35
200
70
100
125
175
15
15
30
40
225
60
80
100
150
15
15
25
35
200
Circuit
Breaker
Amps
Motor
Circuit
Protector
Amps
140M Motor Starter with Adjustable Current Range
Available Catalog Numbers
60
80
100
150
15
15
25
35
200
30
30
50
70
3
7
15
15
100
140M-C2E-B25 140M-D8E-B25 –
140M-C2E-B63 140M-D8E-B63 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
–
–
140M-C2E-C20 140M-D8E-C20 140M-F8E-C20 –
140M-C2E-C25 140M-D8E-C25 140M-F8E-C25 140M-CMN-2500
–
–
–
–
140M-F8E-C32 140M-CMN-4000
140M-F8E-C45 140M-CMN-6300
– – – 140M-CMN-6300
140M-C2E-B25 140M-D8E-B25 –
140M-C2E-B63 140M-D8E-B63 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
–
–
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C25 140M-D8E-C25 140M-F8E-C25 140M-CMN-2500
–
–
–
–
140M-F8E-C32 140M-CMN-4000
140M-F8E-C45 140M-CMN-6300
– – – 140M-CMN-6300
Table 2.S PF700 400/480 Volt AC Input Recommended Protection Devices
Drive
Catalog
Number kW/HP
Rating
Input
Ratings Output Amps
Dual
Element Time
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min.
Max.
400 Volt AC Input
20BC1P1 0 0.37 0.25 1.08
0.75 1.3
20BC2P1 0 0.75 0.55 1.7
1.2
2.1
1.4
2.4
20BC3P5 0 1.5
0.75 3.1
20BC5P0 0 2.2
1.5
4.5
2.1
3.5
3.2
5.0
4.5
5.5
20BC8P7 0 4 2.2
8.2
20BC011 0 5.5
4 11.0
5.7
7.6
8.7
11.5
9.9
13
20BC015 1 7.5
5.5
15.1
10.4 15.4
17.2
20BC022 1 11 7.5
21.9
15.2 22 24.2
20BC030 2 15 11 30.3
21.0 30
20BC037 2 18.5 15 37.7
26.1 37
33
45
20BC043 3 22 18.5 44.1
30.6 43
20BC056 3 30 22 57.9
40.1 56
480 Volt AC Input
56
64
20
30
40
50
60
75
3
3
6
6
15
15
23.1
33
45
60
74
86
1.9
3.2
6.0
7.5
13.2
17.4
30
45
60
80
90
120
3
6
8
10
17.5
25
20BD1P1 0 0.5
0.33 0.9
20BD2P1 0 1 0.75 1.6
20BD3P4 0 2 1.5
2.6
0.7
1.1
1.4
2.1
2.2
3.4
20BD5P0 0 3
20BD8P0 0 5
2
3
3.9
6.9
3.2
5.0
5.7
8.0
20BD011 0 7.5
5 9.5
7.9
11
20BD014 1 10 7.5
12.5
10.4 14
20BD022 1 15 10 19.9
16.6 22
20BD027 2 20 15 24.8
20.6 27
20BD034 2 25 20 31.2
25.9 34
20BD040 3 30 25 36.7
30.5 40
20BD052 3 40 30 47.7
39.7 52
24.2
33
40.5
51
60
1.2
2.4
4.5
5.5
8.8
12.1
16.5
33
44
54
68
80
1.6
3.2
6.0
7.5
12
16.5
22
25
35
40
50
60
3
3
4
6
10
15
17.5
50
60
70
90
110
10
15
20
30
3
6
8
20
30
40
50
60
75
3
3
6
6
15
15
25
35
40
50
60
3
3
4
6
10
15
17.5
Non-Time
Delay Fuse
Min.
Max.
Circuit
Breaker
(3)
Amps
Motor
Circuit
Protector
(4)
Amps
140M Motor Starter with Adjustable Current Range
Available Catalog Numbers
80
100
125
150
200
20
30
40
50
4
8
12
60
80
120
125
150
200
5
8
12
20
30
45
30
50
50
50
70
7
15
15
20
3
3
7
80
100
125
150
200
20
30
40
50
15
15
15
20
30
50
50
80
80
3
3
7
7
15
15
60
80
120
125
150
200
15
15
15
20
30
45
140M-C2E-B16 – –
140M-C2E-B25 140M-D8E-B25 –
–
–
140M-C2E-B40 140M-D8E-B40 –
140M-C2E-B63 140M-D8E-B63 –
–
–
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
140M-C2E-C20 140M-D8E-C20 140M-F8E-C20 –
140M-C2E-C25 140M-D8E-C25 140M-F8E-C25 –
–
–
–
–
140M-F8E-C32 –
140M-F8E-C45 –
–
–
–
–
–
–
–
–
140M-C2E-B16 –
140M-C2E-B25 –
140M-C2E-B40 140M-D8E-B40 –
–
–
140M-C2E-C63 140M-D8E-C63 – –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C10 140M-D8E-C10 140M-F8E-C10 –
140M-C2E-C16 140M-D8E-C16 140M-F8E-C16 –
–
–
–
140M-C2E-C25 140M-D8E-C20 140M-F8E-C25 140M-CMN-2500
– – 140M-F8E-C32 140M-CMN-4000
–
–
–
–
140M-F8E-C45 140M-CMN-4000
140M-F8E-C45 140M-CMN-4000
– – – 140M-CMN-6300
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping.
Maximum protection device size is the highest rated device that supplies drive protection.
Circuit Breaker - inverse time breaker.
Motor Circuit Protector - instantaneous trip circuit breaker.
Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/ 347. Not UL listed for use on
480V or 600V Delta/Delta systems.
The AIC ratings of the Bulletin 140M Motor Protector may vary. See publication 140M-SG001B-EN-P.
2-86
Grounding, General
Grounding, General
The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
Figure 2.11 Typical Grounding
R (L1)
S (L2)
T (L3)
U (T1)
V (T2)
W (T3)
PE
SHLD
For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.
Figure 2.12 Single-Point Grounding/Panel Layout
➍
R (L1)
T (L3)
S (L2)
➋
➊
PORT
MOD
NET A
NET B
PWR
STS
TE PE
➌
➑
➓
Refer to
explanation of numbered items.
PORT
MOD
NET A
NET B
PWR
STS
TE PE
➓
➏
➏
U (T1)
V (T2)
W (T3)
➒
➎
➒
U (T1)
V (T2)
W (T3)
➎
➐
➐
Grounding, General
2-87
No.
1
Description
Programmable Controller
4
5
2
3
PE
PE (Safety) - ground bus
Nearest building structure steel
Shield
8
9
6
7
Additional shield (if required)
Attach to motor frame
Analog signal
Motor Terminator
10 Common mode core
Install as
Needed Notes
Refer to publication 1770-4.1 for Programmable
Controller Grounding Recommendations
Motor ground
PE to bus to building steel
✔
✔
✔
Ground per local or national codes
Safety Ground - PE
This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. A second terminal is provided for the motor ground connection.
Shield Termination - SHLD
The SHLD terminal (located on the Cable Entry Plate) provides a grounding point for the motor cable shield. It must be connected to an earth ground by a separate continuous lead. The motor cable shield should be grounded to both the drive Cable Entry Plate (drive end) and the motor frame (motor end).
When shielded cable is used for remote control and signal wiring, the shield should be grounded at the source end only, not at the drive.
RFI Filter Grounding
Using an optional RFI filter may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground.
Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the instructions supplied with the filter
2-88
HIM Memory
HIM Memory
HIM Operations
See
Selecting a Language
See also
Language on page 2-91 . 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.
2. Press the Up Arrow or Down Arrow to scroll through the languages.
3. Press Enter to select a language.
Key(s)
ALT
+
Example Displays
Speak English?
Parlez Francais?
Spechen Duetsch?
Plare Italiano?
Using Passwords
By default the password is set to 00000 (password protection disabled).
Logging in to the Drive
Step
1. Press the Up or Down Arrow to enter your password. Press Sel to move from digit to digit.
2. Press Enter to log in.
Key(s) Example Displays
Login: Enter
Password 9999
Logging Out
Step
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.
Key(s)
To change a password
Step
1. Use the Up Arrow or Down Arrow to scroll to
Operator Intrfc. Press Enter.
Key(s)
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.
Example Displays
Example Displays
Operator Intrfc:
Change Password
User Display
Parameters
Password:
Old Code: 0
New Code: 9999
Verify: 9999
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.
Input Devices
Input Devices
2-89
Setting the User Display
Step
1. Press the Up Arrow or Down Arrow to scroll to Operator Intrfc. Press Enter.
Key(s)
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.
4. Press Enter. Set a scale factor.
Sel
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.
Example Displays
Operator Intrfc:
Change Password
User Display
Parameters
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.
Contactors
See
Motor Start/Stop Precautions on page 2-100
Circuit Breakers / Fuses
See
Fuses and Circuit Breakers on page 2-83
Filters
Internal EMC
Refer to
External EMC
This section is under construction. If further information is required, please contact factory.
2-90
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 as a thermostat, for example, closes its contact to
Run the drive and opens to
Stop the drive
Run/Stop
PORT
MOD
NET A
NET B
PWR
STS
•
In other applications, the maintained device (such as a limit switch), can directly control both Run/Stop and direction control . . .
Run Forward
Run Reverse
PORT
MOD
NET A
NET B
PWR
STS
•
Or, a combination of the two may be desirable.
Run
Forward/Reverse
PORT
MOD
NET A
NET B
PWR
STS
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 either with momentary inputs . . .
Start
Stop
Start
Stop
Forward
Reverse
•
Or, with a maintained input.
Start
Stop
Forward/Reverse
PORT
MOD
NET A
NET B
PORT
MOD
NET A
NET B
PORT
MOD
NET A
NET B
PWR
STS
PWR
STS
PWR
STS
Input Power
Conditioning
Jog
Language
Input Power Conditioning
2-91
In general, the drive is suitable for direct connection to an AC line of the correct voltage. Certain conditions can exist, however, that prompt consideration of a line reactor or isolation transformer ahead of the drive.
The basic rules to aid in determining whether a line reactor or isolation transformer should be considered are as follows:
1. If the source is greater than 6 times the drive kVA then use a reactor or transformer.
2. If the AC source for the drive does not have a ground reference (neutral or phase ground), an isolation transformer with the neutral of the secondary grounded is highly recommended. These products contain PE referenced capacitors for EMC compliance and PE referenced MOV devices for input transient voltage limiting. If the drive must be operated on an ungrounded voltage source, these devices should be disconnected from PE by removing the appropriate jumpers (Refer to Disconnecting
MOVs and Common Mode Capacitors in the User Manual). Transients occurring on a non-ground referenced voltage source may generate excessive line to ground voltages which could exceed the limits of the insulation system of the drive. Under these conditions, it is highly recommended that a system level transient voltage suppression device be employed in order to limit the potential line to ground voltage.
Figure 2.13 Phase to Ground MOV Removal (PF70)
Three-Phase
AC Input
R
S
T
JP2 JP3 1 2 3 4
3. Power factor capacitor switching will cause line voltage transients.
Characteristics of how the capacitors are switched and the impedance of the distribution system will determine the nature of the voltage transients. If the transients are severe enough and the source impedance as seen by the drive is low enough, nuisance fuse blowing, overvoltage faults or drive power structure damage may occur. Historically if there have been voltage transient issues at the facility where the drive is being applied, the use of a 5% 3 phase reactor or appropriately sized isolation transformer for the drive 3 phase power is recommended.
Refer to
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
2-92
Masks
Masks
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.
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]
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.
288 thru
297 x
15 x
14 x
13 x
12 x
11 x
10 x
9 x
8 x
7 x
6
Bit #
Factory Default Bit Values
277 [Start Mask]
Controls which adapters can issue start commands.
278 [Jog Mask]
Controls which adapters can issue jog commands.
279 [Direction Mask]
1
5
D
PI P ort
5
D
PI P ort
4
D
PI P
D ort
3
PI P ort
2
D
PI P ort
1
D ig ital In
1
4
1
3
1
2
1
1
1
0
1 =Control Permitted
0 =Control Masked x =Reserved
See
See
See
Controls which adapters can issue forward/reverse direction commands.
280 [Reference Mask]
Controls which adapters can select an alternate reference; [Speed Ref A, B Sel] or [Preset Speed 1-7].
281 [Accel Mask]
Controls which adapters can select
[Accel Time 1, 2].
282 [Decel Mask]
Controls which adapters can select
[Decel Time 1, 2].
283 [Fault Clr Mask]
Controls which adapters can clear a fault.
See
See
See
See
284 [MOP Mask]
Controls which adapters can issue MOP commands to the drive.
285 [Local 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.
See
See
288 thru
297
288 thru
297
288 thru
297
288 thru
297
288 thru
297
288 thru
297
288 thru
297
288 thru
297
288 thru
297
Masks
2-93
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:
Direction Mask
0 0 0 0 0 1 0 0
Adapter # 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
2-94
MOP
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
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)
MOP
2-95
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.
2-96
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]
The rated power of the motor may be entered in horsepower or in kilowatts.
This parameter determines the units on the following parameter.
Motor Overload
Motor Overload
2-97
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 nameplate FLA programming is used to set the overload feature. This parameter, 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 the Fault Config parameter to zero disables the motor thermal overload. Since the MTO cannot distinguish individual currents in a multimotor application, it is suggested that the MTO be disabled.
The operation of the overload is actually based on three parameters, Motor
Nameplate Full Load Amps, Motor Overload Factor, and Motor Overload
Hz. Motor nameplate full load amps is multiplied by the motor overload factor to allow the user to move the motor overload protection into the drive overload area (simulating a higher motor service factor) by defining the continuous level of current allowed by the MTO.
Motor Overload Hz is used to allow the user to adjust the response of the
MTO to lower motor speeds (lower output frequencies) where a higher degree of protection may be required due to decreased motor cooling.
Motor Overload Curve
100000
10000
1000
100
10
100 125 150 175 200
Full Load Amps (%)
225
250
Cold
Hot
[Motor OL Hz]
[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.
2-98
Motor Overload
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
120
100
80
60
40
20
OL Hz = 10
OL Hz = 25
OL Hz = 50
0 10 20 30 40 50 60 70 80 90 100
% of Base Speed
1 Minute
150%
100%
1 Minute
20 Minutes
{Motor OL Factor]
[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%.
The effective overload factor is a combination of overload Hz and overload factor.
Motor Overload
2-99
Changing Overload Factor
140
120
100
80
60
40
20
OL % = 1.20
OL % = 1.00
OL % = 0.80
120
125
130
135
FLA%
105
110
115
140
145
150
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.
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%
291
244
209
180
934
619
456
357
Cold Trip
Time
6320
1794
122
94
74
60
667
375
240
167
Hot Trip
Time
5995
1500
170
175
180
185
FLA%
155
160
165
190
195
200
88
82
76
70
128
115
105
96
Cold Trip
Time
160
142
21
19
17
15
36
31
27
23
Hot Trip
Time
50
42
220
225
230
235
FLA%
205
210
215
240
245
250
46
44
41
39
58
54
51
48
Cold Trip
Time
66
62
7
7
8
8
11
10
10
9
Hot Trip
Time
14
12
2-100
Motor Start/Stop Precautions
Motor Start/Stop
Precautions
Mounting
!
!
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 occasionally, an auxiliary contact on that device should also be wired to a digital input programmed as a
“Stop” function.
ATTENTION: The drive start/stop control circuitry includes solidstate 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. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present - the motor will coast to a stop. An auxiliary braking method may be required.
Refer to the User Manual for Mounting Clearances. Drive mounting dimensions are presented in
Output Current
Output Devices
Output Current
2-101
[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.
Drive Output Disconnection
!
ATTENTION: Any disconnecting means wired to the drive output terminals U, V and W must be capable of disabling the drive if opened during drive operation. If opened during drive operation, the drive will continue to produce output voltage between U, V, W. An auxiliary contact must be used to simultaneously disable the drive.
Allen-Bradley Drives can be used with an output contactor between the drive and motor. This contactor can be opened under load without damage to the drive. It is recommended, however, that the drive have a programmed
“Enable” input and that this input be opened at the same time as the output contactor.
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 2-31 . Remember that the voltage doubling phenomenon occurs at dif-
ferent 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 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.
2-102
Output Frequency
Output Frequency
Output Power
Output Voltage
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]
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.
This parameter displays the output kW of the drive. The ouput 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]
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
Overspeed Limit
2-103
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.
illustrates a typical Custom V/Hz profile. Minimum Speed is
entered in Hertz and determines the lower speed reference limit during normal operation. Maximum Speed is entered in Hertz and determines the upper speed reference limit. The two “Speed” parameters only limit the speed reference and not the output frequency.
The actual output frequency at maximum speed reference is the sum of the speed reference plus “speed adder” components from functions such as slip compensation.
The Overspeed Limit is entered in Hertz and added to Maximum Speed and the sum of the two (Speed Limit) limit the output frequency. This sum
(Speed Limit) must is compared to Maximum Frequency and an alarm is initiated which prevents operation if the Speed Limit exceeds Maximum
Frequency.
Figure 2.14 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
1
Allowable Speed Reference Range
Maximum
Voltage
Motor NP
Voltage
Frequency Trim due to Speed
Control Mode
Overspeed
Limit
Break
Voltage
Start
Boost
Run
Boost
0 Minimum
Speed
Break
Frequency
Motor NP Hz Maximum
Speed
Output
Frequency
Limit
Maximum
Frequency
Frequency
Note 1: The lower limit on this range can be 0 depending on the value of Speed Adder
2-104
Owners
Owners
An owner is a parameter that contains one bit for each of the possible 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.
Non Exclusive: Multiple adapters can simultaneously issue the same command and multiple bits may be high.
288 [Stop Owner]
Adapters that are presently issuing a valid stop command.
Read Only 276 thru
285 x
15 x
14 x
13 x
12 x
11 x
10 x
9 x
8 x
7 x
6
ort
5 ort
4 ort
3 ort
2 ort
1
0
5
D
PI P
D
PI P
D
PI P
D
PI P
0
4
0
3
0
2
0
1
D
PI P
1
0
D igital In
1 =Issuing Command
0 =No Command x =Reserved
Bit #
289 [Start Owner]
Adapters that are presently issuing a valid start command.
290 [Jog Owner]
See [Stop Owner]
See [Stop Owner]
Adapters that are presently issuing a valid jog command.
291 [Direction Owner]
Adapter that currently has exclusive control of direction changes.
292 [Reference Owner]
Adapter that has the exclusive control of the command frequency source selection.
293 [Accel Owner]
Adapter that has exclusive control of selecting [Accel Time 1, 2].
See [Stop Owner]
See [Stop Owner]
See [Stop Owner]
See [Stop Owner] 294 [Decel Owner]
Adapter that has exclusive control of selecting [Decel Time 1, 2].
295 [Fault Clr Owner]
Adapter that is presently clearing a fault.
See [Stop Owner]
296 [MOP Owner]
Adapters that are currently issuing increases or decreases in MOP command frequency.
297 [Local 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.
See [Stop Owner]
See [Stop Owner]
276 thru
285
276 thru
285
276 thru
285
276 thru
285
Some ownership must be exclusive; that is, only one Adapter at a time can issue certain commands and claim ownership of that function. For example, it is not allowable to have one Adapter command the drive to run in the
forward direction while another Adapter is issuing a command to make the drive run in reverse. Direction Control, therefore, is exclusive ownership.
140
276 thru
285
142
276 thru
285
276 thru
285
276 thru
285
276 thru
285
Owners
2-105
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.
The operator first views the Start owner to be certain that the Start button on the HIM is issuing a command.
Start Owner
0 0 0 0 0 0 0 0
Adapter # 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
0 0 0 0 0 0 1 0
Adapter # 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
0 0 0 0 0 0 0 1
Adapter # 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
and
2-106
Parameter Access Level
Parameter Access
Level
PET
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”.
Pulse Elimination Technique – See
Reflected Wave on page 2-127 .
Power Loss
Power Loss
2-107
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
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 2.4VDC
per minute (for a 480VAC drive). An increase in Vmem is blocked during deceleration to prevent a false high value due to the bus being pumped up by regeneration. Any change to Vmem is blocked during inertia ride through.
Vslew The rate of change of Vmem in volts per minute.
Vrecover The threshold for recovery from power loss.
Vtrigger The threshold to detect power loss.
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 60VDC 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.
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.
Vinertia The software regulation reference for Vbus during inertia ride through.
Vclose The threshold to close the pre-charge contactor.
Vopen
Vmin
Voff
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 2.T PF70 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1
Vtrigger2
Vopen
Vmin
Voff 3
200/240 VAC
1.2 VDC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
204 VDC
?
400/480 VAC
2.4 VDC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
407 VDC
300 VDC
600/690 VAC
3.0 VDC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
509 VDC
?
2-108
Power Loss
550
500
450
400
350
300
700
650
600
700
650
600
550
500
450
Line Loss Mode = Decel
Recover
Close
Trigger
Open
400
350 400
AC Input Volts
Table 2.U PF700 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1,2
Vtrigger1,3
Vopen
Vopen4
Vmin
Voff 5
200/240 VAC
1.2 VDC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
153 VDC
153 VDC
–
450
Note 1:Vtrigger is adjustable, these are the standard values.
Line Loss Mode = Coast
550
500
450
400
350
300
700
650
600
Recover
Close
Trigger
Open
350 400
AC Input Volts
450
550
500
450
400
350
300
700
650
600
400/480 VAC
2.4 VDC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
305 VDC
305 VDC
200 VDC
700
650
600
550
500
450
400
350
350
Line Loss Mode = Coast
Recover
Close
Trigger
Open
400
AC Input Volts
600/690 VAC
3.0 VDC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
382 VDC
382 VDC
–
Line Loss Mode = Decel
Recover
Close
Trigger
Open
400
AC Input Volts
450
450
Line Loss Mode = Half Voltage
Recover
Close
Trigger
Open
350 400
AC Input Volts
450
Power Loss
2-109
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.
•
“Inertia” – Decelerate the motor at just the correct rate so that the energy absorbed from the mechanical load balances the losses.
•
“Half Voltage” – Allow the drive to power the motor down to half bus voltage.If Parameter #184 [Power Loss Mode] = “Coast”
013
185
184 [Power Loss Mode]
Sets the reaction to a loss of input power.
Power loss is recognized when:
•
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”.
Default:
Options:
0
0
1
2
3
4
“Coast”
“Coast”
“Decel”
“Continue”
“Coast Input”
“Decel Input”
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
2-110
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.
Bus Voltage
680V
620V
560V
500V
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
Decel
This mode of operation is useful if the mechanical load is high inertia and low friction. By recapturing the mechanical energy, converting it to electrical energy and returning it to the drive, the bus voltage is maintained.
As long as there is mechanical energy, the ride through time is extended and the motor remains fully fluxed 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.
Power Loss
2-111
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.
Bus Voltage
680V
620V
560V
500V
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
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,
2-112
Power Loss 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.
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.
Bus Voltage
680V
620V
560V
365V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
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.
Power Loss
2-113
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.
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.
2-114
Power Loss
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.
Preset Frequency
Preset Frequency
2-115
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].
2-116
Process PI Loop
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).
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.
Process PI Loop
2-117
There are two ways the PI Controller can be configured to operate.
•
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 Adder
Spd Ref
PI Ref
PI Fbk
Process PI
Controller
PI Disabled
Linear Ramp
& S-Curve
+
+
+
+
Slip
Comp
Open
Loop
Process
PI
Speed Control
Spd Cmd
2-118
Process PI Loop
When the PI is enabled, the output of the PI Controller is added to the ramped speed reference.
Slip Adder
Spd Ref
Linear RAmp
& S-Curve
+
+
+
+
Slip
Comp
Open
Loop
Process
PI
Spd Cmd
PI Ref
PI Fbk
Process PI
Controller
PI Enabled 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
Pressure
Transducer
Motor
PI Feedback
Desired Pressure
[PI Reference Sel]
However, when additional valves in the system are opened and the pressure in the system drops, the 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.
Process PI Loop
2-119
Slip Adder
Spd Ref
PI Ref
PI Fbk
Process PI
Controller
PI Disabled
Linear RAmp
& S-Curve
+
+
Slip
Comp
Open
Loop
Process
PI
Speed Control
Spd Cmd
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
Spd Ref
Linear RAmp
& S-Curve
+
+
Slip
Comp
Open
Loop
Process
PI
Spd Cmd
PI Ref
Process PI
Controller
PI Fbk PI Enabled
Speed Control
Configuration
To operate the drive in PI regulator Mode, the speed regulation mode must be changed by selecting “Process PI” through the [Speed Control] 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
•
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.
2-120
Process PI Loop
PI Enabled
PI Output
Spd Cmd
The option to invert the sign of PI Error is selected in the PI
Configuration parameter.
PI_Config
.Invert
+
PI Ref Sel
–
PI_Config
.Sqrt
-
PI Fdbk Sel
PI Fbk
PI Error
•
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 Pre-load Value = 0
PI Pre-load Value
PI Pre-load Value > 0
Process PI Loop
2-121
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.
PI Enabled
Start at Spd Cmd
PI Output
Spd Cmd
Pre-load to Command Speed
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.
•
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.
2-122
Process PI Loop
Spd Ref
PI Ref
PI Fbk
Linear
Ramp
& S-Curve
Process PI
Controller
Spd Ramp
+
+
PI Output
≥
0
PI_Config
.ZeroClamp
+32K
0
0
-32K
+32K
-32K
Spd Cmd
•
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.
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
Normalized Feedback
50.0
75.0
100.0
•
Stop Mode (PF700 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. When set to “0” the drive will perform a normal stop.
•
Anti-Wind Up (PF700 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.
Process PI Loop
2-123
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 regulator output can be turned on/off. PI Enabled determines when PI Output is part, or all of the commanded speed.
The logic evaluated for PI Enabled is shown in the following ladder diagram.
The drive must be in run before PI Enabled can turn on. PI Enabled will stay off when the drive is jogged. The PI is disabled when the drive begins a ramp to stop.
If a digital input is configured to provide PI Enable and that digital input is turned on then PI Enabled may turn on. Note that when a digital input is configured to provide PI Enable that input takes precedence over the PI Control parameter.
If a digital input is not configured to provide PI Enable and the PI
Enable bit in the PI Control parameter is turned on then PI Enabled may turn on. If PI_Control.PI_Enable is left on all the time then the
PI may become enabled as soon as the drive goes into run. If analog input signal loss is detected PI Enabled is turned off.
Running Stopping
DigInCfg
.PI_Enable
DigIn
.PI_Enable
Signal Loss
PI_Status
.Enabled
DigInCfg
.PI_Enable
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.
2-124
Process PI Loop
– If the current limit or voltage limit is active then the PI is put into hold.
DigInCfg
.PI_Hold
DigIn
.PI_Hold
PI_Status
.Hold
DigInCfg
.PI_Hold
Current Lmt or Volt Lmt
PI_Control
.PI_Hold
•
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 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.
Process PI Loop
2-125
PF70 options include DPI adapter ports, MOP, preset speeds, analog inputs and PI setpoint parameter. In the PF700, 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 2-6
.
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.
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.
2-126
Process PI Loop
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
Z
-1
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.
PI_Config
.ZeroClamp
PI_Config
.Exclusive
PI_Status
.Enabled
Spd Ref
PI Pos Limit
PI Neg Limit
PI Kp
PI ExcessErr
*(PI Ref Sel)
PI_Status
.Enabled
PI_Config
.RampCmd
0
*(PI Fbk Sel)
PI_Config
.Sqrt
PI_Config
.Invert
PI Ki
PI_Status
.Hold
Preload Value
Spd Cmd
PI_Config
.PreloadCmd
PI_Status
.Enabled
PI Ref
Linear
Ramp
PI Cmd
+
-
-
Spd Cmd
PI_Config
.Exclusive
Current Limit or Volt Limit
PI Fbk
Figure 2.15 Process PI Block Diagram
abs
≥
PI Error
PI XS Error
*
*
+
+
+
+ z
-1
PI Output
Linear Ramp
& S-Curve
Spd Ramp
+
+
≥
0
+32K
-32K
+32K
0
0
-32K
Spd Cmd
Zclamped
In Limit
Reflected Wave
Reflected Wave
2-127
[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 @ 480 V input) result at the motor and can cause motor winding failure.
The patented reflected wave correction software in the PowerFlex 70 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 + 10% High Line = 540V DC bus X 2.25 = 1200 V
480 V Line + 10% High Line = 715V DC bus X 2.25 = 1600 V
600 V Line + 10% High Line = 891V DC bus X 2.25 = 2000 V
(inverter duty grade motor insulation)
The software is standard and requires no special parameters or settings.
Inverter 500
V/div
0
<T
α
1670 Vpk
Motor
500
V/div
0
0 5 10 15 20 25 30
Time ( sec)
35 40 45 50
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 PVC 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
2-128
Reflected Wave 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 over-voltage as a function of cable length. This is for no correction versus the modulation correction code for varied lengths of #12 AWG PVC cable to 600 feet for a 4 kHz 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
2.5
2.4
2.3
2.2
2.1
2
1.9
1.8
1.7
1.6
0
No Correction 4 kHz Carrier
Corrected 4 kHz Carrier
No Correction 8 kHz Carrier
Corrected 8 kHz Carrier
100 200 300 400
Cable Length (Feet)
500 600
Without the correction, the over-voltage increases to unsafe levels with increasing cable length for both carrier frequencies.
The patented modulation correction code reduces the over-voltage for both carrier frequencies and maintains a relatively flat over-voltage level for increasing cable lengths beyond 300 feet.
Reset Meters
2-129
Reset Meters
This section is under construction. If further information is required, please contact factory.
Reset Run
Refer to
Auto Restart (Reset/Run) on page 2-24
.
RFI Filter Grounding
See
RFI Filter Grounding on page 2-87
2-130
S Curve
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.
80.0
60.0
40.0
20.0
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
4.0
Seconds
5.0
6.0
7.0
8.0
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
50.0
40.0
30.0
20.0
10.0
0.0
0.0
0.5
1.0
1.5
2.0
Seconds
2.5
3.0
3.5
4.0
S Curve
2-131
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
50.0
40.0
30.0
20.0
10.0
0.0
0.0
1.0
2.0
3.0
Seconds
4.0
5.0
6.0
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
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
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
4.0
5.0
Seconds
2-132
S Curve
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
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
Scaling Blocks
Scaling Blocks
2-133
This section is under construction. If further information is required, please contact factory.
2-134
Shear Pin Fault
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]
Enables/disables annunciation of the listed faults.
x
15 x
14 x
13 x
12 x
11 x
10 x
9
Bit #
Factory Default Bit Values x
8 x
7
1
6
D
0
5
ib t utR ries in st T
Sh ear P
M oto r O verL d
U nd erV ge olta er L oss
Po w
0 1
x
1 0
1 =Enabled
4 3 2 1 0
0 =Disabled x =Reserved
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.
147 [Current Lmt Sel]
Selects the source for the adjustment of current limit (i.e. parameter, analog input, etc.).
Default:
Options:
0
0
1
2
“Cur Lim Val”
“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.
Skip Bands
Skip Bands
2-135
[Skip Freq 1-3]
The skip band function provides three skip bands that the drive will ramp through but will not continuously run within. The user will be able to set the skip frequency (center frequency) for each band and the skip band centered on the skip frequency. The skip band applies to all three skip frequencies.
The skip band function operates as follows.
1. Greater than or equal to the center frequency and less than or equal to the high value of the band sets the output to the high value of the band. See grayed area of 'Upper Band' below.
2. Less than the center frequency and greater than or equal to the low value of the band, sets the output to the low value of the band. See grayed area of 'Lower Band' below.
3. The skip frequency will have hysteresis so the output does not toggle between high and low values.
Hyst.
Upper Band Lower Band
Conditions
If none of the skip bands touch or overlap, each band has its own high/low limit. See example #1 below.
If skip bands overlap or touch, the center frequency is recalculated based on the highest and lowest band values. See example #2 below.
Set Values
60 Hz
54 Hz
Example #1
45 Hz
Adjusted Values
60 Hz
54 Hz
45 Hz
33 Hz
Example #2
27 Hz
30 Hz
13.5 Hz
Example #2
9 Hz
0 Hz
Time
Command Frequency
Skip Band Output
11.25 Hz
0 Hz
2-136
Skip Bands
If a skip band(s) extend beyond the max or min limits, the highest or lowest band values, respectively, will be clamped at the limit. The center frequency is recalculated based on the highest and lowest band values. If the band is outside the limits, the skip band is inactive.
400 Hz
Skip Frequency #3
Max Frequency
Skip Frequency #2
}
Skip Frequency #3 (Inactive)
}
Skip Frequency #2 (Adjusted)
Skip Frequency #1
Min Frequency
}
Skip Frequency #1 (Adjusted)
0 Hz
Disabling
If a skip band is not required, its skip frequency value is set to zero.
Range
The skip bands apply to both forward and reverse directions.
Sleep Mode
Sleep Mode
2-137
The basic operation of this function is to start (wake) the drive when an analog signal is greater than or equal to the user specified [Wake Level], and stop the drive when an analog signal is less than or equal to the user specified [Sleep Level].
Enabling the sleep wake function is accomplished by setting the
[Sleep-Wake Mode] parameter to “Direct”.
All previously defined permissives (stop, enable, faults, type 2 alarms, etc.) are honored. In addition to the sleep function, at least one of the following assignments must be made to a digital input, and the input must be closed:
(Enable, Stop-CF, Run, Run Fwd, Run Rev).
Restarting following a fault condition will be possible by either a rising edge of the timed wake signal or a separate start signal. A wake signal condition will not interfere with the resetting of a fault or restarting of the drive with another signal.
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). Upon power up, timers should be initialized to the state that does not permit a start condition, and then start counting if the analog signal satisfies the level requirement.
Separate start commands are also honored (including a digital input “start”), but only when the sleep timer is not satisfied, essentially acting 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, and
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.
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. All defined analog inputs for a product shall be considered as valid Sleep/Wake sources. The Sleep/Wake function is completely
2-138
Sleep Mode
Sleep Timer
Satisfied
Sleep Level
Satisfied
Wake Timer
Satisfied
Wake Level
Satisfied
Wake Level
Sleep Level
Analog Signal
Drive
Run
Sleep-Wake
Function
Start
Stop 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.
Wake Up
Go to Sleep
Wake
Time
Example Conditions
Wake Time = 3 Seconds
Sleep Time = 3 Seconds
Sleep
Time
Wake
Time
Sleep
Time
Speed Control
Speed Mode
Speed Regulation
Speed Control Speed Mode Speed Regulation
2-139
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. Additional choices are available on the PowerFlex 700 (see
•
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 [Speed Mode]
Sets the method of speed regulation.
Default:
Options:
0
0
1
2
“Open Loop”
“Open Loop”
“Slip Comp”
“Process PI”
121 thru
138
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
2-140
Speed Control Speed Mode Speed Regulation
Figure 2.16 Rotor Speed with/without Slip Compensation
0
0
Slip Compensation
Inactive
Load
Applied
No Load
0.5 p.u. Load
1.0 p.u. Load
1.5 p.u. Load
Slip Compensation
Active
Load
Applied
1.5 p.u. Load
1.0 p.u. Load
0.5 p.u. Load
Slip Compensation
Active
Load
Removed
Slip @
F.L.A.
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 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
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.
Speed Control Speed Mode Speed Regulation
2-141
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 2.17 Rotor Speed Response Due to Impact Load and Slip Com Gain
Impact Load
Removed
Impact Load
Applied
Increasing Slip
Comp Gain
Increasing Slip
Comp Gain
Rotor Speed
Reference
0
0
Time
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.
PowerFlex
Drive
#1
PowerFlex
Drive
#2
Dough Stress
Relief
CUTTERS
Cookie Line
5/40
PowerFlex
Drive
#3
PowerFlex
Drive
#4
OVEN
2-142
Speed Control Speed Mode Speed Regulation
Process PI –
See
Encoder Feedback (PowerFlex 700 Only)
This section is under construction. If further information is required, please contact factory.
Droop (PowerFlex 700 Only)
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 increase in motor torque could cause undesirable operation in some process. Typically, if two or more motors are mechanically linked to the same load, this increased torque will cause one motor to assume more of the load and it may set up an unstable “struggle” between motors. In this case, the droop function will decrease the output frequency to maintain a consistent torque level, allowing multiple motors to
“share” the work.
Without droop active, as the load increases, the rotor speed decreases creating uneven loading on the motors.
With droop, the correct amount of compensation is deducted from the drive output frequency based on motor load. Thus, the torque level decreases and other motors can share the load. Conversely, when the load is reduced, the rotor speed decreases momentarily until the droop decays to zero.
Application Considerations
The Droop function is enabled by selecting “Droop” as the speed control method in [Speed Control]. The amount of Droop that will be subtracted from the output frequency at full load is determined by the setting of the
[Slip @ F.L.A.]. The response of the droop circuit can be adjusted by setting
[Slip Comp Gain], 1 being the slowest and 40 the fastest.
The droop feature is used in applications that have two or more motors that are mechanically connected via the load. Each drive must control only one motor for the function to work properly. The control source should supply all of the drives with an identical speed reference. This setup will allow the system load to be shared by each motor.
Application Example - Automotive Chain Conveyor
The above diagram shows a typical example for the Speed Droop feature.
The chain conveyor is used to transfer car bodies through the final assembly area. This application is usually a 5-15 HP motor with a 250:1 (typical) gear reduction. Since the motors are mechanically interlocked, they will need to load share. The “take-up” adjusts the tension of the chain but does not directly affect the load of an individual motor. Therefore, the drive must adjust the output frequency based on load changes.
Speed Control Speed Mode Speed Regulation
2-143
Gear
Box
PowerFlex
Drive
#1
TAKE UP
Gear
Box
PowerFlex
Drive
#2
To accomplish this, the PLC or other controller, will control the speed command being sent to the drives. Both drives can be programmed for droop operation. Or the lead drive may be used as the “speed regulator” with the second drive used as a “torque helper” to share the load. The speed regulator will be used to shed the load of an individual motor as the system cycles through the process.When a car is finished and removed from the line, the load on drive #1 will decrease. At this time, another vehicle is added to the conveyor causing drive #2 to see an increase in load. Drive/ motor #2 will decrease its output frequency causing more of the load to be taken by drive/motor #1.
2-144
Speed Reference
Speed Reference
Speed Reference Scaling
[Speed Ref A, B Sel]
[TB Man Ref Sel]
The reference generation function is to provide a reference to the drive. Its purpose is to determine which reference source should be used based on parameters and logic command. Seven references can be selected by logic command. The first two references (A & B) have selectable sources.
References A & B can be trimmed by a trim that has selectable sources. The other five are fixed at preset frequencies three to seven. The user will be able to select if the reference is unipolar, which is limited to a positive value and enables the direction bit or bipolar which disables the direction bit allowing the reference sign to command direction. The min and max speed limit the final reference going to the skip band module.
Seven references can be selected through logic command.
Logic command (drive control command) is a bit enumerated parameter, which contains the final command after it has been funneled through a command evaluation module of masks, owners, and transitions. Logic commands come from the terminal block, DPI peripherals, and HIM all at the same time. Logic command could consists of stop, start, jog, accel , decel ,MOP inc/dec, direction, etc. The command evaluation module is not within the scope of this document and will be covered in another document.
The first two references are programmable. The user can select which source they would like for each reference. If an analog input reference or pulse input reference (PowerFlex 700 Only) is chosen, two scale parameters are provide to scale the reference. The scale min/max are based on other parameter (uni/bipolar, analog in config, etc.). See also
more information.
The last five are fixed references, preset frequencies 3-7.
Reference A & B can be trimmed with a selectable source trim. If an analog input reference or pulse input reference (PowerFlex 700 Only) is chosen, two scale parameters are provide to scale the reference. The trim is a +/– reference which can be set to trim none, A, B, or Both.
Auto / Manual
Many applications require a “manual mode” where adjustments can be made and setup can be done by offering local control of the drive speed.
Typically, these adjustments could 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. Also see
Speed Reference
2-145
Trim
[Trim In Sel]
Reference A and Reference B can be trimmed with a selectable source. The trim is an input signal value (+/-) which ia added to the reference. If an analog input is chosen as the trim source, two scale parameters are provide to scale the trim signal.
The choices for Trim source select are:
•
LED HIM
•
DPI Peripheral 1 (LCD HIM)
•
DPI Peripheral 2 - 5
•
MOP
•
Preset Speed 1 - 7
•
Analog Input 1 - 2
Trim Enable Select
Trim
A
B
Both
None
Reference A
Reference B
+
+
+
+
Trimmed
Reference A
Trimmed
Reference B
Min / Max Speed
[Max Speed]
Max and min speed limits are applied to the reference. These limits apply to the positive and negative references. The min speed limits will create a band that the drive will not run continuously within, but will ramp through. This is due to the positive and negative min speeds. If the reference is positive and less than the positive min, it is set to the positive min. If the reference is negative and greater than negative min, it is set to the negative min. If min is not 0, hysteresis is applied at 0 to prevent bouncing between positive and negative mins. See below.
Max Spd Max Spd
Min Spd
Min Spd
– Min Spd
Band
– Max Spd – Max Spd
2-146
Speed Reference
Follower/Leader
This section is under construction. If further information is required, please contact factory.
HIM Speed Reference
This section is under construction. If further information is required, please contact factory.
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.
Start Inhibits
Start Inhibits
2-147
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 2-148 .
2-148
Start Permissives
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
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.
Start-Up
Start-Up
2-149
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)
ALT
ALT
Esc
Example LCD Displays
S.M.A.R.T. List
Start Mode
Stop Mode
Minimum Speed
Sel
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.
2-150
Start-Up
Basic Start Up (Top Level)
HIM
Main Menu:
<Diagnostics>
Parameter
Device Select
Memory Storage
StartUp
Preferences
Startup
Drive active?
Esc
Yes
0-2
PowerFlex 70
StartUp .
The drive must be stopped to proceed. Press
Esc to cancel.
Abort
No
Stop
7. Done
/Exit
Startup previously aborted?
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
Backup
Yes
Startup Menu
1. Input
Voltage
2. Motor
Dat/Ramps
3. Motor
Tests
4. Speed
Limits
5. Speed
Control
6. Strt,Stop,
I/O
'Esc' key
0-3
PowerFlex 70
StartUp .
Make a selection
Abort
<Backup>
Resume
StartUp Menu
Any state
Resume
Backup
Go to previous state
Go to Backup screen for previous state
Go to 1-0
Go to 2-0
Go to 3-0
Go to 4-0
Go to 5-0
Go to 6-0
Backup
Backup
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
Rated Volts
>300?
1-1
StartUp
1. Input Voltage
Enter choice for
Input Supply
400V, 50 Hz
<480V, 60 Hz>
Yes
Enter
1-3
StartUp
1. Input Voltage
Reset all parameters to their defaults?
<Yes>
No
Enter
Yes
1-4
StartUp
1. Input Voltage
Clear fault to continue.
No
1-2
StartUp
1. Input Voltage
Enter choice for
Input Supply
208V, 60 Hz
<240V, 60 Hz>
Fault Clear
No
Go to 0-1 (2)
Start-Up
2-151
2-152
Start-Up
2-0
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
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Power
123.4 kW xxx.x <> yyy.y
Enter
2-3
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP FLA
+456.78 Amps xxx.xx <> yyy.yy
Enter
2-4
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Volts
123.4 Volt xxx.x <> yyy.y
Enter
2-5
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Hertz
60.0 Hz x.x <> y.y
Enter
2-6
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP RPM
+456 RPM xxx <> yyy
Basic Start Up (Motor Data/Ramp)
2-7
StartUp
2. Motr Dat/Ramp
Enter choice for
Stop Mode A
Backup
Enter
Enter
Backup
Stop Mode A
= "DC Brake" or
"Ramp to
Hold"?
Yes
2-8
StartUp
2. Motr Dat/Ramp
Enter value for
DC Brake Level
1.0 Amps
0.0 < 30.0 Amps
Enter
Backup
Stop Mode A
= "DC
Brake"?
Yes
2-9
StartUp
2. Motr Dat/Ramp
Enter value for
DC BrakeTime
1.0 Secs
0.0 < 90.0 Secs
No
2-10
StartUp
2. Motr Dat/Ramp
Enter choice for
DB Resistor Type
None
Internal
External
No
Enter
2-11
StartUp
2. Motr Dat/Ramp
Enter value for
Accel Time 1
6.0 Secs
0.0 < 60.0 secs
Enter
Enter
2-12
StartUp
2. Motr Dat/Ramp
Enter value for
Decel Time 1
6.0 Secs
0.0 < 60.0 secs
Enter
2-13
StartUp
2. Motr Dat/Ramp
Enter value for
S Curve %
0 %
0 < 100 %
None - Bus Reg Mode A = Adj Freq.
Intenal - Bus Reg Mode A = Both, DB 1st.
External - Bus Reg Mode A = Both, DB 1st.
Enter Go to 0-1 (3)
Start-Up
2-153
Enter/
Backup
3-0
Startup
3. Motor Tests
This section optimizes torque performance and tests for proper direction.
3-4
Startup
B. Directn Test
Press Jog or Start to begin.
Basic Start Up (Motor Tests)
Direction
Test
Enter
Startup
3. Motor Tests
Complete these steps in order:
<A. Auto Tune>
B. Directn Test
C. Done
3-1
Done
Auto Tune
Startup
A. AutoTune
Rotate Tune only with no load and low friction.
Static Tune when load or friction are present.
3-2
Go to 0-1 (4)
Enter/
Backup
Fault Clear
Enter
3-3
Startup
A. AutoTune
Make a selectioon
<Rotate Tune>
Static Tune
3-8
Startup
A. Auto Tune.
Static Tune will energize motor with no shaft rotation. Press
Start to begin.
Static
Tune
Rotate
Tune
Startup
A. Auto Tune
Rotate Tune will energize motor, then cause shaft rotation. Press
Start to begin.
3-9
3-12
Startup
3. Motor Tests
Test aborted due to user stop.
Clear fault to continue.
Start
3-5
Startup
B. Directn Test
Is direction of motor forward?
<Yes>
No
Enter/
Backup
Yes
(stops drive)
3-6
Startup
B. Directn Test
Test complete.
No
(stops drive)
3-7
Startup
B. Directn Test
Press Enter.
Then power down and swap 2 output wires to motor.
Start
3-10
Startup
A. Auto Tune
Executing test.
Please wait....
Start
Rotate/Static
Tune complete
(stops drive)
3-11
Startup
A. Auto Tune
Test complete.
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.
2-154
Start-Up
4-0
StartUp
4. Speed Limits
This section defines min/max speeds, and direction method
Basic Start Up (Speed Limits)
Backup
Enter
4-1
StartUp
4. Speed Limits
Disable reverse operation?
Yes
<No>
No
4-2
StartUp
4. Speed Limits
Enter choice for
Direction Method
<Fwd/Rev Command>
+/- Speed Ref
Yes
4-3
StartUp
4. Speed Limits
Enter value for
Maximum Speed
+60.00 Hz xxx.xx <> yyy.yy
Enter
Enter
Backup
MaxSpd + OSL
> MaxFreq?
Yes
4-5
StartUp
4. Speed Limits
Maximum Freq and
Overspeed Limit will be changed to support your
Maximum Speed.
No
Backup
4-4
StartUp
4. Speed Limits
Enter value for
Minimum Speed
+5.78 Hz xxx.xx <> yyy.yy
Enter
4-6
StartUp
4. Speed Limits
Rejecting this change will prevent starting
Accept
Reject
Accept
MaxSpd + OS
Lmt > 400Hz?
Reject
MaxFreq = MaxSpd
+ OS Limit
No
OS Limit =
MaxFreq - MaxSpd
MaxFreq = 400Hz
Enter
Yes
Go to 0-1 (5)
Start-Up
2-155
5-0
StartUp
5. Speed Control
This section defines a source from which to control speed.
5-2
Adapter
StartUp
5. Speed Control
Enter choice for
Comm Adapter
Port 5-internal
Port 2-external
Port 3-external
Enter
Go to 0-1 (6)
Enter
5-3
StartUp
5. Speed Control
Enter choice for
Remote HIM
Port 2 (common)
Port 3
5-4
StartUp
5. Speed Control
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
5-5
StartUp
5. Speed Control
Enter value for
Preset Speed 2
10.0 Hz
xxx.x < yyy.y
5-6
StartUp
5. Speed Control
Enter value for
Preset Speed 3
15.0 Hz
xxx.x < yyy.y
5-7
StartUp
5. Speed Control
Enter value for
Preset Speed 4
20.0 Hz
xxx.x < yyy.y
Enter
Basic Start Up (Speed Control)
5-1
StartUp
5. Speed Control
Enter choice for
Speed Control
<Analog Input>
Comm Adapter
Local HIM-Port 1
Remote HIM
Preset Speeds
MOP
Remote
HIM
Preset
Speeds
Local HIM-
Port 1
Go to 0-1 (6)
MOP
Analog Input
5-14
StartUp
5. Speed Control
Digital Inputs
5 & 6 will be set to MOP Inc &
MOP Dec.
Enter
5-15
StartUp
5. Speed Control
Save MOP speed at power down ?
<Yes>
No
5-11
StartUp
5. Speed Control
Note: Factory default settings provide preset speed operation from the digital inputs, unless you change their function.
Enter
5-16
StartUp
5. Speed Control
Save MOP speed at stop ?
<Yes>
No
Enter/
Backup
Preset
Speed 1
Preset
Speed 2
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 3
Preset
Speed 4
Preset
Speed 5
Preset
Speed 6
Done
Preset
Speed 7
Enter
5-17
PF70 StartUp
5. Speed Control
Enter value for
MOP Rate
5.0 Hz xx.x < yy.y
Enter
Go to 0-1 (6)
5-8
StartUp
5. Speed Control
Enter value for
Preset Speed 5
25.0 Hz
xxx.x < yyy.y
5-9
StartUp
5. Speed Control
Enter value for
Preset Speed 6
30.0 Hz
xxx.x < yyy.y
5-10
StartUp
5. Speed Control
Enter value for
Preset Speed 7
35.0 Hz
xxx.x < yyy.y
Enter
5-21
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
Enter
Enter
5-22
StartUp
5. Speed Control
The next two parameters link a low speed with a low analog value.
5-23
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Lo
0.0 V
xxx.x < yyy.y
Enter
5-24
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
5-13
StartUp
5. Speed Control
Enter choice for
Input Signal
Analog Input 1
Analog Input 2
5-18
Analog
Input 1
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
Analog
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
5-25
Enter
5-19
StartUp
5. Speed Control
The next two parameters link a high speed with a high analog value.
5-20
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Hi
10.0 V
xxx.x < yyy.y
Enter
5-26
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
Enter
5-28
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
Enter
5-29
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
Enter
5-31
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
2-156
Start-Up
6-0
StartUp
6. Strt,Stop,I/O
This section defines I/O functions including start and stop from digital ins
Backup
Enter
6-3
StartUp
A. Dig Inputs
Digital Inputs
1-4 will be set to defaults.
Yes
Enter
6-1
StartUp
6. Strt,Stop,I/O
Complete these steps in order:
<A. Dig Inputs>
B. Dig Outputs
C. Anlg Outputs
D. Done
A. Dig Inputs
6-2
StartUp
A. Dig Inputs
Make a selection
<Easy Configure>
Custom Configure
Easy Configure
DigIn 5,6 = MOP
Inc, Dec?
No
Enter
Dir Mode =
Reverse
Disable?
Yes
6-6
Backup
6-4
StartUp
A. Dig Inputs
Digital Inputs
1-6 will be set to defaults.
No
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
Yes
C. Anlg
Outputs
D. Done
B. Dig
Outputs
Go to 6-29
Custom Configure
Backup
Dir Mode =
Bipolar?
6-7
StartUp
A. Dig Inputs
Digital Input 1 will be set to
Not Used.
2-wire
Enter
6-8
StartUp
A. Dig Inputs
Digital Input 2 will be set to
Run/Stop.
Enter
3-wire
6-9
StartUp
A. Dig Inputs
Digital Input 1 will be set to
Stop.
Enter
6-10
StartUp
A. Dig Inputs
Digital Input 2 will be set to
Start.
Enter
Go to 6-1 (B)
Basic Start Up (Start,Stop,I/O)
Go to 0-1 (7)
Go to 6-24
No
No
6-5
StartUp
A. Dig Inputs
Is reverse required from digital inputs?
<Yes>
No
Yes
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
6-11
Enter
Go to 6-1 (B)
6-12
2-wire
StartUp
A. Dig Inputs
Digital Input 1 will be set to
Run Forward.
6-13
Enter
StartUp
A. Dig Inputs
Digital Input 2 will be set to
Run Reverse.
Done
6-17
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
Enter
Enter/
Backup
Digital In 1
Digital In 2
Digital In 3
Digital In 4
Digital In 5
Digital In 6
3-wire
6-14
StartUp
A. Dig Inputs
Digital Input 3 will be set to Fwd/
Reverse.
Enter
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
Start.
6-18
StartUp
A. Dig Inputs
Enter choice for
Digital In1 Sel
6-19
StartUp
A. Dig Inputs
Enter choice for
Digital In2 Sel
6-20
StartUp
A. Dig Inputs
Enter choice for
Digital In3 Sel
6-21
StartUp
A. Dig Inputs
Enter choice for
Digital In4 Sel
6-22
StartUp
A. Dig Inputs
Enter choice for
Digital In5 Sel
6-23
StartUp
A. Dig Inputs
Enter choice for
Digital In6 Sel
Start-Up
2-157
Basic Start Up (Start,Stop,I/O [2])
Go to 6-1 (C)
Done
6-24
StartUp
B . Dig Outputs
Make a selection
<Digital Out 1>
Digital Out 2
Done
6-25
StartUp
B. Dig Outputs
Enter choice for
Digital Out 1 Sel
Digital
Out 1
Digital
Out 2
6-27
StartUp
B. Dig Outputs
Enter choice for
Digital Out 2 Sel
No
Enter
Enter Enter
Digital Out 1 Sel
= ENUM choice that uses
"Level"?
Yes
6-26
StartUp
B. Dig Outputs
Enter value for
Dig Out 1 Level
Backup
Backup
Digital Out 2 Sel
= ENUM choice that uses
"Level"?
Yes
StartUp
B. Dig Outputs
Enter value for
Dig Out 2 Level
No
Enter
6-29
StartUp
C. Anlg Outpts
Enter choice for
Analog Out 1 Sel
Enter
6-30
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Hi
Enter
6-31
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Lo
Enter
Go to 6-1 (D)
2-158
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 coats or free spin until the mechanical energy is dissipated.
Output Voltage
Output Current
Motor Speed
Time
Coast Time is load dependent
Stop
Command
2. Dynamic Braking is explained in detail in the PowerFlex Dynamic
Braking Selection Guide, presented in
3. Brake to Stop 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. This voltage is only removed by one of two events;
– Opening an Enable digital input
– Reissuing the Start command
Caution must be used when setting [DC Brake Level]. Excess motor current could damage the motor.
Caution must also be observed, since motor voltage will exist even though a Stop command was issued.
Output Voltage
Output Current
Motor Speed
DC
Hold Level
Time
DC Hold Time
Stop
Command
Stop Modes
2-159
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
DC Hold Time
Zero
Command
Speed
The drive output voltage will be zero when the hold time is finished
2-160
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]. The DC hold is removed only by removing the “Enable” input or by a valid start input.
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.
Output Voltage Output Voltage
Output Current
Motor Speed
Output Current
Motor Speed
Output Current
Output Voltage
DC
Hold Level
Time
Stop
Command
Zero
Command
Speed
Re-issuing a
Start Command
Test Points
Thermal Regulator
234
236
235
237
32
[Testpoint 1 Sel]
[Testpoint 2 Sel]
Selects the function whose value is displayed value in [Testpoint x Data].
These are internal values that are not accessible through parameters.
See Testpoint Codes and Functions on page 4-10 for a listing of available codes and functions.
[Testpoint 1 Data]
[Testpoint 2 Data]
The present value of the function selected in [Testpoint x Sel].
Default:
Min/Max:
Display:
Default:
Min/Max:
Display:
499
0/999
1
Read Only
0/65535
1
Table 2.V Testpoint Codes and Functions
4
5
2
3
0
1
Code Selected in
[Testpoint x Sel]
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
See
Test Points
2-161
2-162
Torque Performance Modes
Torque Performance
Modes
[Torque Perf Mode]
V/Hz Control
V/Hz
Current
Resolver
Voltage
Control
Inverter
+
+
Current
Limit
Motor
Flux
Vector
Control
Voltage Feedback
Slip
Estimator
V/Hz
When torque performance is set to Custom V/Hz the following parameters are used to define the relationship between frequency and voltage. The following examples are for a 480v class drive.
Maximum Voltage
Base Voltage
(Nameplate) Voltage
Break Voltage
Start/Accel Boost
Run Boost
Break
Frequency
Base Frequency
(Nameplate)
Maximum
Frequency
The performance of the V/Hz modes and SVC mode are outlined below.
These specifications do not apply to Economize mode due to weakened field conditions. Slip compensation incorporates the effects of field weakening so as to minimize the speed regulation error due to either economize mode or operation above base frequency. The specifications below are applicable over the constant torque speed range.
Specification
Speed Regulation/accuracy (w/ slip compensation)
Operating Speed Range (w/slip compensation)
Dynamic Speed Accuracy
(speed response to a 95% step load change)
Velocity Bandwidth (w/slip compensation and no encoder)
Minimum settability of velocity bandwidth/slip compensation
Normal Duty
Fan/Pump and
Custom V/Hz
0.5% (40:1 speed range)
40:1
0.5% base speed
10 rad/s
0.1 rad/s
SVC
0.1% (60:1 speed range)
120:1
0.1% base speed
Heavy Duty
Fan/Pump and
Custom V/Hz
0.5% (40:1 speed range)
40:1
20 rad/s (50 rad/s desired)
0.1 rad/s
10 rad/s
0.1 rad/s
SVC
0.1% (60:1 speed range)
120:1
0.5% base speed 0.1% base speed
20 rad/s (50 rad/s desired)
01 rad/s
Torque Performance Modes
2-163
This curve is intended for applications such as fans and pumps where the load increases as the speed increases. This mode is intended to have a V/Hz profile that more closely matches the developed torque to the load torque.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
Base Frequency
(Nameplate)
Maximum
Frequency
Allowable Output Frequency Range -
Bus Regulation or Current Limit
Allowable Output Frequency Range - Normal Operation
1
Allowable Speed Reference Range
Maximum
Voltage
Motor NP
Voltage
Frequency Trim due to Speed
Control Mode
Overspeed
Limit
Break
Voltage
Start
Boost
Run
Boost
0 Minimum
Speed
Break
Frequency
Motor NP Hz Maximum
Speed
Output
Frequency
Limit
Maximum
Frequency
Frequency
Note 1: The lower limit on this range can be 0 depending on the value of Speed Adder
Sensorless Vector
In sensorless vector control the drive maintains a consistent magnetizing current up to base speed, the output voltage increases as a function of load.
Maximum Voltage
Base Voltage
(Nameplate) ve
Apppro ximate Full Load Cur
Apppro ximate No Load Cur ve
Ir Voltage
Base Frequency
(Nameplate)
Maximum
Frequency
2-164
Torque Performance Modes
Autotune
[Autotune]
The purpose of Autotune is to identify the motor flux current and stator resistance for use in Sensorless Vector Control and Economizer modes. The result of the flux current test procedure is stored in the parameter [Flux
Current]. The product of [Flux Current] and the result of the stator resistance test procedure will be stored in the parameter [IR Voltage Drop].
There are two options for autotuning:
•
Static - the motor shaft will not rotate during this test.
•
Dynamic - the motor shaft will rotate during this test.
The static test determines only stator resistance, while the dynamic
Autotune procedure determines both the stator resistance and motor flux current.
[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.
If it is not possible or desirable to run the Autotune tests, there are two other methods for the drive to determine the [IR Voltage Drop] and [Flux Current] parameters. One method retrieves the default parameters stored in the power
EEprom, and the other method calculates them from the user-entered motor nameplate data parameters.
If the stator resistance and flux current of the motor are known, the user can calculate the voltage drop across the stator resistance and directly enter these values into the [Flux Current] and [IR Voltage Drop] parameters.
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]
In addition to the motor nameplate parameters, the user must also enter a value in the [Autotune] parameter to determine which Autotune tests to perform.
The following options for the [Autotune] parameter are as follows:
0 = Ready
1 = Static Tune
2 = Rotate Tune
3 = Calculate
The procedure to identify the motor flux current, stator resistance, and IR voltage drop is started with the [Autotune] parameter. The tests are initiated
Torque Performance Modes
2-165
after a value is entered (1 for static or 2 for dynamic) into this parameter and the start button is pressed. When the tests are finished, the [Autotune] parameter is set to 0 (ready), the drive is stopped, and the Autotune procedure is complete.
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
When the drive is initially powered up, the [Autotune] parameter is defaulted to a value of 3(calculate). With this setting, any changes made by the user to motor nameplate HP, Voltage, Frequency, or Power activates a new calculation, which will update the [IR Voltage Drop] and [Flux
Current] parameters. This calculation is based on a typical motor with those nameplate values. The Autotune parameter will not be reset to zero after this calculation is performed; calculations will continue to be performed every time motor nameplate values are changed.
Flux Current
This parameter displays only the flux producing component of output current. It displays the amount of current that is out of phase with the output voltage. This current is reactive current and is used to produce flux in the motor.
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.
2-166
Torque Performance Modes
Figure 2.18 Accel Profile during Normal Start - No Flux Up
Frequency
Reference
Rated Flux
Stator
Rotor
0
Oscillation due to flux being established
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.
Figure 2.19 Flux Up Current versus Flux Up Time
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 2.20 Rated Flux Reached
Flux Up
Voltage
Motor Flux
Flux Up
Ir Voltage - SVC
Greater of IR Voltage or
Voltage Boost - V/Hz
Normal
Operation
Stator Voltage
Rotor Speed
Motor Flux
Stator Freq
Time
Torque Performance Modes
2-167
Torque Current
This parameter displays only the torque producing component of output current. It displays the amount of current that is in phase with the output voltage. This current is real current and is used to produce torque in the motor.
IR Drop Volts
[IR Voltage Drop]
The test to identify the IR drop of the drive and motor does not require the load to be uncoupled from the motor and should be run even if the flux current identification procedure is skipped.
Flux Current
[Flux Current Ref]
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 and the no load current is know then the value can be entered into the flux current parameter and this step in the drive commissioning can be skipped. If it is not possible to uncouple the load and the no load current is not known, then a value of zero is entered into flux and this step in the drive commissioning can be skipped.
2-168
Troubleshooting
Troubleshooting
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).
Unbalanced or Ungrounded Distribution Systems
2-169
Unbalanced or
Ungrounded
Distribution Systems
Unbalanced Distribution Systems
This drive is designed to operate on three-phase supply systems whose line voltages are symmetrical. Surge suppression devices are included to protect the drive from lightning induced overvoltages between line and ground.
Where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal), or where the supply ground is tied to another system or equipment that could cause the ground potential to vary with operation, suitable isolation is required for the drive. Where this potential exists, an isolation transformer is strongly recommended.
Ungrounded Distribution Systems
All drives are equipped with an MOV (Metal Oxide Varistor) that provides voltage surge protection and phase-to-phase plus phase-to-ground protection which is designed to meet IEEE 587. The MOV circuit is designed for surge suppression only (transient line protection), not continuous operation.
With ungrounded distribution systems, the phase-to-ground MOV connection could become a continuous current path to ground. Energy ratings are listed below. Exceeding the published phase-to-phase or phase-to-ground energy ratings may cause physical damage to the MOV.
Three-Phase
AC Input
R
S
T
Ground
Joules (J)
Joules (J)
Joules (J)
Joules (J)
1 2 3 4
Phase-to-Phase MOV Rating
Includes 2 Phase-Phase MOVs
Phase-to-Ground MOV Rating
Includes Phase-Phase & Phase-Ground MOVs
Device Rating (V AC)
Phase-Phase Total
Phase-Ground Total
240 480/600
160J 320J
220J 380J
240/480 600
280J 320J
360J 410J
240/480 600
280J 300J
360J 370J
2-170
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.
There are two operations to manage the operation of 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.
Figure 2.21 User Sets
Reset Defaults
PowerBoard
EEprom
Factory
Default Data
Drive Rating & Motor
Parameters
1
Reset
Active EE
Non Drive Rating & Motor
Parameters
Flash Memory
SaveUserSet
400V
Default Data
2
1 User Set 1
Save
User set
480V
Default Data
3
Active EE 2 User Set 2
Restore
User set
3 User Set 3
RestoreUserSet
Load
Application
Set
Flash Memory
Application Set
Voltage class
Voltage class
2-171
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
2-172
Watts Loss
Watts Loss
The following table lists watts loss data for PowerFlex drives running at full load, full speed and a factory default PWM Frequency of 4 kHz. Data for other load/speed/PWM combinations can be determined using the calculator on the PowerFlex e-Library.
PowerFlex 70
For PowerFlex 70 drives, Internal Watts are those dissipated by the control structure of the drive and will be dissipated into the cabinet regardless of mounting style. External Watts are those dissipated directly through the heatsink and will be outside the cabinet for flange mount and inside the cabinet for panel mount.
Table 2.W 480V Watts Loss at Full Load/Speed, 4kHz
(1)
3
5
7.5
10
1
2
Normal Duty HP Internal
0.5
17.9
19.5
21.6
15
20
24.0
28.2
27.8
32.0
34.2
42.9
External
11.5
27.8
43.6
64.6
99.5
140.0
193.3
305.4
432.9
Total
29.4
47.3
65.2
88.6
127.7
167.8
225.3
339.6
475.8
Table 2.X 240V Watts Loss at Full Load/Speed, 4kHz
3
5
7.5
10
1
2
Normal Duty HP Internal
0.5
19.2
20.5
22.6
25.4
33.2
34.2
48.1
External
12.2
30.7
44.6
67.3
141.3
205.7
270.4
Total
31.4
51.2
67.2
92.7
174.5
239.9
318.5
PowerFlex 700
For PowerFlex 700 drives, a flange mount version is not offered - only total watts are shown (see
(1) Includes HIM.
Table 2.Y 480V Watts Loss at Full Load/Speed, 4kHz
(1)
15
20
25
30
40
3
5
7.5
10
1
2
Normal Duty HP Total
0.5
43.9
54.2
66.4
84.8
157.2
187.6
213.1
326.3
397.9
445.8
464.3
619.7
Watts Loss
2-173
(1) Includes HIM and Standard I/O Board.
2-174
Watts Loss
Appendix
A
Dynamic Brake Selection Guide
The Dynamic Braking Selection Guide provided on the following pages contains detailed information on selecting and using dynamic brakes.
Dynamic Braking
www.abpowerflex.com
Selection Guide
A-2
Dynamic Brake Selection Guide
Important User Information
Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls” (Publication SGI-1.1 available from your local Allen-Bradley Sales Office or online at
http://www.ab.com/manuals/gi
) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.
In no event will the Allen-Bradley Company 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, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
!
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 the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful application and understanding of the product.
Shock Hazard labels may be located on or inside the drive to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the drive to alert people that surfaces may be at dangerous temperatures.
Table of Contents
What This Guide Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dynamic Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How to Determine Dynamic Brake Requirements . . . . . . . . . . . 2-1
Determine Values of Equation Variables . . . . . . . . . . . . . . . . . . 2-4
Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Evaluating the Capability of the Internal Dynamic Brake Resistor . .
How to Select an External Dynamic Brake Resistor . . . . . . . . . 4-1
ii
Notes:
Table of Contents
Section
1
What This Guide Contains
This Selection Guide contains the information necessary to determine whether or not dynamic braking is required for your drive application and select the correct resistor rating.
•
Section 1 provides an overview of dynamic braking principles.
•
Section 2 steps you through the calculations used to determine if dynamic braking is required for your drive application.
•
Section 3 steps you through the calculations used to determine if the internal dynamic brake option is adequate for your drive application.
•
Section 4 steps you through the calculations needed to select an externally mounted dynamic brake resistor for your drive application.
How Dynamic Braking Works
When an induction motor’s rotor is turning slower than the synchronous speed set by the drive’s output power, the motor is transforming electrical energy obtained from the drive into mechanical energy available at the drive shaft of the motor. This process is referred to as
motoring. When the rotor is turning faster than the synchronous speed set by the drive’s output power, the motor is transforming mechanical energy available at the drive shaft of the motor into electrical energy that can be transferred back to the drive. This process is referred to as
regeneration.
Most AC PWM drives convert AC power from the fixed frequency utility grid into DC power by means of a diode rectifier bridge or controlled
SCR bridge before it is inverted into variable frequency AC power.
Diode and SCR bridges are cost effective, but can only handle power in the motoring direction. Therefore, if the motor is regenerating, the bridge cannot conduct the necessary negative DC current, the DC bus voltage will increase and cause an overvoltage fault at the drive. More complex bridge configurations use SCRs or transistors that can transform DC regenerative electrical power into fixed frequency utility electrical energy. This process is known as line regeneration.
A more cost effective solution can be provided by allowing the drive to feed the regenerated electrical power to a resistor which transforms it into thermal energy. This process is referred to as dynamic braking.
1-2
Dynamic Brake Components
A Dynamic Brake consists of a Chopper (the chopper transistor and related control components are built into PowerFlex drives) and a
Dynamic Brake Resistor.
shows a simplified Dynamic Braking schematic.
Figure 1.1 Simplified Dynamic Brake Schematic
+ DC Bus
Dynamic
Brake
Resistor
FWD
Voltage
Divider
To
Voltage
Control
Signal
Common
To
Voltage Dividers
Chopper
Transistor
Chopper Transistor
Voltage Control
FWD
Voltage
Divider
To
Voltage
Control
– DC Bus
Chopper
The
Chopper
is the Dynamic Braking circuitry that senses rising DC bus voltage and shunts the excess energy to the Dynamic Brake Resistor. A
Chopper contains three significant power components:
The
Chopper Transistor
is an Isolated Gate Bipolar Transistor (IGBT).
The Chopper Transistor is either ON or OFF, connecting the Dynamic
Brake Resistor to the DC bus and dissipating power, or isolating the resistor from the DC bus. The most important rating is the collector current rating of the Chopper Transistor that helps to determine the minimum resistance value used for the Dynamic Brake Resistor.
1-3
Chopper Transistor Voltage Control
regulates the voltage of the DC bus during regeneration. The average values of DC bus voltages are:
•
375V DC (for 240V AC input)
•
750V DC (for 480V AC input)
Voltage dividers reduce the DC bus voltage to a value that is usable in signal circuit isolation and control. The DC bus feedback voltage from the voltage dividers is compared to a reference voltage to actuate the
Chopper Transistor.
The
Freewheel Diode
(FWD), in parallel with the Dynamic Brake
Resistor, allows any magnetic energy stored in the parasitic inductance of that circuit to be safely dissipated during turn off of the Chopper
Transistor.
Resistor
The
Resistor
dissipates the regenerated energy in the form of heat. The
PowerFlex Family of Drives can use either the internal dynamic brake resistor option or an externally mounted dynamic brake resistor wired to the drive.
The internal resistor kit for the drive may be used for the application if the required energy, deceleration time, and duty, all are small enough to be within the capabilities of the resistor.
The internal resistor is protected by drive software so that its duty cycle capability is not exceeded. The duty cycle is attenuated by the magnitude of the ‘DB Suppress’ signal coming from the Thermal Model algorithm.
The Thermal Model algorithm uses resistor thermal property constants to compute DB resistor temperature from applied resistor power that is computed from knowing the DB transistor duty cycle (DutyDB ). When the Thermal Model computes that the DB resistor temperature is nearing the maximum rise allowed, the ‘DB Suppress’ signal begins to rise reaching full value when maximum temperature rise is reached..
When the internal resistor cannot provide the required braking capability an external resistor may be supplied by the user that has more capability
A DB Resistance Auto-Detect algorithm is used. This algorithm is executed as part of the ‘power-up’ diagnostics and is only re-enabled until the drive is fully powered down again. This algorithm checks that the resistance measured across the DB terminals of the power board is within limits that are stored in the power board EEPROM.
1-4
The algorithm runs as follows:
•
Opens the precharge relay if not already open.
•
Pulses the DB transistor on in a series of increasing width pulses.
•
Measures the resulting capacitor bank voltage drop during each pulse.
•
Verifies the drop is within allowed limits (stored in the power board
EEPROM).
If the resistance measured is out of limits and the DB regulator is enabled then the ‘DB Resistance Out of Range’ fault is set. If the DB
Regulator is not enabled with this out of limits condition, no fault is set.
But, if some time after power-up the [Bus Reg Mode] parameter is set to enable the DB Regulator, the fault is set at that time.
Section
2
How to Determine Dynamic Brake Requirements
When a drive is consistently operating in the regenerative mode of operation, serious consideration should be given to equipment that will transform the electrical energy back to the fixed frequency utility grid.
As a general rule, Dynamic Braking can be used when the need to dissipate regenerative energy is on an occasional or periodic basis. In general, the motor power rating, speed, torque, and details regarding the regenerative mode of operation will be needed in order to estimate what
Dynamic Brake Resistor value is needed.
The Peak Regenerative Power of the drive must be calculated in order to determine the maximum resistance value of the Dynamic Brake
Resistor. Once the maximum resistance value of the Dynamic Brake
Resistor current rating is known, the required rating and number of
Dynamic Brake Resistors can be determined. If a Dynamic Brake
Resistance value greater than the minimum imposed by the choice of the peak regenerative power is made and applied, the drive can trip off due to transient DC bus overvoltage problems. Once the approximate resistance value of the Dynamic Brake Resistor is determined, the necessary power rating of the Dynamic Brake Resistor can be calculated.
The power rating of the Dynamic Brake Resistor is estimated by applying what is known about the drive’s motoring and regenerating modes of operation. The Average Power Dissipation must be estimated and the power rating of the Dynamic Brake Resistor chosen to be greater than that average. If the Dynamic Brake Resistor has a large thermodynamic heat capacity, then the resistor element will be able to absorb a large amount of energy without the temperature of the resistor element exceeding the operational temperature rating. Thermal time constants in the order of 50 seconds and higher satisfy the criteria of large heat capacities for these applications. If a resistor has a small heat capacity (defined as thermal time constants less than 5 seconds) the temperature of the resistor element could exceed its maximum.
Peak Regenerative Power can be calculated as:
•
Horsepower (English units)
•
Watts (The International System of Units, SI)
•
Per Unit System (pu) which is relative to a value
The final number must be in watts of power to estimate the resistance value of the Dynamic Brake Resistor. The following calculations are demonstrated in SI units.
2-2
Gather the Following Information
•
Power rating from motor nameplate in watts, kilowatts, or horsepower
•
Speed rating from motor nameplate in rpm or rps (radians per second)
•
Motor inertia and load inertia in kg-m
2
or lb.-ft.
2
•
Gear ratio
(GR)
if a gear is present between the motor and load
•
Motor shaft speed, torque, and power profile of the drive application
shows the speed, torque, and power profiles of the drive as a function of time for a particular cyclic application that is periodic over t
4 seconds. The desired time to decelerate is known or calculable and is within the drive performance limits. In
variables are defined:
ω
(t)
= Motor shaft speed in radians per second (rps)
ω
=
2
π
N
----------
60
N(t)
= Motor shaft speed in Revolutions Per Minute
(RPM)
T(t)
= Motor shaft torque in Newton-meters
1.0 lb.-ft. = 1.355818 N-m
P(t) = Motor shaft power in watts
1.0 HP = 746 watts
ω
ω
-P b o b
= Rated angular rotational speed
Rad
--------s
= Angular rotational speed less than
ω b
(can equal 0)
Rad
--------s
= Motor shaft peak regenerative power in watts
2-3
Figure 2.1 Application Speed, Torque and Power Profiles
ω
ω
(t) b
ω o
0 t1 t2 t3 t4 t1 + t4
T(t)
0
P(t) t1 t2 t3 t4 t1 + t4
-Pb
0 t1 t2 t3 t4 t1 + t4 t t t
2-4
Determine Values of Equation Variables
Step 2 Total Inertia
J
T
=
J m
+
(
GR
2
×
J
L
)
J
T
J m
= Total inertia reflected to the motor shaft (kg-m
= Motor inertia (kg-m
2
or lb.-ft.
2
)
2
GR = Gear ratio for any gear between motor and load
(dimensionless)
J
L
= Load inertia (kg-m
2
or lb.-ft.
2
)
1.0 lb.-ft.
2
= 0.04214011 kg-m
2
or lb.-ft.
2
)
Calculate Total Inertia:
J
T
=
[ oooooooooo
]
+
( oooooooooo
× oooooooooo
)
Record Total Inertia:
J
T
=
2-5
Step 3 Peak Braking Power
P b
=
J
T
[ ω
( b
( t
3
ω
– t
–
2
)
ω ) ]
----------------------------------------
P b
= Peak braking power (watts)
1.0 HP = 746 watts
J
ω
ω
T b o
= Total inertia reflected to the motor shaft (kg-m
2
)
= Rated angular rotational speed
Rad
--------s
=
2
π
N
------------
60 b
= Angular rotational speed, less than rated speed down to zero
Rad
--------s
= Rated motor speed (RPM) N b t
3
– t
2
= Deceleration time from
ω b
to
ω o
(seconds)
Calculate Peak Braking Power:
P b
=
[ ooooooooo
] × [
( ooooooooo ooooooooo
]
–
× ( ooooooooo ooooooooo
)
– ooooooooo
)
Record Peak Braking Power:
P b
=
Compare the peak braking power to that of the rated motor power. If the peak braking power is greater that 1.5 times that of the motor, then the deceleration time
(t
3 go into current limit.
– t
2
) needs to be increased so that the drive does not
2-6
Step 4 Minimum Power Requirements for the Dynamic Brake
Resistors
It is assumed that the application exhibits a periodic function of acceleration and deceleration. If
(t
3
– t
2
)
equals the time in seconds necessary for deceleration from rated speed to
ω o
speed, and t
4
is the time in seconds before the process repeats itself, then the average duty cycle is (t
3
– t
2
)/t
4
. The power as a function of time is a linearly decreasing function from a value equal to the peak regenerative power to some lesser value after (t
3
– t
2
) seconds have elapsed. The average power regenerated over the interval of
(t
3
– t
2
)
seconds is: P
-----
2
×
( ω b
+
ω b
ω
------------------------
)
P b
ω b
ω o
P av
= Average dynamic brake resister dissipation (watts) t
3
– t
2
= Deceleration time from
ω b
to
ω o
(seconds) t
4
= Total cycle time or period of process (seconds)
= Peak braking power (watts)
= Rated angular rotational speed
= Angular rotational speed,
Rad
--------s less than rated speed down to zero
Rad
--------s
The Average Power in watts regenerated over the period t
4
is:
P av
=
( t
2
)
-----------------t
–
4 t P
-----
2
( ω b
+
ω b
ω
------------------------
)
Calculate Average Power in watts regenerated over the period t
4
:
P av
=
( oooooo
– oooooo
[ oooooo
]
)
×
[ oooooo
]
2
×
( oooooo
[
+ oooooo oooooo
]
)
Record Average Power in watts regenerated over the period t
4
:
P av
=
2-7
Step 5 Percent Average Load of the Internal Dynamic Brake
Resistor
Skip this calculation if an external dynamic brake resistor will be used.
AL
=
P
-------100
P db
×
AL = Average load in percent of dynamic brake resistor
P av
= Average dynamic brake resistor dissipation calculated in
P db
= Steady state power dissipation capacity of dynamic brake resistors obtained from
(watts)
Calculate Percent Average Load of the dynamic brake resistor:
AL
=
[
[ oooooooooo
----------------------------------oooooooooo
]
]
×
100
Record Percent Average Load of the dynamic brake resistor:
AL =
The calculation of AL is the Dynamic Brake Resistor load expressed as a percent.
P db is the sum of the Dynamic Brake dissipation capacity and is obtained from
. This will give a data point for a line to be
drawn on one the curves provided in
Table 2.A Rated Continuous Power for Internal DB Kits
Drive Voltage Frame
P db
Internal Resistor Continuous Power (watts)
230
230
230
230
A
B
C
D
48
28
40
36
460
460
460
460 (15HP)
460 (20HP)
C
D
A
B
D
48
28
40
36
36
2-8
Step 6 Percent Peak Load of the Internal Dynamic Brake Resistor
Skip this calculation if an external dynamic brake resistor will be used.
PL
=
P
-------100
P db
×
PL = Peak load in percent of dynamic brake resistor
P av
P db
= Peak braking power calculated in Step 2 (watts)
= Steady state power dissipation capacity of dynamic brake resistors obtained from
(watts)
Calculate Percent Peak Load of the dynamic brake resistor:
PL =
[
[ oooooooooo
----------------------------------oooooooooo
]
]
×
100
Record Percent Average Load of the dynamic brake resistor:
PL
=
The calculation of
PL
in percent gives the percentage of the instantaneous power dissipated by the Dynamic Brake Resistors relative to the steady state power dissipation capacity of the resistors. This will give a data point to be drawn on one of the curves provided in
2-9
Example Calculation
A 10 HP, 4 Pole, 480 Volt motor and drive is accelerating and decelerating as depicted in
.
•
Cycle period t
4
is 40 seconds
•
Rated speed is 1785 RPM and is to be decelerated to 0 speed in 15.0
seconds
•
Motor load can be considered purely as inertia, and all power expended or absorbed by the motor is absorbed by the motor and load inertia
•
Load inertia is 4.0 lb.-ft.
2
and is directly coupled to the motor
•
Motor rotor inertia is 2.2 lb.-ft.
2
Calculate the necessary values to choose an acceptable Dynamic Brake.
Rated Power
=
10 HP
×
746 watts
=
7.46 kW
This information was given and must be known before the calculation process begins. This can be given in HP, but must be converted to watts before it can be used in the equations.
Rated Speed
=
ω b
=
1785 RPM
=
2
π ×
1785
----------
60
=
186.98 Rad
------------------------s
Lower Speed =
ω o
= 0 RPM = 2
π ×
0
-----
60
=
0 Rad
------------s
This information was given and must be known before the calculation process begins. This can be given in RPM, but must be converted to radians per second before it can be used in the equations.
Total Inertia = J
T
= 6.2
lb.-ft.
2
= 0.261 kg-m
2
This value can be in lb.-ft.
2
or Wk
2
, but must be converted into kg-m
2 before it can be used in the equations.
Deceleration Time
=
( t
3
– t
2
)
=
15 seconds
Period of Cycle = t
4
= 40 seconds
2-10
V d
= 750 Volts
This was known because the drive is rated at 480 Volts rms. If the drive were rated 230 Volts rms, then V d
= 375 Volts .
All of the preceding data and calculations were made from knowledge of the application under consideration. The total inertia was given and did not need further calculations as outlined in
Peak Braking Power
=
P b
=
J
T
[ ω
( b
( t
3
ω
2
) o
)
----------------------------------------
– t
–
ω ]
P b
=
[ (
15
– 0
) ]
=
608.6 watts
Note that this is 8.1% of rated power and is less than the maximum drive limit of 150% current limit. This calculation is the result of
and determines the peak power that must be dissipated by the Dynamic
Brake Resistor.
Average Braking Power = P av
=
( t
3
– t
2
) t
4
P
-----
2
( ω b
+
ω b
ω )
P av
=
15
-----
40
608.6
------------
2
186.92
+ 0
------------------------
186.92
= 114.1 watts
This is the result of calculating the average power dissipation as outlined in
. Verify that the sum of the power ratings of the Dynamic Brake
Resistors chosen in
Step 4 is greater than the value calculated in
Refer to
to determine the continuous power rating of the
resistor in the given drive frame you are using. You will need this number to determine the Percent Average Load and the Percent Peak
Load.
Percent Average Load
=
AL
=
100
×
P
--------
P av db
AL
=
100
×
114.1
------------
285%
40
=
This is the result of the calculation outlined in
plotted at the decel time of the application moving up vertically to this percentage.
2-11
Percent Peak Load
=
PL
=
100
×
P
--------
P db
PL
=
100
×
608.6
------------
40
=
1521%
This is the result of the calculation outlined in
plotted at zero seconds moving up vertically to this percentage.
Figure 2.2 Resistor Power Curve
2000
1800
1600
1400
1200
1000
800
3000
2800
2600
2400
2200
PL (Peak Percent Load) = 1521%
600
AL (Average Percent Load) = 285%
400
200
0
Decel Time = 15.0 Seconds
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 29 30
Decel Time (Seconds)
AL and PL are plotted and connected with a dotted line. This is the Motor
Power Curve. If any portion of this curve lies to the right of the constant temperature power curve of the Dynamic Brake Resistor, the resistor element temperature will exceed the operating temperature limit. The drive will protect the resistor and shut down the Chopper transistor. The drive will then likely trip on an overvoltage fault.
2-12
Notes:
Section
3
Evaluating the Capability of the Internal Dynamic Brake Resistor
Record the values calculated in
AL =
PL
= t
3
– t
2
=
PowerFlex 70 Drives
Find the correct Figure for your PowerFlex 70 drive rating.
Drive Voltage
240
240
240
480
480
480
Frame(s)
A and B
C
D
A and B
C
D
Figure Number
1. Plot the point where the value of AL (Average Load), calculated in
Step 5 , and the desired deceleration time
(t
3
– t
2
)
intersect.
2. Plot the value of PL (Peak Load), calculated in
, on the vertical axis (0 seconds).
3. Connect PL at 0 seconds and AL at (t
3
– t
2
) with a straight line. This line is the power curve described by the motor as it decelerates to minimum speed.
If the power curve lies to the left of the constant temperature power curve of the Dynamic Brake Resistor, then there is no problem with the intended application. If any portion of the power curve lies to the right of the constant temperature power curve of the Dynamic Brake Resistor, then there is an application problem. The Internal Dynamic Brake
Resistor will exceed its rated temperature during the interval that the transient power curve is to the right of the resistor power curve capacity.
3-2
Figure 3.1 PowerFlex 70 – 240 Volt, A and B Frames
3000
2800
2600
2400
2200
2000
1800
1600
1400
240A/B
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
Figure 3.2 PowerFlex 70 – 240 Volt, C Frame
3000
2800
2600
2400
2200
2000
1800
1600
240C
1400
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
3-3
Figure 3.3 PowerFlex 70 – 240 Volt, D Frame
3000
2800
2600
2400
2200
2000
1800
1600
1400
240D
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
Figure 3.4 PowerFlex 70 – 480 Volt, A and B Frames
3000
2800
2600
2400
2200
2000
1800
1600
480A/B
1400
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
3-4
Figure 3.5 PowerFlex 70 – 480 Volt, C Frame
3000
2800
2600
2400
2200
2000
1800
1600
1400
480C
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
Figure 3.6 PowerFlex 70 – 480 Volt, D Frame
3000
2800
2600
2400
2200
2000
1800
1600
480D
1400
1200
1000
800
600
400
200
0
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 29 30
Decel Time (Seconds)
Section
4
How to Select an External Dynamic Brake Resistor
In order to select the appropriate External Dynamic Brake Resistor for your application, the following data must be calculated.
Peak Regenerative Power
(Expressed in watts of power.)
This value is used to determine the maximum resistance value of the
Dynamic Brake Resistor. If this value is greater than the maximum imposed by the peak regenerative power of the drive, the drive can trip off due to transient DC bus overvoltage problems.
Table 4.A Minimum Dynamic Brake Resistance for PowerFlex 70 Drives
Drive Voltage
230
Frame
A
Minimum External Resistance (Ohms 10%)
32.9
230
230
230
460
B
C
D
A
32.9
28.7
21.7
63.4
460
460
460 (15HP)
460 (20HP)
D
D
B
C
63.4
71.1
42.3
29.1
Power Rating of the Dynamic Brake Resistor
The average power dissipation of the regenerative mode must be estimated and the power rating of the Dynamic Brake Resistor chosen to be greater than the average regenerative power dissipation of the drive.
4-2
Record the Values Calculated in Section 2
P b
=
P av
=
Calculate Maximum Dynamic Brake Resistance Value
R db1
=
0.9
×
V
2
P b
R db1
= Maximum allowable value for the dynamic brake resistor
(ohms)
V d
P b
= DC bus voltage the chopper module regulates to
(375V DC or 750V DC)
= Peak breaking power calculated in Section 2:
(watts)
Calculate Maximum Dynamic Brake Resistance:
R db1
=
0.9
[
× ( ooooooooo ooooooooo
]
)
2
-----------------------------------------------
Record Maximum Dynamic Brake Resistance:
R db1
=
The choice of the Dynamic Brake resistance value should be less than the value calculated in this step. If the value is greater, the drive can trip on DC bus overvoltage. Do not reduce P b
by any ratio because of estimated losses in the motor and inverter. This has been accounted for by an offsetting increase in the manufacturing tolerance of the resistance value and the increase in resistance value due to the temperature coefficient of resistor element.
4-3
Select Resistor
Select a resistor bank from
or
or your resistor supplier that has:
• a resistance value that is less than the value calculated ( R db1 in ohms)
• a resistance value that is greater than the minimum resistance listed in
• a power value that is greater than the value calculated in
( P av
in watts)
!
ATTENTION: The internal dynamic brake IGBT will be damaged if the resistance value of the resistor bank is less than the minimum resistance value of the drive. Use
to verify that the resistance value of the selected resistor bank is greater than the minimum resistance of the drive.
4-4
110
110
85
85
110
110
110
110
Ohms
154
154
154
154
154
154
59
59
59
59
85
85
85
85
59
59
Watts
182
242
408
604
610
913
255
338
570
845
850
1278
326
438
730
1089
1094
1954
473
631
1056
1576
1577
2384
Table 4.B Resistor Selection for 240V AC Drives
Catalog
Number
222-1A
222-1
225-1A
225-1
220-1A
220-1
222-2A
222-2
225-2A
225-2
220-2A
220-2
222-3A
222-3
225-3A
220-3A
225-3
220-3
222-4A
222-4
225-4A
225-4
220-4A
220-4
32
32
20
20
32
32
32
32
Ohms
45
45
45
45
45
45
20
20
20
20
Watts
617
827
1378
2056
2066
3125
875
1162
1955
2906
2918
4395
1372
1860
3063
4572
4650
7031
Catalog
Number
222-5A
222-5
225-5A
220-5A
225-5
220-5
222-6A
222-6
225-6A
225-6
220-6A
220-6
222-7A
222-7
225-7A
220-7A
225-7
220-7
181
181
181
181
237
237
181
181
237
237
237
237
342
342
342
342
439
439
342
342
439
439
439
439
Ohms
615
615
615
615
615
615
1577
2373
2068
2055
620
822
3108
1385
1096
1088
435
734
473
628
1057
1570
Watts
242
404
602
605
915
180
254
339
568
847
848
1281
329
1645
Table 4.C Resistor Selection for 480V AC Drives
440-4A
440-4
440-5A
445-5
442-5A
442-5
440-5
445-5A
440-3A
445-3
442-3
445-3A
442-4A
442-4
445-4A
445-4
Catalog
Number
442-1
445-1A
440-1A
445-1
440-1
442-1A
442-2A
442-2
445-2A
445-2
440-2A
440-2
442-3A
440-3
29
29
29
29
44
44
29
29
44
44
44
44
56
56
56
56
81
81
56
56
81
81
81
81
Ohms
128
128
128
128
128
128
440-9
442-9A
442-10
445-10A
440-10A
445-10
440-10
442-10A
440-8
445-8
445-8A
442-8
442-9
445-9A
445-9
440-9A
Catalog
Number
442-6A
442-6
445-6A
445-6
440-6A
440-6
440-7A
440-7
445-7
442-7
442-7A
445-7A
440-8A
442-8A
12784
2561
5130
8487
12667
12826
19396
3800
10045
6642
4490
2657
3381
5720
8454
8537
Watts
874
1162
1951
2906
2912
4395
4629
6944
4592
1837
1389
3102
6702
2010
4-5
4-6
Notes:
To contact Drives Technical Support . . .
Tel: (1) 262 512-8176, Fax: (1) 262 512-2222
Email: [email protected]
Online: www.ab.com/support/abdrives
Reach us now at www.rockwellautomation.com
Wherever you need us, Rockwell Automation brings together leading brands in industrial automation including Allen-Bradley controls,
Reliance Electric power transmission products, Dodge mechanical power transmission components, and Rockwell Software. Rockwell Automation's unique, flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners, distributors and system integrators around the world.
Americas Headquarters, 1201 South Second Street, Milwaukee, WI 53201-2496, USA, Tel: (1) 414 382-2000, Fax: (1) 414 382-4444
European Headquarters SA/NV, Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific Headquarters, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication PFLEX-SG001A-EN-P – March 2001
Copyright 2001 Rockwell International Corporation. All rights reserved. Printed in USA.
A
AC Supply Source Considerations,
Accel Mask,
Accel Owner,
Accel Time,
Accel Time 1, 2,
Agency Certification,
Alarm x Code,
Alarms,
Alarms Group,
Altitude Derates,
Ambient Temperature Derates,
Analog In Config,
Analog In Hi,
Analog In Lo,
Analog In1 Value,
Analog In2 Value,
Analog Inputs,
Analog Out1 Sel,
Analog Outputs,
Analog Outputs Group,
Anlg In 1, 2 Loss,
Anlg In Config,
Anlg In Loss,
Anlg In Sqr Root,
Armored Cable,
Auto / Manual,
,
Auto Restart,
Auto Rstrt Delay,
Auto Rstrt Tries,
B
Bipolar Inputs,
Bus Reg Gain,
Bus Reg Mode A, B,
C
Cable
I/O, Analog,
I/O, Digital,
Power, Armored,
Power, Shielded,
Cable Entry Plate
SHLD Terminal,
Cable Termination,
Cable Trays,
Carrier (PWM) Frequency,
CE
Conformity,
Requirements,
Circuit Breakers,
Clear Fault Owner,
Coast,
Common Mode Interference,
Compensation,
Conduit,
Contactors
Input,
Control Wire,
Copy Cat,
Current Limit,
Current Lmt Gain,
Current Lmt Sel,
,
Current Lmt Val,
D
Datalinks,
DC Brake Level,
DC Brake Lvl Sel,
DC Brake Time,
DC Braking,
DC Bus Voltage,
Decel Mask,
Decel Owner,
Decel Time,
Derating Guidelines,
Diagnostics Group,
Dig Out1 Level,
Dig Out1 OffTime,
Dig Out1 OnTime,
Dig Out2 Level,
Dig Out2 OffTime,
Dig Out2 OnTime,
Digital In1 Sel,
Digital In2 Sel,
Digital In3 Sel,
Digital In4 Sel,
Digital In5 Sel,
Digital In6 Sel,
Digital Inputs,
Digital Inputs Group,
Digital Out1 Sel,
Index
Index-2
Digital Out2 Sel,
,
Digital Outputs,
Digital Outputs Group,
Dimensions
Flange Mount,
Mounting
PowerFlex 70,
PowerFlex 700,
Direction Control,
Direction Mask,
Direction Owner,
Distribution Systems
Unbalanced,
Ungrounded,
DPI,
Drive Output Disconnection,
Drive Overload,
Drive Ratings,
Dynamic Braking,
,
E
Economizer,
Efficiency Derates,
EMC
Directive,
EMC Instructions,
EMI/RFI Filter Grounding, RFI Filter,
exclusive ownership,
F
Fan Curve,
Fault 1-8 Time,
Fault Clr Mask,
Fault Config 1,
Fault Config x,
Faults,
Filter, RFI,
Flange Mount, PowerFlex 70,
Flux Current,
Flux Current Ref,
Flux Up,
Flux Up Mode,
Flying Start En,
Flying Start Gain,
Flying StartGain,
Fuses,
G
Grounding
Filter,
Safety, PE,
Shields,
Group
Alarms,
Analog Outputs,
Diagnostics,
Digital Inputs,
Digital Outputs,
Masks & Owners,
Power Loss,
Speed References,
H
HIM Memory,
HIM Operations,
Human Interface Module
Language,
Password,
User Display,
I
I/O Wiring
Analog,
Digital,
Input Contactor
Start/Stop,
Input Devices,
Contactors,
Input Modes,
Input Potentiometer,
Input Power Conditioning,
Input/Output Ratings,
IR Drop Volts,
IR Voltage Drop,
Isolation Transformer,
J
Jog Mask,
Jog Owner,
L
Language Select, HIM,
Local Mask,
Local Owner,
Logic Mask,
Low Voltage Directive,
M
Masks & Owners Group,
Max Speed,
Maximum frequency,
MOP Mask,
MOP Owner,
Motor Cable Lengths,
Motor Nameplate,
Motor NP FLA,
Motor NP Hz,
Motor NP Power,
Motor NP Pwr Units,
Motor NP RPM,
Motor NP Volts,
Motor OL Factor,
Motor OL Hz,
Motor Overload,
Motor Start/Stop,
Mounting Dimensions,
O
Output Current,
Output Devices
Output Reactor,
Output Frequency,
Output Reactor,
Output Voltage,
Overspeed,
Owners,
P
Parameter access level,
Parameters
Accel Mask,
Accel Owner,
Alarm x Code,
Analog In1 Value,
Analog In2 Value,
Analog Out1 Sel,
Anlg In Config,
Anlg In Loss,
Auto Rstrt Delay,
Auto Rstrt Tries,
Clear Fault Owner,
Current Lmt Sel,
Decel Mask,
Decel Owner,
Dig Out1 Level,
Dig Out1 OffTime,
Dig Out1 OnTime,
Dig Out2 Level,
Dig Out2 OffTime,
Dig Out2 OnTime,
Digital In1 Sel,
Digital In2 Sel,
Digital In3 Sel,
Digital In4 Sel,
Digital In5 Sel,
Digital In6 Sel,
Digital Out1 Sel,
Digital Out2 Sel,
Direction Mask,
Direction Owner,
Fault Clr Mask,
Fault Config x,
Flying Start En,
Flying Start Gain,
Flying StartGain,
Jog Mask,
Jog Owner,
Local Mask,
Local Owner,
Logic Mask,
MOP Mask,
MOP Owner,
Power Loss Mode,
Reference Mask,
Reference Owner,
Speed Mode,
Speed Ref A Sel,
Start Mask,
Start Owner,
Stop Owner,
Testpoint 1 Sel,
Testpoint x Data,
Password, HIM,
PE,
PE Ground,
PET Ref Wave,
PI Config,
PI Control,
PI Error Meter,
PI Feedback Meter,
PI Feedback Sel,
PI Integral Time,
PI Output Meter,
Index-3
Index-4
PI Preload,
PI Prop Gain,
PI Ref Meter,
PI Reference Sel,
PI Setpoint,
PI Status,
PI Upper/Lower Limit,
Potentiometer, Wiring,
Power Loss,
Power Loss Group,
Power Loss Mode,
Power Up Marker,
Power Wire,
Process PI Loop,
R
Reactors,
Reference Mask,
Reference Owner,
Reference, Speed,
Repeated Start/Stop,
Reset meters,
RFI Filter Grounding,
S
S Curve,
Safety Ground,
Sensorless Vector,
Shear Pin,
Shielded Cables
Power,
SHLD Terminal,
Signal Loss,
Signal Wire,
Skip Freq 1-3,
Sleep Mode,
Specifications
Agency Certification,
Control,
Derating Guidelines,
Electrical,
Environment,
Heat Dissipation,
Input/Output Ratings,
Protection,
Speed Control,
Speed Mode,
Speed Pot,
Speed Ref A Sel,
Speed Ref A, B Sel,
Speed Reference,
Speed References Group,
Start Inhibits,
Start Mask,
Start Owner,
Start/Stop, Repeated,
Start-Up,
Stop Mode A, B,
Stop Modes,
Stop Owner,
T
TB Man Ref Sel,
Test Points,
Testpoint 1 Sel,
Testpoint x Data,
Thermal Regulator,
THHN wire,
Torq Performance Modes,
Torque Current,
Torque Perf Mode,
U
Unbalanced Distribution Systems,
Ungrounded Distribution Systems,
User Display, HIM,
User Sets,
V
Voltage class,
W
Watts Loss,
Wire
Control,
Signal,
Wiring
Potentiometer,
www,
www.rockwellautomation.com
Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201
Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36-BP 3A/B, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
Europe: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 17741
Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733
U.S. Allen-Bradley Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
Publication PFLEX-RM001C-EN-E – December, 2001
Supersedes PFLEX-RM001B-EN-E dated May, 2001 Copyright © 2001 Rockwell Automation. All rights reserved. Printed in USA.
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Table of contents
- 5 Specifications & Dimensions
- 5 PowerFlex 70/700 Specifications
- 6 Input/Output Ratings
- 6 Heat Dissipation
- 7 Derating Guidelines
- 9 PowerFlex 70 Dimensions
- 12 PowerFlex 70 Flange Mount Dimensions
- 20 PowerFlex 700 Dimensions
- 23 Detailed Drive Operation
- 23 Accel Time
- 23 AC Supply Source Considerations
- 24 Alarms
- 28 Analog Inputs
- 40 Analog Outputs
- 44 Auto / Manual
- 46 Auto Restart (Reset/ Run)
- 48 Bus Regulation
- 52 Cable, Control
- 52 Cable Entry Plate Removal
- 53 Cable, Motor Lengths
- 55 Cable, Power
- 58 Cable, Standard I/O
- 58 CabIe Trays and Conduit
- 58 Carrier (PWM) Frequency
- 59 CE Conformity
- 61 Copy Cat
- 62 Current Limit
- 64 Datalinks
- 66 DC Bus Voltage / Memory
- 67 Decel Time
- 68 Digital Inputs
- 85 Digital Outputs
- 89 Direction Control
- 90 DPI
- 93 Drive Overload
- 97 Drive Ratings (kW, Amps, Volts)
- 98 Economizer
- 98 Efficiency
- 99 Fan Curve
- 99 Fan
- 100 Faults
- 103 Flying Start
- 105 Fuses and Circuit Breakers
- 108 Grounding, General
- 110 HIM Memory
- 110 HIM Operations
- 111 Input Devices
- 112 Input Modes
- 113 Input Power Conditioning
- 113 Jog
- 113 Language
- 114 Masks
- 116 MOP
- 118 Motor Nameplate
- 119 Motor Overload
- 122 Motor Start/Stop Precautions
- 122 Mounting
- 123 Output Current
- 123 Output Devices
- 124 Output Frequency
- 124 Output Power
- 124 Output Voltage
- 125 Overspeed Limit
- 126 Owners
- 128 Parameter Access Level
- 128 PET
- 129 Power Loss
- 137 Preset Frequency
- 138 Process PI Loop
- 149 Reflected Wave
- 151 Reset Meters
- 151 Reset Run
- 151 RFI Filter Grounding
- 152 S Curve
- 155 Scaling Blocks
- 156 Shear Pin Fault
- 157 Skip Bands
- 159 Sleep Mode
- 161 Speed Control Speed Mode Speed Regulation
- 166 Speed Reference
- 169 Start Inhibits
- 170 Start Permissives
- 171 Start-Up
- 180 Stop Modes
- 183 Test Points
- 183 Thermal Regulator
- 184 Torque Performance Modes
- 190 Troubleshooting
- 191 Unbalanced or Ungrounded Distribution Systems
- 192 User Sets
- 193 Voltage class
- 194 Watts Loss
- 197 Dynamic Brake Selection Guide
- 201 Table of Contents
- 203 Section 1
- 207 Section 2
- 219 Section 3
- 223 Section 4
- 230 PFLEX-SG001A Back Cover
- 231 A-D
- 232 E-L
- 233 M-P
- 234 R-W