Powerflex 750-Series Products With Totalforce Control: Reference Manual
Powerflex 750-Series Products With Totalforce Control: Reference Manual
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Preface
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Drive Configuration Configuring Accel/Decel Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Automatic Device Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Precharge Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sleep/Wake Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Start Permissive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Low Speed Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power Loss Ride-through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Auxiliary Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Motor Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Motor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Selecting Velocity Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 2
TotalFORCE Control Features Adaptive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CIP Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Secondary Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Energy Pause Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Predictive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Predictive Maintenance CIP Objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DeviceLogix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Emergency Override Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Reference Motion Planners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Chapter 3
Active Front End TotalFORCE AC Line Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Control Droop Control for Parallel Operation of Bus Supplies . . . . . . . . . . . . . . 138
AC Line Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Backup Generator Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Chapter 4
Diagnostics and High Speed Trending. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Input Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
This manual is intended for qualified personnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must
have an understanding of the parameter settings and functions.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Topic Page
The following topics have been added to this publication:
Motor Stop Modes 19
Start Permissive 29
Auxiliary Power Supply 41
Motor Control Modes 41
Motor Types 48
Selecting Velocity Feedback 56
Predictive Maintenance CIP Objects 91
Input Phase Loss Detection 168
Dynamic Braking 201
Carrier (PWM) Frequency 221
Analog Inputs 222
Analog Outputs 230
Digital Inputs 235
Digital Outputs 246
PTC Motor Thermistor Input 255
The following topics have been updated:
Adaptive Control 57
Energy Pause Function 71
AC Line Commissioning 135
AC Line Tuning 143
Anti-Sway Applications 191
Dynamic Bus Control 212
Drive Configuration
Topic Page
Configuring Accel/Decel Time 7
Automatic Device Configuration 9
Precharge Sequence 14
Sleep/Wake Mode 15
Motor Stop Modes 19
Start Permissive 29
Low Speed Operation 32
Power Loss Ride-through 36
Auxiliary Power Supply 41
Motor Control Modes 41
Motor Types 48
Selecting Velocity Feedback 56
Configuring Accel/Decel You can configure the drive’s acceleration time and deceleration time.
Time
Acceleration Time
Parameters 10/11:1915 [VRef Accel Time 1] and 10/11:1916 [VRef Accel Time 2] set
the acceleration ramp that is applied to velocity reference commands. Defined
as the time to accelerate from zero to Motor Rated Hz 10/11:402 [Motor NP
Hertz] or to Motor Rated RPM 10/11:403 [Motor NP RPM]. The setting of Hertz
or RPM is programmed in parameter 0:46 [Velocity Units].
A digital input function controls the selection between [VRef Accel Time 1] and
[VRef Accel Time 2]. Digital Input Functions are configured through the
Feedback & I/O file in Port 0. See the PowerFlex Drives with TotalFORCE®
Control Programming Manual, publication 750-PM101 for more information
on Digital Input functions. Or, a Logic Command that is sent over a
communication network or DeviceLogix™ software can also be used.
This value isn’t used when 10/11:933 [Ref Time Base] = 1 ‘Time’. Instead, 10/
11:934 [Ref Accel Time] and 10/11:935 [Ref Decel Time] are applied directly as
acceleration and deceleration times. Used only in FVC mode.
Deceleration Time
Parameter 10/11:1917 [VRef Decel Time 1] and 10/11:1918 [VRef Decel Time 2] set
the deceleration ramp time that is applied to velocity reference commands.
Defined as the time to decelerate from the Motor Rated Hz 10/11:402 [Motor
NP Hertz] or to Motor Rated RPM 10/11:403 [Motor NP RPM]. The setting of
Hertz or RPM is programmed in 0:46 [Velocity Units].
A digital input function controls the selection between [VRef Decel Time 1] and
[VRef Decel Time 2]. See Digin Functions in the PowerFlex Drives with
TotalFORCE Control Programming Manual, publication 750-PM101. Or, a
Logic Command that is sent over a communication network or DeviceLogix
software can also be used.
This value is used for these stop modes: Ramp, Ramp to Hold, and
DecelToHold.
This value isn’t used when 10/11:933 [Ref Time Base] = 1 ‘Time’. Instead, 10/
11:934 [Ref Accel Time] and 10/11:935 [Ref Decel Time] are applied directly as
acceleration and deceleration times. Used only in FVC mode.
Automatic Device Automatic Device Configuration (ADC) is a Studio 5000 Logix Designer®
Configuration application feature that supports the automatic download of drive
configuration data. When the RSLogix 5000® software controller establishes
an I/O connection with a drive and its associated peripherals, it checks a
configuration signature for each port. This check determines if an ADC
download is needed. The purpose is to reduce downtime during a field
replacement by automatically downloading the configuration rather than
manually with a separate tool.
Compatibility
The latest drive AOPs ship with each release of Studio 5000 Logix Designer and
are also available for free download at the Product Compatibility and
Download Center (PCDC), rok.auto/pcdc.
To identify the drive AOP version that you are using, open the AOP, click the
icon in the upper left corner of the window and select ‘About Module Profile’.
ADC works with all versions of the PowerFlex 755T drives when the Logix I/O
connection is made through the built-in Ethernet/IP™ port.
Firmware updates are available for download at the Product Compatibility and
Download Center (PCDC), rok.auto/pcdc.
If you do not have the minimum levels of software and hardware, the ADC
feature isn’t available (ADC icon is missing or appears dimmed). Drive
configuration settings are stored inside the ACD project file. With ADC
enabled, the Logix controller automatically downloads the configuration
settings for a particular drive port if it detects that there’s a configuration
signature mismatch with a port.
Activation
To activate the ADC feature, click Device Definition under the Overview tab of
the drive.
devices. The checkboxes appear unavailable when the global Enable Automatic
Device Configuration checkbox is cleared.
ADC can’t be configured for some ports/devices, such as a Safe Torque Off
option module (20-750-S3). The Safety Controller manages the configuration
of the 20-750-S3 Network STO option module.
The column on the right with Fail Drive Connection on Peripheral Error
indicates that the controller does not establish a network I/O connection with
the drive if an error occurs with this peripheral device.
When ADC is enabled, it’s visible in the Overview page of the drive:
When ADC is enabled, ADC is triggered anytime the Logix controller detects a
configuration signature mismatch when establishing an EtherNet/IP network
I/O connection.
ADC can execute the first time the Logix controller connects to the drive after
ADC has been enabled. The configuration signatures in the controller and
drive synchronize, and stops future ADC downloads from occurring unless a
configuration change is made or the drive / peripheral is replaced. If a port has
configuration parameters that require a reset to become active, ADC will reset
the drive after the respective port parameters are downloaded.
ADC can work in tandem with the Firmware Supervisor. If the Firmware
Supervisor is configured and enabled for a drive (‘Exact Match’ keying must be
used), the drive/ peripheral firmware is automatically updated (if necessary)
before any ADC operation for that port.
Precharge Sequence PowerFlex 755T products use a precharge sequence to control power-up. The
precharge sequence starts as soon as the drive detects incoming three-phase
power on the input terminals. The sequence ends when the main control board
is able to communicate with all necessary peripherals. The following frame-
specific sections guide you through the precharge sequence and define what
occurs at each step.
Frames 5 and 6
1. Three-phase power is applied.
2. Incoming three-phase power is stepped down and the main control
board is powered.
3. The main control board performs a check before it initiates the precharge
sequence.
4. A precharge resistor bank is connected between the AC line and the input
of the converter. This resistor bank limits the voltage that is available
while the DC bus and LCL filter capacitors begin charging.
5. When the DC bus is 85% of the nominal voltage rating, the AC precharge
circuit bypasses the precharge resistor bank. Full line voltage is applied to
the input of the converter to complete the precharge sequence.
6. Main control board checks for an ‘Ok’ status to verify that the precharge
sequence was completed successfully and that the drive is ready.
Frames 7…15
1. Three-phase power is applied.
2. The operator closes the main fuse disconnect (FD1).
3. A step-down transformer limits incoming three-phase power to 240V.
Power is applied to the AC precharge board and to the 24V DC network.
4. 24V DC is applied to the control pod and main control board. Fiber-optic
communication is established between the main control board and the
AC precharge board.
5. The main control board performs a check and sends an ‘Ok’ status to the
AC precharge board to proceed with the precharge sequence.
6. The AC precharge board closes the AC precharge contactor to connect the
precharge resistor bank to the DC bus and the LCL filter module.
7. When the DC bus is 85% of nominal voltage rating, the AC precharge
circuit closes the AC precharge circuit breaker (CB1). The AC precharge
contactor opens to disconnect the precharge resistor bank from the DC
bus.
8. The switched mode power supply (SMPS) of the converter and inverter
power modules is at 400V DC.
9. The power layer interface (PLI) board, current sense board (CSB), and
gate driver are powered by SMPS.
10. The main control board checks communications between AC precharge
board, PLI board, CSB board, and gate driver.
11. If the check comes back ‘Ok’, the precharge is complete and the drive is
ready.
Sleep/Wake Mode The purpose of the sleep/wake function is to start (wake) the drive when an
analog signal level is greater than or equal to the value in parameter 9:94 [Wake
Level]. One common application of this function is for efficient control of
pumps that use feedback from digital limit sensors to maintain a holding tank
between a ‘high’ and ‘low’ level. The drive stops (sleeps) when an analog signal
level is less than or equal to the value in parameter 9:92 [Sleep Level].
Parameter 9:91 [SleepWake RefSel] selects the source of the analog signal. Set
parameter 9:90 [Sleep Wake Mode] to 1 ‘Direct’ to enable the sleep/wake
function to work as described.
To function in Invert mode, set parameter 9:90 [Sleep Wake Mode] to 2 ‘Invert’.
The Invert setting changes the logic so that an analog signal level that is less
than or equal to parameter 9:94 [Wake Level], the drive starts. The drive stops
when an analog signal level is greater than or equal to parameter 9:92 [Sleep
Level].
To add Port 9, double-click the drive. Under the Overview tab, click Device
Definition:
Once you are in Device Definition, go to Dynamic Features and set the
Application Set to ProcPID Only to activate Port 9: PID.
If you would like to activate DLX, you can activate it under Emb Logic Select:
DeviceLogix.
Sleep/Wake Operation
Drive Run
Sleep/Wake Function
Start
Stop
Wake Level
Sleep Level
Example Conditions
Analog Signal Wake Time = 3 Seconds
Sleep Time = 3 Seconds
Conditions to Start/Restart
For the Invert function, refer to the [Anlg Inn LssActn] parameter.
Normal operation requires that parameter 9:94 [Wake Level] is set to greater
than parameter 9:92 [Sleep Level]. However, there are no limits that help
prevent the parameter settings from crossing, but you can’t start the drive
until those settings are corrected. These levels are programmable while the
drive is running. If parameter 9:92 [Sleep Level] is made greater than
parameter 9:94 [Wake Level] while the drive is running, the drive continues to
run. As long as the parameter 9:91 [SleepWake RefSel] signal remains at a level
that doesn’t trigger the sleep condition. Parameter 9:93 [Sleep Time] is also
factored in. Once the drive goes to sleep in this situation, it isn’t allowed to
restart until the level settings are corrected (increase parameter 9:94 [Wake
Level], or decrease parameter 9:92 [Sleep Level]). If however, the levels are
corrected before the drive goes to sleep, normal Sleep/Wake operation
continues.
Timers
Parameter 9:93 [Sleep Time]
Parameter 9:95 [Wake Time]
Timers determine the length of time required for Sleep/Wake levels to produce
true functions. These timers start counting when the Sleep/Wake levels are
met and count in the opposite direction whenever a respective level isn’t met.
If the timer counts to the user specified time, it creates an edge to toggle the
Sleep/Wake function to the respective condition (sleep or wake). On power-up,
timers are initialized to the state that does not permit a start condition. When
the analog signal satisfies the level requirement, the timers start counting.
Interactive Functions
Separate start commands are also honored (including a digital input start), but
only when the sleep timer isn’t satisfied. Once the sleep timer times out, the
sleep function acts as a continuous stop. There are two exceptions that ignore
the Sleep/Wake function.
1. When a device is commanding local control. For example a HIM in
Manual mode or a digital input that is programmed to parameter
0:132 [DI M Manual Ctrl].
2. When a jog command is being issued.
Sleep/Wake Sources
The parameter 9:91 [SleepWake RefSel] signal source for the sleep/wake
function can be any analog input, whether it’s being used for another function
or not, a DeviceLogix software source (parameter 9:1120 [DLX Real Out SP1]
through 9:1127 [DLX Real Out SP8]), or a valid numeric edit configuration.
Configure the sleep/wake source with parameter 9:91 [SleepWake RefSel].
Also, parameters [Anlg Inn Hi] and [Anlg Inn Lo] have no effect on the
function, however, the factory calibrated result, parameter [Anlg Inn Value] is
used. In addition, the absolute value of the calibrated result is used, which
makes the function useful for bipolar direction applications.
Parameter [Anlg Inn LssActn] configures the analog in loss function, which is
unaffected and therefore operational with the sleep/wake function, but not
tied to the sleep or wake levels and is triggered off the [Anlg Inn Raw Value]
parameter.
Motor Stop Modes Motor Stop Mode A/B can be configured as a method of stopping the drive
when a stop command is given. A normal stop command results when the run
input changes from true to false. However, when using Torque Prove,
parameter 9:50 [Trq Prove Cfg] with bit 0 enabled, parameter 10/11:110/111 [Mtr
Stop Mode A/B] must be set to 1 ‘Ramp’.
Parameter 10/11:145 [Stop Dwell Time] can also be used with a stop command.
This option can be used to set an adjustable time between detecting zero speed
and turning off the drive output.
Braking Methods
PowerFlex 755T products offer several methods for stopping a load. Set the
stop method or mode with parameters 10/11:110 [Mtr Stop Mode A] and 10/
11:111 [Mtr Stop Mode B]. These modes are listed in the following table.
A ‘Ramp’ selection always provides the fastest stopping time. PowerFlex 755TR
and PowerFlex 755TM Regenerative Bus Supplies provide regeneration to the
AC line. PowerFlex 755TL and PowerFlex 755TM Non-Regenerative Supply can
require a method of dissipating regenerative energy from the DC bus such as a
dynamic braking resistor or regenerative brake for example. The PowerFlex
Dynamic Brake Resistor Calculator application technique, publication
PFLEX-AT001, explains dynamic braking in detail.
Coast
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
Time
Stop Command Coast Time is load-dependent
Ramp
Bus Voltage
Output Voltage
Output Current
Motor Speed
Output Current
Command Speed
Output Voltage
DC
Hold
Level
Time
Stop Command Zero Command Speed DC Hold Time
Ramp mode can also include a timed DC hold brake. Once the drive has
reached zero output hertz on a Ramp to Stop and both parameter 10/11:153 [DC
Brake Time] and parameter 10/11:152 [DC Brake Level] aren’t zero, the drive
applies DC to the motor that is producing current at the DC Brake Level for the
DC Brake Time. Only available with induction motor control modes.
Bus Voltage
Output Voltage
Current Limit
Output Current
Motor Speed
Time
Stop Command Zero Speed
Current limit stop isn’t typically set up as the normal Stop mode. Usually the
normal stop is programmed at some ramp rate. For the current limit stop, a
digital input is used for the function. However, you certainly could set the
normal stop as current limit stop. Available with all motor control modes.
Current limit stop ramp rate is 0.1 second and isn’t programmable.
Example
Current Limit Stop
DC Bus Voltage Motor Current 10/11:2076 Motor Speed
DC Bus Voltage
In this example, the current limit was set high enough to allow the full rating of
the drive to be used in the stop sequence.
Example
Current Limit - Lowered Limit
DC Bus Voltage Motor Current 10/11:2076 Motor Speed
DC Bus Voltage
In this example, the current limit was set at some value such that when the
stop was issued the output current was clamped at that setting. The decel time
is extended.
Decel to Hold
Zero
Speed
Hold
Current
Time
Hold Zero
Stop Command Zero Command Speed Speed for Start Command
indeterminate
amount of time.
This method uses drive output reduction to ramp the motor to zero speed and
speed regulator output to hold the load at zero speed once it has stopped. This
option is intended for use with an encoder and safety module to verify that the
drive is holding zero speed. Available with all motor control modes.
• A Stop command initiates motor deceleration using the active Decel
Time, until it reaches the Zero Speed threshold.
• It holds by continuing to modulate with a zero speed (zero frequency)
output.
• The level of output current depends on the load.
• The hold persists until there’s a new start command, new run command,
or another kind of stop command.
Ramp to Hold
Time
DC Hold for
Stop Command Zero Command Speed indeterminate Start Command
amount of time.
This method combines two of the stop methods. It uses drive output reduction
to ramp the motor to zero speed and DC braking to hold the load at zero speed
once it has stopped. Only available with induction motor control modes.
• Stop command initiates 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.
• When the output reaches zero, the three-phase drive output goes to zero
(off) and the drive outputs a DC voltage on the last used phase to provide
the current level programmed in parameter 10/11:152 [DC Brake Level].
This voltage causes a holding brake torque.
• DC voltage to the motor continues until a Start command is reissued or
the drive is disabled.
• If a Start command is reissued, DC Braking ceases and the drive returns
to normal AC operation. If an Enable command is removed, the drive
enters a Not Ready state until the enable is restored.
DC Brake
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
DC
Hold
Level
Time
(B) (C) (A)
Stop Command
DC Hold Time
This method uses DC injection of the motor to Stop and/or hold the load. DC
Brake is selected by setting parameter 10/11:110/111 [Mtr Stop Mode A/B] to 5
‘DC Brake’. You can also choose the amount of time the braking is applied and
the magnitude of the current used for braking with parameter 10/11:153 [DC
Brake Time] and parameter 10/11:152 [DC Brake Level]. This mode of braking
generates up to 40% of rated motor torque for braking and is typically used for
low inertia loads with infrequent Stop cycles. Only available with induction
motor control modes.
• On Stop, three phase drive output goes to zero (off).
• Drive outputs the DC voltage on the last used phase to provide the
current level programmed in parameter 10/11:152 [DC Brake Level]. This
voltage causes a stopping brake torque. If the voltage is applied for a time
that is longer than the actual possible stopping time, the remaining time
is used to attempt to hold the motor at zero speed (decel profile ‘B’ on the
diagram).
• DC voltage to the motor continues for the amount of time that is
programmed in parameter 10/11:153 [DC BrakeTime]. Braking ceases
after this time expires.
• After the DC Braking ceases, no further power is supplied to the motor.
The motor/load might not be stopped. The drive has released control of
the motor/load (decel profile ‘A’ on the diagram).
• The motor, if rotating, coasts from its present speed for a time that is
dependent on the remaining kinetic energy and the mechanics of the
system (inertia, friction, and so forth).
• Excess motor current and/or applied duration, could cause motor
damage. Motor voltage can exist long after the Stop command is issued.
The right combination of Brake Level and Brake Time must be
determined to provide the safest, most efficient stop (decel profile ‘C’ on
the diagram).
Fast Brake
Bus Voltage
Output Voltage
Output Current
Motor Speed
Command Speed
Time
Stop Command
IMPORTANT For this feature to function properly the active [Bus Reg Mode
A/B] must be set to 1 ‘Adjust Freq’ and not be 0 ‘Disabled’.
Example
Block Diagram
Current Regulator
Brake
Level
Bus Voltage
Gain
Reference
Frequency
Bus Voltage
Flux Braking
Flux Braking works in all motor control modes. Flux braking only works with
induction motors and only during deceleration.
Traces
In the following plots, the Accel/Decel times are 0.5 s. Parameter 10/11:116/117
[Bus Reg Mode A/B] is set to option 1 ‘Adjust Freq’. There’s a fair amount of
inertia that is connected to the motor shaft. Parameter 10/11:110/111 [Mtr Stop
Mode A/B] is set to 1 ‘Ramp’ to stop.
In the plot below the Flux Braking feature is disabled. Note the decel time.
Here the bus regulator is controlling the stop time.
Flux Braking - Disabled
In the next plot, all conditions are the same except the Flux Braking feature is
enabled. Note that the flux to the motor is increased and the decel time is
shorter.
Finally the same test with the gains set to maximum levels. Slightly faster
decel. The use of the gains varies with the connected load.
Flux Braking - Full Gains
Start Permissive Certain status conditions must be met to permit the motor inverter to start in
any mode, such as run, jog, or autotune.
When all permissive conditions are met, the motor inverter and/or line side
active converter is considered ready to start. The ready condition is confirmed
through the ready status in motor inverter parameters 10/11:354 [Motor Side
Sts 1] and 10/11:355 [Motor Side Sts 2] and the line converter parameter 13:225
[Line Side Sts 1].
Permissive Conditions
• No faults can be active.
• No Type 2 alarms can be active.
• The DI Enable input, if configured, must be closed.
• The DC bus precharge logic must indicate it is a start permissive.
• All Stop inputs must be negated and any drive stop/inhibit functions
must not be issuing a stop command.
• No configuration changes (parameters being modified) can be in-
progress.
• The drive’s safety option module logic must be satisfied.
Parameter 10/11:351 - Motor Side Inverter Start Inhibits displays the conditions
that are currently inhibiting the motor side inverter from starting.
Parameter 10/11:352 - Last Motor Side Inverter Start Inhibits displays the
conditions that kept the motor side inverter from starting during the last
inhibit.
Bit 0 ‘Faulted’ – System is in a faulted state.
Bit 1 ‘Alarm’ – A Type 2 alarm exists.
Bit 2 ‘Enable’ – An Enable input is open.
Bit 3 ‘Precharge’ – System is in precharge.
Bit 4 ‘Stop’ – The motor side inverter is receiving a stop command.
Bit 5 ‘Database’ – Database is performing a download operation.
Bit 6 ‘Startup’ – The assisted Start routine in the HIM is active and
preventing a start.
Bit 7 ‘RotarySwitch’ – Rotary switches on the main control board are
set to a combination (888) that prevents start.
Bit 8 ‘Safety’ – A Functional Safety option module is preventing a start.
Bit 9 ‘Sleep’ – The Sleep function is issuing a stop.
Bit 10 ‘Profiler’ – Profiler function is issuing a stop.
Bit 11 ‘CommutNotCfg’ – The permanent magnet motor commutation
function hasn’t been configured for use.
Bit 12 ‘Ovrd Event’ – Inverter start is inhibited due to fault, but
converter can continue running.
Bit 13 ‘Standby’ – Indicates that the system is in a low energy (paused)
state.
When the drive receives a new start command, it copies the value from
parameter 10/11:351 [M Start Inhibits] into this parameter.
PowerFlex 755TL/TR drives and PowerFlex 755TM regenerative bus supply line
converter conditions that are inhibiting modulation start are shown in
parameter 13:235 [L Start Inhibits]. Conditions that prevented the last start
command are shown in parameter 13:236 [LLastStrtInhibit].
Parameter 13:235 - Line Side Converter Start Inhibits displays the conditions
that are inhibiting the line side converter from starting and modulating.
Bit 0 ‘Faulted’ – Indicates that a Fault is present. Faults provide
notification of events. They prevent the line side converter from
modulating.
Bit 1 ‘Alarm’ – Indicates a Type 2 alarm is present. Type 2 alarms
usually indicate a configuration error. They prevent the line side
converter from starting and modulating.
Bit 2 ‘Enable’ – Indicates that a digital input is configured for the line
side converter Enable function, and it isn’t energized (set).
Bit 3 ‘Precharge’ – Indicates that the line side converter is executing a
Precharge.
Bit 4 ‘Stop’ – Indicates that the line side converter is receiving a stop
command.
Bit 5 ‘Database’ – Indicates that the database is performing a download
operation.
Bit 6 ‘Startup’ – Indicates that the assisted Start routine in the HIM is
active and preventing a start.
Bit 7 ‘RotarySwitch’ – Indicates that the rotary switches on the main
control board are set to a combination that prevents start.
Bit 8 ‘Standby’ – Indicates that the system is in a low energy (paused)
state.
30 Rockwell Automation Publication 750-RM100C-EN-P - August 2022
Chapter 1 Drive Configuration
Bit 9 ‘PLL Not Lock’ – Indicates that the line side converter phase
locked loop isn’t synchronized with the AC line.
Bit 11 ‘DC Bus High’ – Indicates that a DC Bus Overvoltage fault has
occurred.
Bit 12 ‘Ovrd Event’ – Indicates that the line side converter start is
inhibited due to fault, but it can continue running.
Parameter 13:236 - Last Line Side Converter Start Inhibits displays the last
condition to inhibit the line side converter from starting and modulating.
Low Speed Operation High IGBT junction temperatures can restrict drive capabilities, particularly at
low operating frequencies. One strategy to reduce junction temperature is to
reduce switching frequency when operating at low commanded frequencies.
This feature is available in all motor control modes except in flux vector control
for Interior Permanent Magnet motors (IPM FV) in firmware revisions 6 and
later. It’s available for induction motors only.
Operation
For drives and common bus inverters that are configured for an induction
motor control mode, the firmware reduces the inverter carrier PWM
frequency to one third of the user-selected value to decrease current derating if
the following conditions apply.
• Inverter control parameter 10/11:420 [Mtr Ctrl Config] bit 10 ‘LoPWM
FreqEn’ is set.
• Inverter output frequency is less than the value of the inverter control
parameter PWM Trans Freq.
• Less than 20% of the user-entered motor nameplate frequency.
• Selected carrier PWM frequency is less than or equal to 4 kHz.
Configuration
To activate the feature, set parameter 10/11:420 [Mtr Ctrl Config] bit 10
‘LoPWM FreqEn’ to 1.
Use parameter 10/11:429 [PWM Trans Freq] to set the threshold where the
function activates.
Review the example where you set parameter 10/11:429 [PWM Trans Freq] to 5
Hz. When the output frequency is above 5 Hz, the function is inactive and the
PWM frequency is whatever you selected in parameter 10/11:425 [PWM
Frequency]. When the output frequency drops below 5 Hz, the function
activates and reduces the PWM frequency to one third of the value in
parameter 10/11:425 [PWM Frequency].
The following plot that shows the expected operation. The setup for this plot is
the drive is commanded to output 5 Hz and the PWM Trans Freq is set to 5 Hz
(this setup is only intended to illustrate the feature). So, when the output
frequency dithers around the PWM Trans Freq, the feature is activated and
deactivated. There’s no hysteresis that is involved, and it does not transition
based on a set number of PWM cycles. The transition is instant (you can do one
actual carrier followed by one emulated followed by one actual, and so forth).
Performance
Current Ripple
There’s greater current ripple when the carrier frequency is reduced. Consider
this thermally if the motor is to be run for long periods in this state.
Derating
See the PowerFlex Drives with TotalFORCE Control Technical Data for
derating curves across product ratings. The following derating curve is for low
speed operation. The gold trace is for 4 kHz operation. Let us say the drive is
programmed to reduce the carrier frequency if the speed of the motor drops
below 10 Hz. The derating at 10 Hz is stated as 87%.
480V AC Power Rating Low Speed/Load Derating for IP20, UL Type 1 and IP54, UL Type 12
Cat. LD ND HD Output Freq. PWM Frequency
Frame
No.
20G… 1.33 kHz 2 kHz 4 kHz
Cont. Cont. Cont.
Hp Amps Hp Amps Hp Amps Hz 1.33 kHz 2 kHz 4 kHz
0 79 72 55 120
2 100 93 73
100
4 100 100 81
6 100 100 84 80
4 kHz
8 100 100 86
Load (%)
60
D617 7 500 617 500 600 400 500 10 100 100 87
40
15 100 100 90
20 100 100 92 20
30 100 100 94
0
0 10 20 30 40 50 60 70
45 100 100 95
Frequency (Hz)
60 100 100 96
480V AC Power Rating Low Speed Derating with Reduced Carrier Frequency for IP20, UL Type 1 and IP54, UL Type 12
Cat. LD ND HD Output Freq. PWM Frequency
Frame
No.
20G… 0.444 kHz 0.666 kHz 1.33 kHz
Cont. Cont. Cont.
Hp Hp Hp Hz 0.444 kHz 0.666 kHz 1.33 kHz
Amps Amps Amps
0 91 88 79 120
60
D617 7 500 617 500 600 400 500 10 100 100 100
40
15 100 100 100
20 100 100 100 20
Power Loss Ride-through The power loss ride-through feature is an algorithm that is set to take a specific
action when power grid disturbances are detected.
Power Disturbances
Power disturbances are the deviations of input line voltage and frequency
from ideal specifications for short periods of time. Voltage and frequency
disturbances are a major concern in many industrial applications. Voltage
sags, swells, and frequency disturbances cause equipment malfunction and
production interruption. Under certain circumstances, the financial loss is
severe and can’t be tolerated. International committees have established
standards such as IEC-61000-4-34, IEC-61000-4-11, and Semi F47. These
standards help the food, textile, and electronic industries to avoid wasteful
financial loss and provide guidelines help maintain continued system
operation during power disturbances.
What Are the main types of power disturbances and why do they occur?
Voltage sags and short time power losses are the most common power
disturbances. A voltage sag is a reduction in voltage for a definite period. It can
be symmetrical so the reduction in voltage occurs equally on all three phases. It
can be asymmetrical, so the reduction does not occur equally on the three
phases. Normal operating conditions such as motor starting and/or
transformer inrush current can cause most voltage sags. Proper system design
helps to avoid or alleviate voltage sags. Short circuit faults also cause voltage
sags if they occur close to the main feeder. Voltage sags can also cause phase
angle jumps. Phase angle jumps can affect power electronic converters use of
phase angle information for their switching.
A power loss of short duration is a special case of voltage sag. The supply
voltage and current drop to zero. A current drop can occur when the power
utility interrupts the supply of power. The power utility can decide to shed
loads when malfunctions and overcurrent conditions occur. Critical loads
switched to emergency backup generators can cause a power loss of several
seconds.
To use power loss ride-through with PowerFlex 755T active front end
converters, frames 7…15, requires two additional power sources. A 240V AC
UPS to keep the main circuit breaker (MCB) closed and 24V DC to keep the
fiber-optic communications with peripheral boards alive.
Loss of Synchronization
The operation of the AFE relies on accurate detection of the line voltage angle.
The power disturbance module continuously monitors detection error. It
detects the condition if the error exceeds a certain threshold. Wrong
connections and transient conditions on the grid cause loss of
synchronization. Transient conditions include the following: power
interruption, voltage sag, sudden frequency disturbance, and angle jumping.
Loss of synchronization is a critical condition. You can choose from the
following actions: ‘Ride Thru’ or ‘Fault’.
Voltage Sag
A voltage sag is the loss or reduction of grid voltage for a short duration. The
time can range from a few milliseconds to a few seconds. The power
disturbance module monitors the input voltage in real time. It detects a
voltage sag condition when the voltage of one or more phase drops by more
than 50% of its nominal value. You can choose from the following actions:
‘Ignore’, ‘Alarm’, ‘Ride Thru’, or ‘Fault’.
The operation of the AFE relies on a stable input frequency. The power
disturbance module monitors the rate of change of frequency against time. It
detects a high frequency variation condition when the frequency change
against time exceeds 100 Hertz per second. You can choose from the following
actions: ‘Ignore’, ‘Alarm’, ‘Ride Thru’, or ‘Fault’.
Phase Loss
The operation of the AFE relies on a balanced supply. The power disturbance
module monitors the current of each incoming phase. It detects a phase loss
condition when the current on any of the phases drops too low. You can choose
from the following actions: ‘Ignore’, ‘Alarm’, ‘Ride Thru’, or ‘Fault’.
Power Loss
The power disturbance module monitors the root mean square (RMS) values of
the input line voltages. It detects a power loss condition when the RMS voltage
of the three input phases drops to less than 15% of the nominal value. You can
choose from the following actions: ‘Ignore’, ‘Alarm’, ‘Ride Thru’, or ‘Fault’.
Rockwell Automation Publication 750-RM100C-EN-P - August 2022 37
Chapter 1 Drive Configuration
Ride Thru mode is one of the selectable actions available when the power
disturbance module detects abnormal conditions. Ride Thru mode
temporarily disables PWM gating of the IGBTs in the line side converter. This
avoids instability and reduces the probability of fault. It also preserves the
energy in the DC bus capacitors. It can support the load for a short time.
Because the fly back diodes remain in circuit, the Line Side Converter behaves
like a passive diode bridge. Ride Thru disables the voltage and current loops. It
also resets the voltage and current integrators.
The flow diagram in Figure 1 illustrates the operation of Ride Thru mode. The
Power Disturbance module continuously monitors the incoming voltages and
currents and frequency. When it detects an abnormal condition, it follows the
Disturbance Action. If the selected Disturbance Action is ‘Ride Thru’, it
disables PWM gating and the control loops. When the abnormal condition
clears (voltages, current and frequency return to normal), the control loops
and PWM gating resume. If the abnormal condition lasts longer than the time
in the Ride Thru Time parameter, the product follows the selection in the Ride
Thru Expired Action parameter.
Power Disturbance?
Disturbance Action =
Ride Thru?
Yes
Disable PWM,
Reset Current
Loop Integrator, No
Reset Voltage Ride Thru Expired Ride Thru Expired
Loop Integrator Action = Alarm? Action = Fault?
Yes Yes
Figure 2 is a set of oscilloscope traces from an actual test. In this test, we’ve
induced a power loss condition. We have set parameters 13:181 [PLL LOS Det
Actn] to 0 ‘Ride Thru’, 13:170 [PwrLoss Det Actn] and 13:173 [VltgSag Det Actn]
to 2 ‘Ride Thru’ in the Line Side Converter. We’ve selected ‘Coast’ for the Ride
Thru option in the Motor Side Inverter.
PowerFlex 755TL and TR drives are 'integrated'. This means they have a Line
Side Converter and a Motor Side Inverter. These drives use Rockwell
Automation Adaptive Bus Reference Ride Thru technology (patent pending).
The Line Side Converter is disabled when the abnormal condition is detected.
If the Ride Thru option is selected, an additional signal passes from the Line
Side Converter to the Motor Side Inverter. When the signal is high, the Motor
Side Inverter takes control of the DC bus. The DC bus regulator in the Motor
Side Inverter can take energy from the load, if necessary, to keep the DC bus
voltage high enough. When the abnormal condition ceases, control passes
back to the Line Side Converter.
Figure 3 is a set of oscilloscope traces from an actual test. In this test, we’ve
induced a power loss condition. We have set parameters 13:181 [PLL LOS Det
Actn] to 0 'Ride Thru', 13:170 [PwrLoss Det Actn] and 13:173 [VltgSag Det Actn]
to 2 'Ride Thru' in the Line Side Converter. We have set parameters 10/11:116
[Bus Reg Mode A] to 1 'Adjust Freq', 10/11:270 [Pwr Loss Actn] to 1 'Alarm', 10/
11:271 [Pwr Loss Mode A] to 1 'Decel', 10/11:272 [Pwr Loss A Level] to 50V and 10/
11:273 [Pwr Loss A Time] to 60 seconds in the Motor Side Inverter. The duration
of the power loss in this test was about ten seconds.
The Power Disturbance Module detected the power loss and disabled the Line
Side Converter. The Motor Side Inverter took control of the DC bus. It drew
energy from the inertia of the load by adjusting the output frequency. The Line
Side Converter resumed control when power was restored. Then the Motor
Side Inverter accelerated the motor back up to speed.
In cases where voltage imbalance conditions are common on the grid, it might
be best to set parameter 13:181 [PLL LOS Det Actn] to 0 ‘Ride Thru’ and to
increase parameter 13:192 [BasicPLL Err Lmt].
In cases where power outages and voltage sags are common on the grid, it
might be best to set parameters 13:181 [PLL LOS Det Actn] to 0 ‘Ride Thru’,
13:170 [PwrLoss Det Actn] and 13:173 [VltgSag Det Actn] to 2 ‘Ride Thru’.
Auxiliary Power Supply Auxiliary power can be used to power the drive’s control circuitry in the event
the incoming supply is removed or lost. For PowerFlex 755TR, 755TL, and
755TM products, connect a user supplied 24V DC auxiliary power source to the
designated terminal block.
When the drive is connected to a user supplied 24V DC power source, the
communication network functions remain operational and online. If
DeviceLogix is used, the program can also continue to run and control any
associated input and outputs.
See the Apply and Remove Power section of the PowerFlex Drives with
TotalFORCE Control Programming Manual, publication 750-PM101, for the
correct power-up sequence when using auxiliary power.
Motor Control Modes The PowerFlex 750-Series Products with TotalFORCE support the
configuration of two motor control profiles, primary and secondary, which
provides application flexibility. Each profile can be configured for any of the
motor control modes regardless of how the other profile is configured. The
only exception is None (0) which can only be selected for the secondary control
profile. See Secondary Motor Control on page 67 for more information on this
functionality.
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] select the
motor control mode for ports 10 (primary) and 11 (secondary) in the drive. The
default selection for 0:65 [Pri MtrCtrl Mode] is 2 ‘Induction SV’ and for 0:67
[Sec MtrCtrl Mode] is 0 ‘None’. Set these two parameters and cycle power to
the drive before performing further commissioning steps.
A change to the motor control mode reconfigures which parameters are visible
in port 10 (primary) and port 11 (secondary). This helps to reduce configuration
time by only showing those parameters that are applicable for the selected
motor control mode. The parameter settings follow.
None (0) – This setting is only valid for 0:67 [Sec MtrCtrl Mode]. When set to
none, port 11 (secondary) isn’t visible. Used when secondary motor control
functionality isn’t required.
InductionVHz (1) – Induction motor, volts per Hertz control mode. Connected
to an induction motor. Commonly used for variable torque applications like
centrifugal pumps and fans for improved efficiency and energy savings, or for
variable speed constant torque applications such as conveyors. Can also be
used for synchronous motor applications. This is the only motor control mode
capable of running multiple motors with one drive.
Induct Econ (3) – Induction motor, economize control mode. Used for
additional energy savings in constant torque applications that have constant
speed reduced load periods.
IPM FV (5) – Interior permanent magnet motor, flux vector control mode.
Connected to an Interior Permanent Magnet motor. Used when high-
performance precise speed regulation and/or position control with closed loop
feedback is required. Can also be configured with direct Torque Reference
input. Capable of being used open loop with less precision.
SPM FV (6) – Surface permanent magnet motor, flux vector control mode.
Connected to a Surface Permanent Magnet motor. Used when high-
performance precise speed regulation and/or position control closed loop is
required. Can also be configured with direct Torque Reference input. Capable
of being used open loop with less precision.
PM VHz (7) – Permanent magnet motor, volts per Hertz control mode.
Connected to a Surface Permanent Magnet motor (SPM) or Permanent
Magnet Synchronous Motor (PMSM). Used for variable torque applications
with improved efficiency energy savings and variable speed constant torque
applications such as conveyors. Also used in multi-motor or synchronous
motor open loop applications.
SynR VHz (9) – Synchronous Reluctance motor, volts per Hertz control mode.
Connected to a Synchronous Reluctance motor. Used for constant torque
applications with improved efficiency energy savings and variable speed
applications such as conveyors. Can also be used in multi-motor applications.
There are four basic control methods available in the drive. These methods are
Volts/Hertz, Sensorless Vector, Economize, and Flux Vector. While the basic
operation of each of these methods is the same regardless of the motor type
being used, it’s important to select the motor control mode for the type of
motor being used because the motor data required by the algorithms can vary.
Volts/Hertz
Volts/Hertz is the simplest form of AC motor control. Volts per Hertz can be
used with induction motors (Induction VHz), permanent magnet motors (PM
VHz), and synchronous reluctance motors (SyncRel VHz). Volts per Hertz is
ideal for variable torque applications like centrifugal pumps and fans. This
mode can also be used when running multiple motors on one drive. Volts/
Hertz operation creates a fixed relationship between output voltage and
output frequency. This is known as a scaler control method because voltage is
scaled based on frequency. The relationship can be defined in two ways by
setting 10/11:486 [VHz Curve] to 0 ‘Custom V/Hz’ or 1 ‘Fan/Pump’. Motor
autotune tests aren’t required in this mode.
Figure 4 - Volts/Hertz
Current Feedback
Torque Current
Estimator
Slip Estimator
0 = ‘Custom V/Hz’
10/11:480 [Start Acc Boost] - Used to create additional torque for breakaway
from zero speed and acceleration of heavy loads at lower speeds.
10/11:481 [Run Boost] - Used to create additional running torque at low speeds.
The value is typically less than the required acceleration torque. The drive will
lower the boost voltage to this level when running at low speeds (not
accelerating). This reduces excess motor heating that could be caused if the
higher start/accel boost level were used.
10/11:400 [Motor NP Volts] and 10/11:402 [Motor NP Hertz] - Set the upper
portion of the curve to match the motor design. Marks the beginning of the
constant power region.
Voltage
10/11:483 [Break Voltage]
10/11:480 [Start Acc Boost]
10/11:481 [Run Boost]
0
10/11:484 10/11:402 10/11:422
[Break Frequency] [Motor NP Hertz] [Maximum Freq]
Frequency
1 = ‘Fan/Pump’
10/11:481 [Run Boost] - Used to create additional running torque at low speeds.
The value is typically less than the required acceleration torque. The Fan/Pump
curve does not use 10/11:480 [Start Acc Boost] and therefore uses 10/11:480 [Run
Boost] regardless of whether the drive is running at speed or accelerating.
10/11:400 [Motor NP Volts] and 10/11:402 [Motor NP Hertz] - Set the upper
portion of the curve to match the motor design. Marks the beginning of the
constant power region.
0 10/11:402 10/11:422
[Motor NP Hertz] [Maximum Freq]
Frequency
Sensorless Vector
Autotune
Parameters
V/Hz Control Inverter
Speed Ref Elec. V Mag Gate
(Hz) + Elec. Ref Current Freq Voltage Signals
Limit V/Hz V Angle Control Motor
+
Torque Current
Estimator
Slip Estimator
Autotune
Parameters
V/Hz Control Inverter
Speed Ref Elec. V Mag Gate
(Hz) Elec. Ref Current Freq Voltage Signals
V/Hz V Angle Control Motor
Limit
Torque Current
Estimator
Voltage
ate F e
oxim Curv
Appr o Load
ate N
oxim
Appr
Stator Voltage Drop at
Motor NP Amps (1)
10/11:402 10/11:422
[Motor NP Hertz] [Maximum Freq]
Frequency
(1) During a motor autotune, the drive measures this voltage drop and stores the equivalent resistance in 10/11:512 [u IM Stator
Res].
Economize
Frequency
In Flux Vector mode, the flux and torque producing currents are
independently controlled and speed is indirectly controlled by a torque
reference. Alternatively, the drive can control torque instead of speed in flux
vector mode. In either case, this mode can be operated either with or without
feedback and will provide the fastest response to load changes.
46 Rockwell Automation Publication 750-RM100C-EN-P - August 2022
Chapter 1 Drive Configuration
Flux Vector control can be used with inductions motors (Induction FV),
surface permanent magnet motors (SPM FV) and interior permanent magnet
motors (IPM FV). Flux Vector is the highest performance motor control
method. Motor data and a motor auto tune is required for correct operation in
this mode. In Flux Vector control, the drive takes the speed reference that is
specified by the Speed Reference Selection block and compares it to the speed
feedback. The speed regulator uses Proportional and Integral gains to adjust
the torque reference for the motor. This torque reference attempts to operate
the motor at the specified speed. The torque reference is then converted to the
torque producing component of the motor current.
Autotune
Parameters
Speed Feedback
Autotune
Parameters
Torque Current
Estimator
Motor Types The following explanation and descriptions of AC motor types are condensed
summaries derived from a variety of sources that focus on the history,
evolution, and feature benefits of the variety of motor designs. These designs
are utilized in all sectors of use and in vast variations of machinery,
equipment, and processes.
The types of AC motors described here, powered by fixed utility frequency, are
limited to speeds based on the number of poles and winding construction.
Variable Frequency Drives (VFDs) broaden practical speed ranges of these
motor types by converting utility power and applying appropriately selected
VFD electronic control modes specifically matched to these unique motor type
designs.
The PowerFlex 750-Series Products with TotalFORCE Control can store two
motor control profiles: primary and secondary. Each profile can be configured
independently. For detailed information about how to configure these motor
control profiles, see Motor Control Modes on page 41.
AC Induction Motors
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following induction motor options.
• 1 = ‘InductionVHz’
• 2 = ‘Induction SV’
• 3 = ‘Induct Econ’
• 4 = ‘Induction FV’
AC Induction Motors (ACIMs) are the simplest and most rugged electric motor
and consist of two basic electrical assemblies: the wound stator and the rotor
assembly. The induction AC motor derives its name from currents flowing in
the secondary member (rotor) that are induced by alternating currents flowing
in the primary member (stator). The combined electromagnetic effects of the
stator and rotor currents produce the force to create rotation.
There are five basic NEMA designs for AC motors: A, B, C, D, and F. The speed-
torque curves for all five designs are shown on the following graph.
300
275
250
225
D
200
125
Full-Load Torque
100
75
50
25
0
0 10 20 30 40 50 60 70 80 90 100
Speed - Percent
Speed - Torque Curves of NEMA A, B, C, D, and F Motors
AC Motors - Design C have high starting torque with normal starting current
and low slip. NEMA design C motor has a higher starting torque than either
the A or B designs. This torque is in the vicinity of 225% of full-load torque.
Design C AC motors are normally used where breakaway loads are high at
starting, but which normally run at rated full load and are not subject to high
overload demands after running speed has been reached.
AC Motors - Design F exhibit low starting torque, low starting current, and low
slip. These AC motors are built to obtain low locked-rotor current. Both locked-
rotor and breakdown torque are low. Normally these AC motors are used
where starting torque is low and where high overloads are not imposed after
running speed is reached.
Wound-rotor AC Motors
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following induction motor options.
• 1 = ‘InductionVHz’
• 2 = ‘Induction SV’
• 4 = ‘Induction FV’
IMPORTANT Because wound-rotor motors were not originally designed for use with
inverters, the dielectric strength of the motor construction cannot
withstand the reflected wave voltages that can get subjected at the
motor connections (1.5 to 2.5 times drive’s bus voltage).
Multi-speed AC Motors
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following induction motor options.
• 1 = ‘InductionVHz’
• 2 = ‘Induction SV’
• 4 = ‘Induction FV’
Two-winding AC motors have two separate windings that can be wound for
any number of poles so that other speed ratios can be obtained. However,
ratios greater than 4:1 are impractical because of AC motor size and weight.
When retrofitted with a VFD, the motor is generally wired for the speed range
intended to be optimized. Autotuned per representative nameplate
information and operated as a single winding single speed induction motor.
Synchronous AC Motors
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following induction motor options.
• 1 = ‘InductionVHz’
There are two major types of synchronous AC motors: non-excited and direct-
current excited electric motors. Application of a VFD is to vary the desired
synchronous speed of the machine.
Motor data and an autotune are required for correct operation in these modes.
For detailed information about how to use each of these features, see the
PowerFlex 755T Flux Vector Tuning Application Technique, publication
750-AT006.
SPM or PMSM is a rotating electrical machine that has the stator phase
windings and rotor permanent magnets. The air gap magnetic field is
provided by these permanent magnets therefore it remains constant.
The torque is produced because the interaction of the magnetic fields causes
the rotor to rotate. In permanent magnet motors, one of the magnetic fields is
created by permanent magnets and the other is created by the stator coils. The
maximum torque is produced when the magnetic vector of the rotor is at 90
degrees to the magnetic vector of the stator.
PMSM motors provide higher power density for their size compared to ACIMs.
This is because with an induction machine, part of the stator current is
required to “induce” rotor current in order to produce rotor flux. These
additional currents generate heat within the motor. In a PMSM, the rotor flux
is already established by the permanent magnets on the rotor.
Field Oriented Control is the most popular control technique used with
PMSMs. As a result, torque ripple can be extremely low, on par with that of
ACIMs. Most PMSMs utilize permanent magnets which are mounted on the
surface of the rotor. This makes the motor appear magnetically “round,” and
the motor torque is the result of the reactive force between the magnets on the
rotor and the electromagnets of the stator. This results in the optimum torque
angle being 90 degrees, which is obtained by regulating the d-axis current to
zero in a typical FOC application.
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following interior permanent magnet motor option.
• 5 = ‘IPM FV’
Some PMSMs have magnets that are buried inside of the rotor structure. These
motors are called Interior Permanent Magnet, or IPM motors. As a result, the
radial flux is more concentrated at certain spatial angles than it is at others.
This gives rise to an additional torque component called reluctance torque,
which is caused by the change of motor inductance along the concentrated and
non- concentrated flux paths.
This causes the optimum Field Oriented Control torque angle to be greater
than 90 degrees, which requires regulating the d-axis current to be a fixed
negative ratio of the q-axis current. This negative d-axis current also results in
field weakening, which reduces the flux density along the d-axis, which in turn
partially lowers the core losses. As a result, IPM motors boast even higher
power output for a given frame size.
Parameters 0:65 [Pri MtrCtrl Mode] and 0:67 [Sec MtrCtrl Mode] have the
following synchronous reluctance motor option.
• 9 = ‘SynR VHz’
• 10 = ‘SynR SV’
Selecting Velocity The PowerFlex 750-Series Products with TotalFORCE Control support the
Feedback selection of two feedback sources: primary source and alternate source.
Parameter 10/11:1000 [Pri Vel Fb Sel] selects the port and parameter of the
feedback channel to be the primary source of motor velocity feedback. This
becomes the source for parameters 10/11:1044 [Motor Vel Fb] and 10/11:1042
[Vel Fb Active].
Parameter 10/11:1006 [Alt Vel Fb Sel] selects the port and parameter of the
feedback channel to be the alternate source of motor velocity feedback. This
becomes the source for parameters 10/11:1044 [Motor Vel Fb] and 10/11:1042
[Vel Fb Active] when an ‘Automatic Switchover’ has occurred.
Parameters 10/11:1000 [Pri Vel Fb Sel] and 10/11:1006 [Alt Vel Fb Sel] become
available in the Flux Vector (FV) selections of the motor control modes.
Feedback Modes
The PowerFlex 750-Series Products with TotalFORCE Control provide several
feedback modes depending on the selection of the parameter 0:65 [Pri MtrCtrl
Mode] (and the parameter 0:67 [Sec MtrCtrl Mode] if this parameter isn’t set to
‘None’). This parameter is only editable on the Dynamic Features Page.
Topic Page
Adaptive Control 57
CIP Security 66
Secondary Motor Control 67
Energy Pause Function 71
Predictive Maintenance 76
Predictive Maintenance CIP Objects 91
DeviceLogix 99
Emergency Override Function 106
Reference Motion Planners 110
Adaptive Control A brief overview of Load Observer, Adaptive Tuning, and Autotune is provided
in this section. For detailed information about how to use each of these
features, see the PowerFlex 755T Flux Vector Tuning Application Technique,
publication 750-AT006.
Load Observer
The load observer feature is a control loop inside the drive that estimates the
mechanical load on the motor and compensates for it while the drive is
running. This feature allows high performance and control loop tuning
simplicity similar to that of a mechanically disconnected motor. Its primary
function is to:
• Automatically compensate for unknown inertia, compliance, and low
frequency resonance
• Automatically compensate for disturbances and changes in inertia
• Force consistent dynamic behavior, which makes the drive easier to tune
Benefits
You can use load observer with out-of-box control loop gains, where the load is
unknown or compliant and thus 10/11:901 [Load Ratio] = 0. You can also use
load observer with autotuned control loop gains where 10/11:901 [Load Ratio] >
0. This value can be a known positive value or one that is calculated by
performing an autotune procedure.
When load observer is enabled with the recommended out-of-box control loop
gains:
• A tuning expert is not needed
• Commissioning time is reduced, especially for high drive count
• Relatively high performance control is provided without tuning
• Changes in inertia, compliance, and low frequency resonances are
compensated for automatically
• Periodic retuning to account for machine wear over time is not needed
Adaptive Tuning
Benefits
When you enable adaptive tuning with the recommended out-of-box control
loop settings, you do not need a tuning expert. You also gain the following
benefits:
• Reduced commissioning time, especially for high drive count
• Automatically suppressed continuously changing resonances
• Periodic identification of resonances and retuning is not needed
• Periodic retuning of filters is not needed
• Minimized tracking errors, machine vibration, and power consumption
• Increased bandwidth and line speeds
• Tighter control of moving parts reduces wear and saves material costs
Autotune
The Autotune function is used to measure motor characteristics. It is
composed of several individual tests, each of which is intended to adjust one or
more motor parameters. These tests require you to enter motor nameplate
information into the drive parameters. Although you can change some of the
parameter values manually, measured values can provide improved
performance. Autotuning is often unnecessary when you apply Load Observer
with the recommended default settings.
2 KPP 2 KVP
1 [Hz] 1 [Hz]
2 KPI 2 KVI
s s
[Hz] [Hz]
Position Regulator Velocity Regulator
The recommended method for tuning the position and velocity regulators is
adjusting the System Bandwidth parameter 10/11:906 [System BW]. By
adjusting the System bandwidth, the proportional and integral gains for the
position and velocity regulators are automatically calculated, which eliminates
the need to adjust each gain individually. For more information on the
Position and Velocity regulators and how to tune them, refer to the PowerFlex
755T Flux Vector Tuning Application Technique, publication 750-AT006.
Bus Observer
The bus observer feature is available in the PowerFlex 755TM regenerative bus
supplies and the PowerFlex 755TL low harmonic and 755TR regenerative
products. Bus observer was added to compensate for unknown capacity
changes in the system demand. Enhanced DC bus voltage regulation and
repeatability of control loop performance in the presence of unknown AC line
conditions are the main goals of the bus observer, rather than command
tracking, which allows for lower gain settings. Bus observer performs the
following functions:
• Enhances the regulation of the DC bus voltage control.
• Compensates for unknown capacity changes in the system demand.
• Compensates for the external connected capacitance that is less than
three times the bus supply.
• Uses current feedback to feed forward the bus voltage regulator.
PowerFlex 755TL/TR drives use power feed forward to enhance the DC bus
regulation. The inverter load is fed forward into the converter to improve DC
bus voltage regulation.
When the bus observer is not used, higher gain settings are required for a
sufficiently robust system. Higher gain settings cause heating of the inductors
and capacitor resonance trips. The accuracy of the total bus capacitance that is
entered directly affects overall performance.
Example: The bandwidth = 400 Hz with bus observer disabled. However, the
bandwidth = 150 Hz with bus observer enabled for equivalent DC bus voltage
regulation with lower inductor temperatures.
BusObsConfig(320):
BusObsConfig
320 BusRegIntegTerm
0- Disabled
1- BusObsOnly.
2- BusObsVltEst. 0,1 DC Bus Command BusRegPropTerm
50 VbusErr
BusObs Volt Est 2 IqRefVbusReg
c Volt Reg Ki 60
Volt Reg BW 55 0
u Volt Reg Kp 57 1
LscCtrlCfg [C5]
IqRefVbusReg
IqRefDcBusObs
+ X
- Limit
BusObsConfig(320):
-1
BusObs Curr Est
0- Disabled X 325
1- BusObsOnly.
2- BusObsVltEst.
X
0
0 1,2 0 1,2
320
BusObsConfig 0
1.0
VoltCtrl [F3]
1,2 BusObs Volt Est
Port 0
DC Bus Volts
3 + X
-
X X
Feed forward power is a drive function that you can use to improve DC bus
voltage regulation in response to changes in the load on the inverter section of
the drive.
Technical Overview
Feed forward power uses the inverter section power demand, parameters 10/
11:4 [Output Power] and 13:44 [FF Power Gain], to command the converter side
of the drive. This command improves DC bus voltage regulation by letting the
DC Bus PI regulator react before the DC Bus voltage sags.
Feed forward power is not used in a PowerFlex 755TM regenerative bus supply
because it does not have the inverter control on the same control board.
40 2
VoltCtrl [H2]
BusObsConfig
320
0
0
DC Bus Obs[H2]
IqRefDcBusObs 1,2
PowerFlex 755T products include two reference notch filters. There are three
instances in which these two filters share a set of common parameters. The
instances are located in the Velocity, Position, and Process PI command paths.
These reference notch filters help prevent the velocity command from
introducing a resonance into the mechanical system or sway into a crane/hoist
system.
You can use the reference notch to counter the pendulum effect that is caused
by the movement of the trolley or gantry in crane and hoist applications. See
Anti-Sway Applications on page 191 information about configuring notch
filters for crane/hoist applications.
Technical Overview
The two notch filters in the velocity reference and position reference paths can
be used to notch out command frequencies that can cause resonance or
instability in mechanical systems. The notch filters have the following
restrictions:
• Available in Flux Vector control modes only.
• Cannot be used in Sensorless Vector or Volts/Hz modes.
Figure 13 and Figure 14 show that the notch filters are located in the reference
command of both the position and velocity command paths.
PRef NF Out
15
Ref NF 1 Ref NF 2 ¦ 1731 Position Command
PRef NF Out
PReg [C3]
Motor Side Sts 1 (Running) Velocity Ramp and Move Profiles (VRef Move)
354 16 Vel Ctrl Options
Motor Side Sts 1 OR (Delayed Ref)
(Stopping)
355 9 VRef Ramp In 1950 8
354 18 Motor Side Sts 2 1923 VRef Ramped
1
0 (Autotuning) 1 Proc 2 [C2] 0
Not Stopping
and Active
Virtual Encoder
0
0
1 VRef Delayed
0 One 1
Stopping LinScurve 1924
or Not Active Scan
SineSquared Delay PRef 1 [C5]
Virtual Enc EPR Virtual Enc Psn
Poly5 (Edges Per Rev)
931 One
1017
Ref NF2 Freq 948 Ref Move Type Scan
Ref NF2 Width 949 Delay Virtual EncDelay
Virtual Encoder
950 PRef 1 [C5]
Ref NF2 Depth
Ref NF2 Gain 951
VRef Filter
VRef NF In
1925
36
Ref NF2 Ref NF1
Accel FF Output
Velocity Comp
2070
Vel Comp Sel
These graphs show a velocity command before and after the reference notch
filter. The command going into the filter is a ramp to 50 rpm in 0.5 seconds
and the first notch filter is set to a frequency of 0.5 Hz.
0.03
10/11:381 [Testpoint REAL 1]
0.025
0.02
0.015
0.01
0.005
0.0
-1 999 1999 2999 3999
Milliseconds
60
10/11:1925 [VRef Filtered]
40
RPM
20
0
-1 999 1999 2999 3999
Milliseconds
0.02
0.015
0.01
0.005
0.0
-1 999 1999 2999 3999
Milliseconds
60
10/11:1925 [VRef Filtered]
40
RPM
20
0
-1 999 1999 2999 3999
Milliseconds
CIP Security PowerFlex 755T products with firmware revision 10.001 or later are CIP Secure
Capable with secure hardware devices and code that is embedded into control
and communication.
Overview
CIP Security is an ODVA standardized method of protecting industrial
automation control systems (IACS) through Ethernet/IP™ and device
authentication, integrity, and confidentiality. As EtherNet/IP becomes a
growing standard, evolving these isolated IACS networks towards smart
manufacturing, network convergence, and industrial security become a
necessity.
For more information on how to deploy CIP Security with PowerFlex 755T
products and at scale across an industrial automation control system, see the
CIP Security with Rockwell Automation Products Application Technique,
publication SECURE-AT001.
Supported Attributes
PowerFlex 755T products with firmware revision 10.001 or later support these
attributes.
Property Description
Certificate that is based on the X.509 v3 standard is used to provide identity.
Device Identity and Pre-shared keys are shared secrets that are shared among trusted entities that are
Authentication used to provide identity.
The TLS protocol facilitates mutual authentication to create trusted endpoints.
Keyed-Hash Message Authentication Code (HMAC) is used as a cryptographic method of
Data Integrity providing data integrity and message authenticity to EtherNet/IP traffic.
Data encryption is used to encode messages or information to help prevent reading or
Data Confidentiality viewing of EtherNet/IP data by unauthorized parties.
Secondary Motor Control Secondary Motor Control functionality is added to PowerFlex 755T drives as
modular control profiles in firmware revision 5 and later. The Secondary
Motor Control modular control profile is installed in port 11 of the PowerFlex
755T drive. When defining the motor control type to be used with the
Secondary Motor Control profile, only parameters for that type of motor
control are present in the profile, similar to port 10 Primary Motor Control.
When used with the primary motor control profile, you can define different
control types, motor types, or motor parameters to increase the flexibility of
the PowerFlex 755T drive.
The motor control type that is defined for the Secondary Motor Control profile
determines the parameters that are accessible in port 11. All motor data and
application tuning configuration of the Secondary Motor Control profile is
done in port 11. You can see the parameter list in the PowerFlex 750-Series
Drives with TotalFORCE Control programming manual, publication
750-PM100.
The active motor control profile is defined in 0:74 [Motor Ctrl Sel]. There are
two methods you can use to change between the primary and secondary motor
control profiles.
Logix Configuration
The motor control profile that is actively being used can be changed by writing
to 0:74 [Motor Ctrl Sel] either through a datalink or with an explicit message
instruction. You can verify that the active motor control profile has changed as
expected by doing a readback from the PowerFlex 755T drive by using 0:75 [Mtr
Ctrl Sel Act].
You can wire a digital input to an I/O option module installed in the PowerFlex
755T drive. The digital input is configured to 0:169 [DI Mtr Ctrl Sel] to switch
between the primary and secondary motor control profiles. If the input is open
or de-energized, the drive selects the Primary Motor Control profile.
If both methods to control the active motor control profile are being used, the
digital input that is configured in 0:169 [DI Mtr Ctrl Sel] takes priority.
You can use the Secondary Motor Control profile to change motor size without
the need to reprogram the drive. In this example, one PowerFlex 755T drive is
used to control a 100 Hp motor, but can be electrically switched over to a 150
Hp motor. The primary motor control profile is configured with the 100 Hp
motor characteristics and tuning requirements. The secondary motor control
profile is configured with the 150 Hp motor characteristics and tuning
requirements.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
100 Hp 150 Hp
Power Structure
100 Hp 150 Hp
You can use secondary motor control when one PowerFlex 755T drive is used to
switch from two different motor control types. For this example, the
PowerFlex 755T drive is configured to switch between controlling an induction
motor and an SPM permanent magnet motor. Induction Flux Vector is
configured in the Primary Motor Control profile, and SPM Motor Flux Vector
is configured in the Secondary Motor Control profile.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
Power Structure
Induction SPM
You can use secondary motor control when one PowerFlex 755T drive is used to
switch from controlling one motor to controlling a multi-motor system. For
this example, the PowerFlex 755T drive is configured to switch between
controlling one motor in induction flux vector mode and controlling a multi-
motor system in induction VHz mode. Induction Flux Vector is configured in
the Primary Motor Control profile, and Induction VHz is configured in the
Secondary Motor Control profile.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
Motors
Energy Pause Function The Energy Pause function sends the drive or bus supply to and from a low-
energy state on command. This function saves energy, reduces wear on parts,
and reduces fan noise.
For frames 5 and 6 of the PowerFlex 755TR/TL/TM and all frame sizes of the
PowerFlex 755TS, an external input contactor can be controlled to disconnect
the drive from the AC line when in energy pause mode.
For frames 7…15 of the PowerFlex 755 TR/TL drives, the line side converters are
disconnected from the AC line and the fans are in a low-energy state when in
energy pause mode.
Table 5 - Total Energy Savings—PowerFlex 755TR/TL/TM Products
Common Bus Inverters [kW]
Frame Drives [kW] Bus Supplies [kW]
IP21, UL Type 1 IP54, UL Type 12
5 0.4 — — —
6 0.6 0.6 — —
7 1.4 1.1 — —
8 1.3 1.1 0.3 0.7
9 2.2 1.8 0.6 1.0
10 3.5 2.5 0.9 1.6
11 4.5 3.7 1.2 2.0
12 5.8 4.8 1.4 2.6
13 7.1 5.9 1.7 3.3
14 8.9 7.3 2.2 3.7
15 11.5 9.6 2.6 5.0
System Requirements
The Energy Pause function is available in PowerFlex 755TL low harmonic
drives, 755TR regenerative drives, 755TM common bus inverters, and 755TS
drives.
• Firmware revision 3 or later is installed for PowerFlex 755TL low
harmonic drives, 755TR regenerative drives, and 755TM bus supplies.
• Firmware revision 10 or later is installed for PowerFlex 755TM common
bus inverters.
• Firmware revision 11 or later is installed for PowerFlex 755TS drives
• A customer-supplied 24V DC auxiliary power source is connected. See
Auxiliary Power Supply on page 41 for more information on using an
auxiliary power supply.
Three machine states govern the energy pause function: Owned, Paused, and
Resuming. These states are a subset of the states that are required to support
the CIP Energy Power Management object. The names come from that object.
Monitor the status of the state machine with parameter 0:59 [Energy Status].
FW Revision
Access Level
Display Name
Read-Write
Data Type
No. Extended Name Values
Description
59 Energy Status RO Bit 3.x 2
Energy Status
Displays the state of the energy function.
Resuming
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Options
Paused
Owned
Default 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Bit 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit 1 ‘Owned’ – indicates that the product (drive or bus supply) is in the ‘Owned’ state. AC precharge is complete and the product is operational. The product moves
to the ‘Paused’ state if it receives an Energy Pause command.
Bit 2 ‘Paused’ – indicates that the product is in the ‘Paused’ state. In this state, the product disconnects from three-phase AC power to save energy. The product
moves to the ‘Resuming’ state if it receives an Energy Resume command (removal of Energy Pause).
Bit 4 ‘Resuming’ – indicates that the product is in the ‘Resuming’ state. This state means that the product is transitioning from the ‘Paused’ to the ‘Owned’ state. In
this state, the product connects to three-phase AC power and performs the AC precharge function. The product moves to the ‘Owned’ state when it successfully
completes the AC precharge function.
Bit 16 ‘Cls Ext Cont’ – the energy function sets this bit to close an external contactor to connect the line side converter to three-phase power. Connect a digital
output function that energizes to close an external contactor. For example, in the I/O card set parameter 10 [RO0 Sel] to this parameter and address. Connect the
relay output to the contactor to energize the coil that closes the contactor. The energy function clears this bit in the Paused state. The bit is set in the ‘Resuming’
and ‘Owned’ states.
AC precharge successful.
Owned State
After powerup and when AC precharge is complete, the function moves to the
Owned state. The Owned state is the traditional operating state. The line side
converter is energized and can modulate. The motor side inverter is energized
and can modulate.
In the Owned state, the function waits for an Energy Pause command. If it
receives one, it moves to the Paused state. An Energy Pause command is
ignored if the line side converter and the motor side inverter are modulating.
For the PowerFlex 755TL low harmonic drives, 755TR regenerative drives, and
755TM bus supplies you must set parameter 0:63 [LS Start Mode] to 2 ‘Conv
Logic’ to use energy pause. PowerFlex 755TM common bus inverters and 755TS
drives do not have this parameter.
Paused State
In the Paused state, the product disconnects three-phase power from the LCL
filter module and line side converter. In frames 7...15, it disconnects three-
phase power by opening the precharge circuit breaker (MCB). It also lowers the
speed of the heatsink fans in the LCL filter and power modules.
Frame 5…6 drives do not have internal precharge circuit breakers. A digital
output controls a contactor that disconnects the whole product from three-
phase power.
To operate the contactor pilot coil, the contactor is wired to a digital output on
an I/O option module.
In this state, the function clears faults that naturally occur as a result of the
three-phase power being disconnected.
In the Paused state, the product waits for an Energy Resume command. If it
receives one, it moves to the Resuming state. For frame 5…7 drives the HMI
indicates a drive status of ‘in precharge’.
Resuming State
The Resuming state moves the product from the Paused state back to the
Owned state. It reconnects three-phase power and then performs the AC
precharge.
In this state, the Energy Pause function clears faults that occur as a result of
the three-phase power being disconnected.
You can activate the Energy Pause function by setting a bit in the controller, or
by using a discrete-wired digital input. The product must be stopped before an
energy pause request can be sent. If a converter or inverter is modulating, the
drive ignores the request to enter energy pause mode and remains in the
Owned state. The product must detect a rising edge of the energy pause
command after the converter and inverter have been stopped.
Logic Command
For PowerFlex 755TM bus supplies, 755TM common bus inverters, and 755TS
drives:
• Program the Logix project to set bit 21 ‘Energy Pause’ of the logic
command word to request an Energy Pause command. For more
information on the logic command word, see the Logic Command and
Use parameter 0:135 [DI Energy Pause] to select a digital input on an I/O
option card in one of the option slots. Wire the input to circuitry that closes or
energizes to create an Energy Pause command, and opens or de-energizes to
create an Energy Resume command.
The Energy Pause function sets parameter 0:59 [Energy Status] bit 16 ‘Cls Ext
Cont’ to close an external contactor to connect the line side converter to three-
phase power.
When both methods (logic command and digital input) are used, an OR
function of the two signals determines the Energy Pause request. An Energy
Pause request results if either signal detects the request. A Resume request
results if both signals are cleared.
Table 6 - Energy Pause Request Results
Logic Command Bit 21 ‘Energy Pause’ DI Energy Pause Digital Input Request Result
0 (cleared) 0 (open or de-energized) Resume Command
0 (cleared) 1 (closed or energized) Energy Pause Command
1 (set) 0 (open or de-energized) Energy Pause Command
1 (set) 1 (closed or energized) Energy Pause Command
When using Energy Pause on a common bus system, pause and resume
commands must be coordinated between the bus supply and common bus
inverters. To pause a common bus system:
• Stop all devices (not modulating)
• Send pause command to common bus inverters
• Wait for all devices to report they are in the Paused state
• Send pause command to the bus supply
• Bus supply reports it is in the Paused state
A resume command for a common bus system must be done in the reverse
order that is used for pause. To resume a common bus system:
• Send resume command to the bus supply
• Wait for the bus supply to report it is in the Owned state
• Send resume command to the common bus inverters
• Common bus inverters report they are in the Owned state
• Devices are ready to start
Predictive Maintenance The overall goal of the predictive maintenance function is to enable regular
maintenance of drives, motors, and machines.
The predictive maintenance function allows you to set the event action and
event levels. The event level changes how much of the total life of a component
is consumed before the predictive maintenance function notifies you to
replace the component.
There is an event level and event action for each type of predictive
maintenance function. The event level and event action parameters are in port
0, because it is logical for all events of the same type to occur at the same level.
For example, it is logical for all heatsink fan events to happen at the same level.
Heatsink fans are in the line side converter and the motor side inverter.
Event Level
The event level determines when the event occurs. The level is expressed in
percent of life used.
The event occurs when the component has used up this amount of predicted
life. The default is 80%. If you leave it at the default setting, the event occurs
when 80% of the component life is used. If you change a level to 50%, the event
occurs when half of the component life is used.
You can change these values to almost any level. Select a level that is
appropriate for your application and drive section. If the drive section is
critical or the application cannot tolerate unplanned downtime, you can use
lower event level values.
Event Action
The event action determines what happens when the event occurs. There are
two choices: Ignore and Alarm. If you select alarm, the event triggers an alarm.
Alarms are notifications and do not interrupt product operation. The alarm
number and alarm text appear on the HIM and in any connected software.
They are also recorded in the alarm queue.
You could choose Ignore if you wanted to use another means to track
remaining life and create a notification. One possible option is to use your own
logic in a controller to monitor elapsed life and remaining life parameters, and
then create a notification on a Human Machine Interface screen.
There is an elapsed life and a remaining life parameter for each component
that is covered by predictive maintenance.
Elapsed Life
The values of these parameters represent the accumulated damage that the
components experience.
The values reflect the runtime on the components and the running conditions.
For example, elapsed life values for fans increment faster when the
temperature is higher and the fan speed is higher. Elapsed life values for IGBTs
increment faster when temperature, load, and carrier frequency are higher.
Elapsed life values for bus capacitors increment faster when temperature,
load, and DC bus ripple are higher.
Remaining Life
The unit of measure for these parameters is always hours, regardless of the
component type. Measuring time in hours helps you schedule replacement
during planned downtime.
Predicted values are based on the rate of change of accumulated damage. For
example, remaining life values for fans are lower when recent temperature and
speed are higher. Remaining life values for IGBTs are lower when recent
temperature, load, and carrier frequency are higher. Remaining life values for
bus capacitors are lower when recent temperature, load, and DC bus ripple are
higher.
These predicted values are similar to the ‘fuel range’ displayed on many
automotive dashboards. The value is high, for a given amount of fuel, when
you are cruising efficiently on the highway. It is low, for the same amount, if
you are stuck in ‘stop and go’ city traffic.
IGBT Modules
Table 7 - Event Level and Event Action Parameters
Parameter No. Parameter Name Units Definition
Enter a value to determine when a Predictive
Maintenance IGBT event in the power modules takes
0:566 IGBT Event Level % place. The event notifies you to replace the power
module.
0 = ‘Ignore’ Select the action taken when the Predictive Maintenance
0:567 IGBT Event Actn 1 = ‘Alarm’ IGBT event in the power modules takes place.
Remaining Lifetime and Elapsed Lifetime: The calculation uses Event Level
and the record of operating conditions from the past 30 days. These conditions
include component data, temperature, load (current), and runtime. Positive
values indicate the estimated number of hours until the event occurs. These
values count down.
Negative values indicate the number of hours that have passed since the event
occurred. The precision of this parameter is limited to the eight most
significant digits. The three least significant digits are rounded. For example,
an internal value of 18760230188 is represented in this parameter as
18760230000.
Table 8 - Output Parameters
Units Definition Parameters
Displays the remaining life for the IGBTs in the line side power
module.
IGBTs in power module L0 14:140 [L0IGBT RemainLif]
Hours IGBTs in power module L1 14:240 [L1IGBT RemainLif]
… …
IGBTs in power module L9 14:1040 [L9IGBT RemainLif]
Displays the unprocessed elapsed life of the IGBTs in the line side
power module.
IGBTs in power module L0 14:139 [L0IGBT ElpsdLife]
Hours IGBTs in power module L1 14:239 [L1IGBT ElpsdLife]
… …
IGBTs in power module L9 14:1039 [L9IGBT ElpsdLife]
Displays the unprocessed elapsed life of the IGBTs in the motor side
power module.
IGBTs in power module M0 12:139 [M0IGBT ElpsdLife]
Cycles IGBTs in power module M1 12:239 [M1IGBT ElpsdLife]
… …
IGBTs in power module M9 12:1039 [M9IGBT ElpsdLife]
Fan or Blower
The following fans have the proposed fan life model implemented:
• Heatsink fan (Power module and LCL filter module blower)
• Control pod fan
• Power bay roof fan: IP54 only (frame 8…12)
• Input bay roof fan: Input bay (frame 8…9) and Control bay (frame 8…12)
• Door fan: Input bay (frame 10…12), Entry wire bay (frame 8…12), and Exit
wire bay (frame 8…12)
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
°C Temperature 0:25 [Ctrl Pod Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp]
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
Remaining 0:513 0:533 0:523 0:553 0:543
Hours Life [PodFan RemainLif] [PwrRfFanRem Life] [In FanRemainLif] [CtrlFanRem Life] [WrgFanRem Life]
Units Definition Motor Side Power Module Fans Line Side Power Module Fans LCL Filter Module Fans
Module M0 = 12:135 [M0HSFanElpsdLife] Module L0 = 14:135 [L0HSFanElpsdLife] Module LCL0 = 14:1245 [F0HSFanElpsdLife]
Elapsed Life Module M1 = 12:235[M1HSFanElpsdLife] Module L1 = 14:235 [L1HSFanElpsdLife] Module LCL1 = 14:1445 [F2HSFanElpsdLife]
Hours … … …
Module M9 = 12:1035 [M9HSFanElpsdLife] Module L9 = 14:1035 [L9HSFanElpsdLife] Module LCL5 = 14:2145 [F9HSFanElpsdLife]
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
Hours Elapsed Life 0:512 [PodFan ElpsdLife] 0:532 [PwrRfFanElpsdLif] 0:522 [In FanElpsdLife] 0:552 [CtrlFanElpsdLif] 0:542 [WrgFanElpsdLif]
DC Bus Capacitors
Airflow Health
Circuit Breakers
Circuit breakers generally have a fixed number of cycles available. This number
varies based on whether the breaker disconnect operation occurs under
electrical load.
Table 17 - Event Level and Event Action Parameters
Units Definition AC Precharge Main Circuit Breaker AC Precharge Contactor DC Precharge Molded Case Switch
% Event Level 0:578 [MCB LifeEvntLvl] 0:582 [PCC LifeEvntLvl] 0:574 [MCS Event Level]
1 or 0 Event Action 0:579 [MCB LifeEvntActn] 0:583 [PCC LifeEvntActn] 0:575 [MCS Event Action]
LCL Capacitors
Rockwell Automation has made the following components field replaceable: all
types of fans, DC bus capacitors, LCL filter capacitors, main circuit breakers in
AC precharge, precharge contactors in AC precharge, and molded case
switches in DC precharge.
IMPORTANT Do not perform a reset while the product is in an Energy Pause paused
state. See Energy Pause Function on page 71 for details.
General Instructions
Reset the Elapsed Life and Remaining Life parameters for a component after
proper replacement. Follow this general procedure to reset the parameters.
1. Go to port 0 and open parameter 0:504 [PredMain Rst En]. Set the bit for
the area that contains the new component.
2. Go to the port and area that contains the parameters that are related to
the new component.
3. Find the parameter for Predictive Maintenance Reset in that area. Then
select the component type that you just replaced.
4. Return to parameter 0:504 [PredMain Rst En] in port 0. Then clear the bit
you set in step 1.
Reset Examples
Follow these steps to reset the Elapsed Life and Remaining Life parameters for
the heatsink fan in the M0 power module in the motor side inverter.
1. Go to port 0 and open parameter 0:504 [PredMain Rst En]. Set bit 10 ‘M0’.
2. Go to the Predictive Main group in the M0 Power Module file in port 12.
3. Find parameter 12:130 [M0PredMaintReset]. Then select 1 ‘M HSFan Life’
in the drop-down menu.
Follow these steps to reset the Elapsed Life and Remaining Life parameters for
the pods on the control pod.
1. Go to port 0 and open parameter 0:504 [PredMain Rst En]. Set bit 0 ‘Port
0’.
2. Stay in port 0, and go to parameter 0:505 [Pred Maint Reset]. Then select
1 ‘PodFan Life’.
Parameter 0:505 [Pred Maint Reset] returns to 0 ‘Ready’ after the reset is
performed.
3. Return to parameter 0:504 [PredMain Rst En] in port 0. Then clear bit 0
‘Port 0’.
Configuration Examples
Now all heatsink fan events occur when 70% of the fan life is consumed. The
heatsink fan events affect the fans in the M0 motor side inverter power
module, the L0 line side converter power module, and the F0 LCL filter.
IGBT Example
Now all IGBT events occur when 60% of the IGBT life is consumed. The IGBT
events affect IGBTs in the M0 Motor Side Inverter power module and the L0
Line Side Converter power module.
Go to parameter 0:567 [IGBT Event Actn]. The value is set to ‘Alarm’ with an
internal value of 1.
When set to alarm, an IGBT event results in a numbered alarm with text to
indicate which power module is affected.
Now the control pod fan event occurs when 70% of the fan life is consumed.
When set to alarm, a Control Pod Fan event results in a numbered alarm with
text.
Monitoring Examples
This section provides instructions for monitoring the Elapsed Life and
Remaining Life.
Follow these steps to view the Elapsed Life and Remaining Life parameters for
the heatsink fan in the M0 power module in the motor side inverter.
1. In the programming tool, go to the port 12 parameters.
This group lists all of the parameters that are related to predictive
maintenance on the M0 power module.
3. Double-click parameters 12:135 [M0HSFanElpsdLife] and 12:136
[M0HSFanRemainLif].
The value for the parameter you selected appears.
Follow these steps to view the Elapsed Life and Remaining Life parameters for
the bus capacitors in the L0 power module in the line side converter.
1. In the programming tool, go to the port 14 parameters.
This group lists all of the parameters that are related to Predictive
Maintenance on the L0 Power Module.
3. Double-click parameters 14:142 [L0BusCapElpsdLife] and 14:143
[L0BusCapRmngLife].
The value for the parameter you selected appears.
Predictive Maintenance CIP This section describes the details of the Predictive Maintenance using CIP
Objects Objects for PowerFlex 755T and 755TS products that are running firmware
revision 10.xxx and later. The names and function of the Predictive
Maintenance CIP Objects are the same as the Predictive Maintenance
Parameters, the difference is in how the data is collected. CIP Objects are like
parameters in that they’re locations where data is stored but the
communication route or mapping for these locations are different. To access
CIP Objects, explicit messaging is required. Configuring these message
instructions requires the Class, Service, Instance, and Attribute for each
Predictive Maintenance data location. The PowerFlex 755T Predictive
Maintenance CIP objects are classified into three levels: Predictive
Maintenance Environmental, Predictive Maintenance Component Group, and
Predictive Maintenance Component Levels.
The Predictive Maintenance Objects are a set of CIP objects that provide a way
to organize and characterize product components and their associated
predictive maintenance data. These CIP objects are designed to be applicable
to a range of products from simple devices with a single component to large
multi-frame products with dozens of components of different types, which
provide a rich set of data for customer predictive maintenance purposes.
Figure 21 shows an hierarchical device example of the relationship between the
predictive maintenance CIP objects within a product.
Logical Group
Sub-assembly Level
Predictive Maintenance
Component (Instance 1…3)
Predictive Maintenance
Component (Instance 4…6)
… Predictive Maintenance
Component (Instance 7…n)
User
9 Maintenance Constant Get UINT Indicates the engineering units being used for the User 0x1001 = General/Count
Maximum Life Maintenance Maximum Life attribute. 0x1104 = Time/Hour
Units
(1) The Settings/Values in this column are instances.
Figure 27 - Set Notifications, Enable/Disable, Remaining Life Threshold, Remaining Life Action
Use the Pred Maint Objects tab in the PowerFlex Drives with TotalFORCE
Control Parameters Reference Data, publication 750-RD101, to select the class
and attribute: Class 0x414 Component Objects, Attribute 2 Remaining Life.
The instance is gathered from the respective component tab. In this case the
heatsink fan is listed in the Fan Group tab. Instance = 1 Heatsink Fan.
Execute the MSG instruction and capture the desired value as shown below the
value captured matches the value the graphical user interface displayed. The
value captured is 682699.
Benefits of DeviceLogix
Local control at the drive level allows for simple local control functions without
the need for programmable logic and automation controllers.
2. Add the Application DLX Only option module in the Peripherals list.
7. Click the blocks or instructions and drag and drop elements on the sheet
to add code.
8. Click one connection pin and move the cursor to another pin and then
release to interconnect items. Notice that the editor makes a connection
line.
Double-click the inputs and outputs to define the tags to use, or double-
click the function blocks to see the parameters.
Use the Tag Editor to add the tags to be used in the code.
1. Select the Show Tag Database option from the Tools menu.
The Tag Database window opens.
For example, to select digital input 0 from an I/O module in port 4, select
4:1 [Dig In Sts] bit 0 ‘Input 0’ and click Add.
Emergency Override The purpose of the function is to allow the drive or bus supply to override its
Function internal protections (faults) in emergency situations. This function is
important for applications where customers would trade product longevity for
continued running during an emergency situation.
IMPORTANT The emergency override of protections and faults can reduce the life of
the product (drive or bus supply). Their purpose is to help protect the
product from conditions that can damage the product.
The person or company that configures the override assumes
responsibility for the damage to the product from the conditions that
would otherwise have triggered the protections.
Configuration
There are two modes for the function: Only Override and Purge Frequency.
Go to parameter 0:454 [Emerg OVRD Mode] and select the desired mode.
Only Override
In Only Override mode, the product overrides faults to continue running. The
product uses its normal methods for starting and stopping. The product
follows its regular position/velocity/torque mode.
Purge Frequency
To set the Purge Frequency, go to parameter 0:457 [Purge Frequency] and enter
the speed value.
Logic Command
Program the Logix project to set bit 15 ‘Emerg OVRD’ to create an Emergency
Override command.
You cannot use both logic command and digital input in the same
configuration. The digital input takes priority over the logic command. If you
choose to configure the digital input function, selecting a nonzero value in
parameter 0:134 [DI EmergencyOVRD], disables bit 15 ‘Emerg OVRD’ in the
Logic Command.
The person or company that designs the drive or bus supply configuration is
responsible for deciding which protections the function can override. That
person or company takes responsibility for the damage to the product from the
conditions that would otherwise trigger the protections.
Set bits in parameter 0:455 [Emerg Prot OVRD] to configure the product to
override classes of protection. Each bit represents a class of protections or
faults. Set a bit to override that class of faults. Clear a bit to allow the class of
faults to stop the drive or bus supply. For example:
• Bit 0 ‘LS Ctrl Flts’ represents the faults from line-side control (port 13). If
the engineer sets this bit, these events do not stop the product (drive or
bus supply). If the engineer leaves it cleared, these events stop the
product.
• Bit 1 ‘LS Pwr Flts’ represents the faults from the line-side power (port 14)
that you can override.
Reference Motion Planners PowerFlex 750-Series drives with TotalFORCE® control provide built-in
motion planners with features for flexible configuration and generation of
Position and Velocity Reference trajectories across a wide range of
applications.
New Features
Benefits
Some applications that benefit from the resulting smooth motion are listed:
• Liquid slosh control
• Crane and hoist anti-sway control
• Cantilevered load vibration suppression
• Robot end effector oscillation
• Material and web handling
• Unidirectional anti-backup applications
• Repetitive motion profiles
• Belt and chain driving applications
This section describes how to use the Point-To-Point (PTP) Position Reference
Motion Planner. Instructions are given on how to configure each of the new
features in the order they are listed in the first section. A block diagram of the
PTP Planner is given, showing relevant parameters.
3 SpdFFRef En
0 = Rate
1406 PTP Vel Max
Adjust parameters described in the following table to setup the base PTP move
profile.
10/11:931 [Ref Move Type] provides a selection of useful move profile types with
easy switching between them.
[counts]
Pos
Sine Squared
5000
Poly5
0 LinScurve and Cubic
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[RPM]
100
Vel
50
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
5
[rev/sec 2 ]
Accel
0
-5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
20
[rev/sec 3 ]
Jerk
-20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev 2 /sec3 ]
Energy
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Overall move time is segmented into two times: acceleration time and
deceleration time. Acceleration time is applied when a trajectory is moving
away from zero velocity, while deceleration time is applied when moving
toward zero velocity. There are two ways to configure move time. Parameter
10/11:933 [Ref Time Base] can be set to ‘Rate’ or ‘Time’.
When 10/11:933 [Ref Time Base] = ‘Rate’, acceleration and deceleration times
are calculated as a function of target distance and parameters in the following
table. This is standard functionality in 750 series drives.
[counts]
Pos
1 6000 counts
10000 counts
20000 counts
0
0 0.5 1 1.5 2 2.5 3
150
[RPM]
100
Vel
50
0
0 0.5 1 1.5 2 2.5 3
5
2
[rev/sec ]
Accel
0
-5
0 0.5 1 1.5 2 2.5 3
20
[rev/sec 3 ]
Jerk
-20
0 0.5 1 1.5 2 2.5 3
Time [sec]
When 10/11:933 [Ref Time Base] = ‘Time’, you can enter acceleration and
deceleration times directly using parameters in the following table. However,
this only affects commands that are generated when 10/11:931 [Ref Move Type]
= ‘SineSquared’, ‘Poly5’, or ‘Cubic’. Rate based calculations are always applied
when 10/11:931 [Ref Move Type] = ‘LinScurve’.
[counts]
Pos
Acc= 0.5sec Dec= 1.5sec
Acc= 1.0sec Dec= 1.0sec
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4Acc= 1.5sec
1.6 Dec=
1.8 0.5sec2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
5
[rev/sec 2 ]
Accel
0
-5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
3
[rev/sec ]
20
Jerk 0
-20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.5
3
[rev /sec ]
Energy
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Adjust parameters described in the following table to set and balance dynamic
limits. Parameters 10/11:1392 [Max Speed Fwd] and 10/11:1393 [Max Speed Rev]
apply to all move types, while the remaining parameters apply when 10/11:931
[Ref Move Type] = ‘SineSquared’, ‘Poly5’, or ‘Cubic’.
Limits are typically set high to protect drive systems from dynamics they
cannot handle. Slower moves are unaffected by limits, however move
dynamics approach limits and then become limited as move times are
decreased or move distance is increased.
You can also apply limits proactively by intentionally lowering them to balance
dynamics and energy. When limited, a dwell is added to ensure the correct
area under the curve and therefore the correct trajectory. The final move time
is automatically increased for best performance if required when inputs
generate constrained circumstances. Moves will smoothly transition in and
out of velocity and acceleration limits when 10/11:931 [Ref Move Type] =
‘SineSquared’, ‘Poly5’, or ‘Cubic’.
Not Limitied
AccDec Lim = 1.5
AccDec Lim = 1.0
0
0 0.5 1 1.5 2 2.5
50
[RPM]
Vel
0
0 0.5 1 1.5 2 2.5
2
[rev/sec 2 ]
Accel
-2
0 0.5 1 1.5 2 2.5
10
3
[rev/sec ]
Jerk
-10
0 0.5 1 1.5 2 2.5
Time [sec]
[counts]
Pos
Not Limitied
AccDec Lim = 1.5
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 AccDec 1.8
1.6 Lim = 1.0 2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
2
[rev/sec 2 ]
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
10
3
[rev/sec ]
Jerk
0
-10
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.5
3
[rev /sec ]
Energy
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
The following example shows what happens when velocity limits are lowered
below what is required by an unconstrained move with adjusted acceleration
and deceleration times.
Not Limitied
Vel Lim = 40
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec 2 ]
2
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec ]
20
3
Jerk
0
-20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.5
3
[rev /sec ]
Energy
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
[counts]
Pos
EnergyBalance = 1.5
0 EnergyBalance = 1.0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 EnergyBalance
1.6 1.8= 0.5 2
[RPM]
50
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec 2 ]
2
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec ]
10
3
Jerk
0
-10
-20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
1
3
[rev /sec ]
Energy
0.5
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Parameters described in the following table are used to monitor the shape and
behavior of the configured move profile. Parameters 10/11:1404 [PTP
Reference] and 10/11:1405 [PTP VRef Fwd] apply to all move types, while the
remaining parameters apply when 10/11:931 [Ref Move Type] = ‘SineSquared’,
‘Poly5’, or ‘Cubic’.
Typical trajectories moving from rest to rest accelerate to a peak velocity and
then decelerate back to zero. When this occurs, parameter 10/11:1411 [PTP Move
Seg] = ‘AccelDecel’. However, when a move profile is initiated while another is
in motion, the new move will start at an initial velocity matching the velocity of
the previous move profile at the point of transition. When the initial velocity is
high enough, there may only be time to perform a velocity dwell and decelerate
to the new target. When this occurs, parameter 10/11:1411 [PTP Move Seg] =
‘DwellDecel’.
[counts]
Pos
AccelDecel
DwellDecel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
2
[rev/sec 2 ]
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
10
3
[rev/sec ]
Jerk
-10
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Initial velocities increase as the target distance becomes closer. In this case,
there may only be time to decelerate to the new target or decelerate to the new
target while hitting the deceleration limit. When this occurs, parameter 10/
11:1411 [PTP Move Seg] = ‘Decel’ or ‘DecelLimited’, respectively.
Decel
DecelLimited
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
500
[RPM]
Vel
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
0
2
[rev/sec ]
Accel
-50
-100
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
2000
[rev/sec 3 ]
Jerk
-2000
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Time [sec]
Initial velocities can increase so much with respect to the approaching target
distance, that there may only be time to decelerate past the new target, then
reverse back to it. When this occurs, parameter 10/11:1411 [PTP Move Seg] =
‘Reversing’.
[counts]
Pos
1
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
1000
[RPM]
500
Vel
0
2
[rev/sec ]
0
Accel
-20
-40
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
200
[rev/sec 3 ]
Jerk
-200
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
This section describes how to use the Velocity Reference Motion Planner.
Instructions are given on how to configure each of the new features in the
order they are listed in the first section. A block diagram of the Velocity
Reference Planner is given, showing relevant parameters.
VRef Ramped
VRef Ramp In 1923
1
Proc 2 [C2]
VRef Vect [E1] VRef Vect [G1]
Ref Time Base
933
0 = Rate
1934 VRef Accel Max
Adjust parameters described in the following table to setup the base Velocity
Reference move profile.
10/11:931 [Ref Move Type] provides a selection of useful move profile types with
easy switching between them.
Adjust parameters described in the following table to define your move target
velocity. You can enter a constant set point or select an input signal. Note that
as an input signal changes, the Velocity Reference motion planner acts as a
filter with a combined cam-on-cam effect.
Overall move time is segmented into two times: acceleration time and
deceleration time. Acceleration time is applied when a trajectory is moving
away from zero velocity, while deceleration time is applied when moving
toward zero velocity. There are two ways to configure move time. Parameter
10/11:933 [Ref Time Base] can be set to ‘Rate’ or ‘Time’.
When 10/11:933 [Ref Time Base] = ‘Rate’, acceleration and deceleration times
are calculated as a function of target velocity and parameters in the following
table. This is standard functionality in 750 series drives.
Figure 48 shows different target velocities for a LinScurve velocity move with a
10 second acceleration time.
When 10/11:933 [Ref Time Base] = ‘Time’, you can enter acceleration and
deceleration times directly using parameters in the following table. However,
this only affects commands that are generated when 10/11:931 [Ref Move Type]
= ‘SineSquared’, ‘Poly5’, or ‘Cubic’. Rate based calculations are always applied
when 10/11:931 [Ref Move Type] = ‘LinScurve’.
Individual acceleration and deceleration times allow you more control over
decoupling acceleration and deceleration moves. The following example shows
various moves with 5 second acceleration times and 10 second deceleration
times.
Adjust parameters described in the following table to set and balance dynamic
limits. Parameters apply when 10/11:931 [Ref Move Type] = ‘SineSquared’,
‘Poly5’, or ‘Cubic’.
Limits are typically set high to protect drive systems from dynamics they
cannot handle. Slower moves are unaffected by limits, however move
dynamics approach limits and then become limited as move times are
decreased or move distance is increased.
You can also apply limits proactively by intentionally lowering them to balance
dynamics and energy. When limited, a dwell is added to ensure the correct
area under the curve and therefore the correct trajectory. The final move time
is automatically increased for best performance when inputs generate
constrained circumstances. Moves will smoothly transition in and out of
acceleration and jerk limits when 10/11:931 [Ref Move Type] = ‘SineSquared’,
‘Poly5’, or ‘Cubic’.
The following example shows what happens when minimum and maximum
jerk limits are lowered below what is required by an unconstrained 10 second
move.
The following example shows what happens when acceleration limits are
lowered below what is required by an unconstrained move with adjusted
acceleration time.
Several parameters described in the following table are used to monitor the
shape and behavior of the configured move profile. Parameter 10/11:1923 [VRef
Ramped] applies to all move types, while the remaining parameters apply
when 10/11:931 [Ref Move Type] = ‘SineSquared’, ‘Poly5’, or ‘Cubic’.
[RPM]
Vel
1000
AccelDecel
DwellDecel
0
0 1 2 3 4 5 6 7 8 9 10
[rev/sec 2 ]
Accel
0
0 1 2 3 4 5 6 7 8 9 10
[rev/sec 3 ]
Jerk
0
-2
0 1 2 3 4 5 6 7 8 9 10
2
[rev/sec 4 ]
Snap
-2
0 1 2 3 4 5 6 7 8 9 10
Time [sec]
Initial accelerations increase as the target velocity becomes closer. In this case,
there may only be time to decelerate to the new target or decelerate to the new
target while hitting the jerk limit. When this occurs, parameter 10/11:1939
[VRef Move Seg] = ‘Decel’ or ‘DecelLimited’, respectively.
1000
Decel
DecelLimited
0
0 0.5 1 1.5 2 2.5 3 3.5 4
50
[rev/sec 2 ]
Accel
0
0 0.5 1 1.5 2 2.5 3 3.5 4
0
[rev/sec 3 ]
Jerk
-50
-100
0 0.5 1 1.5 2 2.5 3 3.5 4
500
[rev/sec 4 ]
Snap
-500
0 0.5 1 1.5 2 2.5 3 3.5 4
Time [sec]
[RPM]
Vel
0
0 1 2 3 4 5 6 7 8 9 10
30
[rev/sec ]
2
20
Accel
10
0
-10
[rev/sec ] 0 1 2 3 4 5 6 7 8 9 10
0
3
Jerk
-10
-20
0 1 2 3 4 5 6 7 8 9 10
20
[rev/sec ]
4
Snap
-20
0 1 2 3 4 5 6 7 8 9 10
Time [sec]
Topic Page
AC Line Commissioning 135
Droop Control for Parallel Operation of Bus Supplies 138
AC Line Tuning 143
Backup Generator Configuration 150
AC Line Commissioning This section covers the steps that are required to tune PowerFlex 755TL, 755TR,
and 755TM regenerative and low harmonic converters to one AC supply source.
It is a procedural guide for configuration only and therefore excludes the
detailed operational information for the parameters being adjusted.
Configuration is supported through direct parameter access as detailed in this
section or through the Regenerative Converter Setup Wizard accessible
through the Studio 5000 Logix Designer® application Add-on Profile or
Connected Components Workbench™ software. For more information on
tuning the drive to the AC line, see AC Line Tuning on page 143.
Basic Configuration
To configure the PowerFlex 755T active front end, enter basic information
about the AC Supply. The information is needed so that the drive can calculate
the system impedance and adjust the current regulator gains accordingly.
1. Enter the nominal AC line frequency in 13:30 [Nom Line Freq]
2. Verify that the selected AC Line Source in 13:31 [AC Line Source] is set to
‘AC Line A’
3. Enter the apparent power rating of the mains AC Supply transformer in
13:32 [AC Line kVA A].
4. Enter the percent impedance of the mains AC Supply transformer in
13:34 [AC Line Imped% A].
The PowerFlex 755T regenerative and low harmonic products have a couple of
methods to address this additional capacitance. If the additional capacitance
value is known, it can be directly inputted into the inverter configuration. If
the actual value is not known, the Bus Observer feature can be enabled to
compensate for the additional capacitance automatically. For more
information see Bus Observer on page 59.
5. Enter the additional capacitance value in 13:52 [Ext Bus Cap]
And/or
Enable the Bus Observer Feature by setting parameter 13:320 [BusObs
Config] to 1 ‘BusObs Only’
Limits
For most applications, the converter limits do not need to be modified from
their default values. If your application requires more restrictive limits, follow
these steps to reduce the settings. For more information about the converter
limits, see the PowerFlex Drives with TotalFORCE Control Programming
manual, publication 750-PM101.
6. Verify and adjust as required the Converter Current Limit in 13:100
[Current Limit].
7. Verify and adjust as required the Regenerative Power Limit in 13:104
[Regen Power Lmt].
8. Verify and adjust as required the Motoring Power Limit in 13:105 [Motor
Power Lmt].
Tuning
For many applications, the default settings work well. In installations with
higher system impedance, the default settings can cause resonance current in
the LCL filters. There are two approaches for reducing this resonance.
The first is to de-tune by adjusting the voltage and current bandwidths and the
second is to use the Active Damping feature. Both methods require you to
monitor the band pass filter current and adjust until the current is below the
fault threshold values that are specified in the tables in the AC Line Tuning
section of this manual. For optimum performance, it is possible to use a
combination of de-tuning and Active Damping.
Review tuning for both sources. Ideally, there is a combination that works for
both the AC line and the generator. If not, the bandwidths and/or Active
Damping values can be changed based on the currently selected AC source
through datalinks.
11. Start the drive. It is preferable that the motor is connected to the load for
the remaining steps.
12. Monitor the LCL resonance current in parameters 14:1216 [F0 Cap BPF
Cur R], 14:1217 [F0 Cap BPF Cur S], and 14:1218 [F0 Cap BPF Cur T], and
the bus voltage in parameter 14:109 [L0 DC BusVoltage].
13. Slowly adjust 13:55 [Volt Reg BW] and 13: 75 [Cur Reg BW] down by the
same percentage until the resonance current is below the fault levels.
Or, slowly reduce 13:81 [Actv Damping Gain] until the resonance current
is below the fault levels.
14. Verify that the Bus Voltage is holding at the desired level without too
much fluctuation. If not, repeat step 7 but use the other method or a
combination of the two until the resonance current is below the fault
level and bus voltage is maintaining a steady level.
15. Stop the drive.
Configuration is complete.
Except for the tuning section, use the Regenerative Converter Setup Wizard in
Connected Components Workbench software for configuration. The wizard
groups the commonly modified parameters to help expedite the
commissioning process. If the wizard shown here is used, perform the
Tuning section steps afterward to avoid LCL filter resonance.
Droop Control for Parallel Droop control of the DC bus voltage reference level is an internal process for
Operation of Bus Supplies sharing the load between multiple AFE bus supplies that are working in
parallel to energize a common DC bus. Droop control provides consistent
current and power sharing between converters so that one converter is not
subjected to a larger share of the load than the other converters. To enable
droop control in the PowerFlex 755T, set parameter 13:45 [DC Bus Ref Sel] to 2
‘Droop Ctrl’.
Overview
As the load on the bus supplies increases, the droop function manages DC bus
voltage evenly between the parallel bus supplies. The droop function
manipulates the DC bus voltage reference to control the output current from
each bus supply. Droop control manipulates the DC bus voltage reference so
that a bus supply can produce a larger share of current when the load is low
and a smaller share of current when the load is high.
In this simple example (Figure 57), we want AFE bus supply #1 to provide
roughly the same amount of current and power to the shared bus as AFE bus
supply #2. One cannot be certain the impedance from the mains to the shared
DC bus is the same between AFE bus supply #1 and AFE bus supply #2. Any
impedance mismatch can lead to a mismatch in current and power delivery. If
the path through AFE bus supply #1 has a lower impedance, then AFE bus
supply #1 delivers more power than AFE bus supply #2. Differences in loading
can produce issues with component wear and reliability, which can result in
unplanned downtime.
Shared DC Bus
Modes of Operation
There are two modes of operation: Linear and Nonlinear. The default mode of
operation is Linear. To change the mode of operation in the PowerFlex 755T,
adjust parameter 13:350 [DroopCtrlModeSel].
Linear Mode
The Linear Mode uses a piecewise linear function to determine the DC bus
voltage reference. In this function, the active current reference is the input
(X-axis). The DC bus voltage reference is the output (Y-axis).
Minimum DC Bus
Voltage
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load Motoring
Regenerating
Current Current Current Current
There are four regions of operation. The Motoring Full Load region is between
positive ‘Trans Droop Current’ and positive full load current. The Motoring No
Load region is between zero current and positive ‘Trans Droop Current’. The
Regen No Load region is between zero current and negative ‘Trans Droop
Current’. The Regen Full Load region is between negative ‘Trans Droop
Current’ and negative full load current. The value in parameter 13:353 [Trans
Droop Cur] defines the positive and negative ‘Trans Droop Current’ points on
the X-axis.
You determine the horizontal boundaries of the regions by entering the value
of parameter 13:353 [Trans Droop Cur]. This value determines the locations of
the inflection points on DC bus voltage droop curve.
In the Motoring Full Load and Regen Full Load regions, the value in parameter
13:351 [FullLd DroopGain] determines the slope of the curve. Set the value of
this parameter as percent increase in DC bus voltage reference (percent of
minimum DC bus voltage) over the positive current range (zero load to full
load).
In the Motoring No Load and Regen No Load regions, the value in parameter
13:352 [NoLd DroopGain] determines the slope of the curve. Set the value of
this parameter as percent increase in DC bus voltage reference (percent of
minimum DC bus voltage) over the positive current range (zero load to full
load).
Slope of Droop
Function
0%
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load
Regenerating Motoring
Current Current Current Current
Nonlinear Mode
The Nonlinear Mode uses a continuous curve to determine the DC bus voltage
reference. The function builds a slope curve using two of the parameters from
the Linear Mode. These are 13:351 [FullLd DroopGain] and 13:352 [NoLd
DroopGain]. It builds the slope curve with a slope at full load equal to 1.2 x
13:351 [FullLd DroopGain] and the slope at the no load point equal to 0.3 x 13:352
[NoLd DroopGain].
0%
0.3 x 13:352 [NoLd DroopGain]
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load
Regenerating Motoring
Current Current Current Current
This results in a smooth and progressive curve for the DC bus voltage
reference.
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load
Regenerating Motoring
Current Current Current Current
Consider the DC bus voltage reference at full load in the regenerating direction
with default values. The reference at that operating point is:
AC Line Tuning PowerFlex 755T regenerative and low harmonic AFE products have parameters
that tune the converter to the AC supply. Tuning lets the converter work
reliably with a wider range of supplies. You can also configure the converter to
switch between two different supplies, which supports the use of backup
generators without having to reconfigure the system.
Overview
The goal of tuning the PowerFlex 755T converter is to obtain a robust bus
supply that provides protection against under voltage and over voltage
conditions without causing resonance or instability. In addition,
• The converter can be configured for two AC line sources to facilitate the
use of a backup generator.
• The robust default current regulator and voltage regulator bandwidths
work well in most installations.
• Gains automatically adjust to the line impedance of two different AC line
sources.
• The converter can switch between AC line sources with limited
interaction.
- Via HIM, Connected Components Workbench software, and Datalinks
– all versions
- Digital Input – firmware revision 4 and later
• The converter tuning capabilities and features of PowerFlex 755T
products accommodate one AC line source or a primary source with a
backup generator.
AC Source Configuration
The first step to configure the converter is to specify some basic information
about the AC source. This basic information is used to calculate the system
impedance, which is used to calculate the current regulator gains
automatically. Table 36 shows the basic AC line source information required.
Table 36 - AC Line Source Data
Parameter No. Parameter Name Definition
13:30 Nom Line Freq 0 = 50 Hz, 1 = 60 Hz
13:31 AC Line Source 0 = AC Line A, 1 = AC Line B
13:32 AC Line kVA A Apparent Power Rating for AC Line Source A
13:33 AC Line kVA B Apparent Power Rating for AC Line Source B
13:34 AC Line Imped% A Impedance of AC Line Source A in %
13:35 AC Line Imped% B Impedance of AC Line Source B in %
system has a backup generator that switches on when the main AC line loses
power.
If the drive is not going to be powered by different sources, populate only one
set of line source data (A or B). Which set is populated does not matter as long
as 13:31 [AC Line Source] is pointing to the set with the correct line
information.
The total system capacitance is used in the automatic calculation of the voltage
regulator gains. Total system capacitance is the sum of all capacitance that is
connected to the DC bus. The drive knows its own capacitance and
automatically accounts for it in the calculations, but it does not know the
capacitance of external devices that are connected to the bus. Use parameter
13:52 [Ext Bus Cap] to specify the external capacitance so that the total system
capacitance is known. External bus capacitance is the sum of the individual
bus capacitance values for each drive and any external bus capacitors that are
connected to the DC bus.
Bus Regulators
The converter uses a cascaded control loop for voltage regulation and current
regulation. The current regulator is the inner loop and the voltage regulator is
the outer loop. This method is similar to the cascaded control loop for torque
regulation that is employed on the inverter.
After the external bus capacitance is specified, the DC bus voltage and current
regulator are tuned by adjusting parameters 13:55 [Volt Reg BW] and 13:75 [Cur
Reg BW]. The default bandwidth values of these parameters work for most
applications. The regulator gains (Kp and Ki) are set to automatically calculate
from the voltage regulator bandwidth and current regulator bandwidth. The
regulator also supports manually entered gain values.
The automatically calculated gain values for the current regulator are
displayed by parameters 13:58 [c Volt Reg Kp] and 13:60 [c Volt Reg Ki]. The
automatically calculated gain values for the voltage regulator are displayed by
parameters 13:78 [c Cur Reg Kp] and 13:80 [c Cur Reg Ki]. These read-only
parameter values are recalculated when their respective bandwidth parameter
value is changed.
The spacing between Kp and Ki gains can be varied by adjusting the damping
factor with parameter 13:56 [Volt Reg Damping]. By default, the system is
critically damped (13:56 [Volt Reg Damping] = 1.000).
Frames 10…15 have multiple LCL filter modules. The first filter module can be
used as a guide to de-tune all filter modules in the product. However, it is
recommended that you check the other modules to make sure that their
currents are below their respective threshold. Table 39 shows the parameter
numbers and thresholds for the additional modules that are based on frame
size. Table cells with a dash indicate that the frame does not have that LCL
module installed.
Table 39 - Resonance Current Thresholds
Resonance Current by Frame 400V/480V (600V/690V) [A]
LCL Module Parameters
10 11 12 13 14 15
F0 14:1216…14:1218 82 (62) 82 (62) 82 (62) 82 (62) 82 (62) 82 (62)
F1 14:1316…14:1318 — — — — — —
F2 14:1416…14:1418 41 (31) 82 (62) 82 (62) 41 (31) 82 (62) 82 (62)
F3 14:1516…14:1518 — — — 82 (62) — —
F4 14:1616…14:1618 — — 41 (31) — 82 (62) 41 (31)
F5 14:1716…14:1718 — — — 41 (31) — 82 (62)
F6 14:1816…14:1818 — — — — 82 (62) —
F7 14:1916…14:1918 — — — — — 82 (62)
F8 14:2016…14:2018 — — — — — —
F9 14:2116…14:2118 — — — — — 41 (31)
13:54 [Volt Reg C/U Sel] will automatically set to 1 ‘User Entered’ for manual
adjustment.
BusObsConfig(320):
BusObsConfig
320 BusRegIntegTerm
0- Disabled
1- BusObsOnly.
2- BusObsVltEst. 0,1 DC Bus Command BusRegPropTerm
50 VbusErr
BusObs Volt Est 2 IqRefVbusReg
c Volt Reg Ki 60
Volt Reg BW 55 0
u Volt Reg Kp 57 1
Active Current
7
Cur Reg C/U Sel 74 CurRegKiIq
Metering [I1]
VqSyncRef
PFC [G3]
c Cur Reg Ki 80 CurRegKpIq
Cur Reg BW 75 0
P
Cur Reg Damping 76 W
u Cur Reg Ki 79 1
Auto Gain M
Calculation CurRegKpId
u Cur Reg Kp 77 1
IdSyncErr CurRegdOut
AC Line Source 31
Reactv Cur Cmd 73
CurPwrLmt [G4]
PI Regulator
AC Line kVA A 32
Reactive Current
AC Line Imped% A 34
Source
8
Impedance
AC Line kVA B 33 Processing Metering [I2]
PFC [G4]
AC Line Imped% B 35
PowerFlex 755T regenerative AFE products can switch between two different
AC line sources. Set parameter 13:31 [AC Line Source] to point to the active AC
line (AC Line A or AC Line B). With firmware revision 3 and earlier, set
parameter 13:31 [AC Line Source] using the HIM, Connected Components
Workbench software, or datalinks.
With firmware revision 4 and later, you can use a digital input to switch
between AC line sources. Set parameter 0:136 [DI AC LineSource] to the digital
input that you want to use to switch sources. When the digital input is off, the
converter uses AC Line A and when it is on, it uses AC Line B.
The converter does not have AC line source-specific gains. In most cases, the
bandwidth for the high impedance line source is sufficient when connected to
a robust source. The actual current regulator gains are scaled according to the
difference in system impedance. If higher performance is desired when
connected to the robust source, you can use datalinks to change the voltage
regulator bandwidth in parameter 13:55 [Volt Reg BW], and the current
regulator bandwidth in parameter 13:75 [Cur Reg BW], based on which source
the converter is using.
When the drive is configured for generator switchover, consider how the drive
reacts to a power loss event. Use the power loss ride-through feature to pause
converter modulation and allow for switching from AC Line A to AC Line B and
vice versa. Use the application requirements and system dynamics to
configure the power loss action and power loss mode for the inverter. For
example, large inertia loads could be decelerated to keep the drive powered for
the time required for the generator to come online and start producing power.
If there is not sufficient inertia to keep the drive alive during the switchover,
you could use a separately sourced 24V DC supply to keep the drive powered
during this time. For information about configuring the drive for a power loss,
refer to the PowerFlex Drives with TotalFORCE Control programming manual,
publication 750-PM100.
Backup Generator This section covers information about how to size and select an appropriate
Configuration generator for use with a PowerFlex 755T drive along with drive configuration
guidance. Step-by-step instructions are provided in Configuration for Backup
Generator on page 152.
There are specific considerations when selecting a generator for use with an
AC drive. The first is impedance. Typically, generators have an impedance in
the range of 10% to 20% compared to 3% to 5% for a transformer that is
connected to the utility AC Supply. This higher impedance leads to larger
voltage drops when the generator is heavily loaded.
The second consideration is power factor. The industry standard for generator
manufacturers is to specify KW at a power factor of 0.8 lagging. It is important
to know the details of how the generator is rated because the PowerFlex 755T
family appears as a 0.95…0.98 power factor to the generator. When sizing the
generator, the real and apparent power must be considered. If the load power
factor is higher (closer to unity) than the rated power factor, the horsepower of
the prime mover limits the output. If the power factor is lower than the rated
power factor, the output is limited by the current rating of the generator.
Generator Selection
When sizing the generator, the alternator portion of the typical generator
rating is 150% of the load KVA requirements. Considerations that require the
generator rating to be higher than the drive include reducing the observed
voltage drop at the drive terminals. Because the impedance is a measure of the
percentage voltage drop at full load versus no load voltage, an oversized
alternator reduces the percentage current draw which results in better voltage
and frequency regulation at the drive terminals.
Another factor is the need to compensate for the drive as a non-linear load.
Most generator manufacturers do not make allowances for non-linear loads.
Regardless generators have been proven to work with drives provided the non-
linear portion of their output is only a small percentage of generator rating.
Ideally, the drives and other non-linear loads would not exceed 20% of the
generator’s total capacity.
If you use six pulse drives, a phase shifting technique can increase the
percentage of non-linear loading of the generator. The phase shifting
technique is commonly accomplished by using an isolation transformer with
one primary winding (Delta) and two secondary windings (Delta/Y). When the
drives are split between the two secondary windings, the peak current that the
generator sees is reduced due to the 30° phase shift in voltage between the two
windings.
The use a harmonic trap filter is an accepted method to reduce the effects of
non-linear loads. The filter draws current from the generator at 60 Hz. This
stored energy is used to supply the non-linear current to the drives as needed.
When using a generator as a power source, the voltage distortion can make it
difficult for drives with a SCR bridge to synchronize with the generator
frequency. For this reason, it is important to select a drive that has a Phase
Locked Loop (PLL) as part of the tracking circuit to allow the drive to respond
quickly to line frequency changes. PowerFlex 755T products use a tunable PI
controller so that the frequency and angle of the incoming voltage are quickly
and accurately tracked even in applications with large frequency oscillations.
While the default settings work well in most cases, the response can be
modified by adjusting 13:86 [Basic PLL Kp] and 13:87 [Basic PLL Ki]) to
accommodate heavily distorted voltage signals if necessary.
The PowerFlex 755T PLL has a feature that helps with generator installations
called ‘Unbalance Rejection’. This feature is a filter that allows the drive to
reject the effects of unbalanced input line voltages. When enabled, it enhances
the performance of the PLL such that no detuning is required even in
installations where the input voltage is highly unbalanced. To enable
Unbalance Rejection set bit 1 of parameter 13:85 [PLL Config] high (1). To fine-
tune the filter, modify parameter 13:89 [Unbl Rej Filt BW]. The default
Bandwidth (BW) is 200 rad/s. Increase the Bandwidth (BW) to increase the
dynamic response for faster attenuation of the unbalance effect. However, this
adjustment introduces an overshoot. Decrease the BW to reduce the dynamic
response and decrease the overshoot.
The PowerFlex 755T family lets you specify and switch between two different
AC line supplies. This capability is useful for backup generator applications
because it automatically adjusts the current regulator gains to accommodate
the difference in input impedance. There are two methods for switching the
line settings. The first is to change the value in parameter 13:31 [AC Line
Source] from the HIM, drive software, or a datalink. The second method is to
assign a physical input to parameter 0:136 [DI AC LineSource] and use a digital
input to select the source. The digital input method is only available with
firmware revision 4 and later.
Due to the high line impedance of typical generator supplies, de-tune Active
Front End converters to avoid the high resonance conditions that are caused
by an interaction between the harmonic filters and the converter control loops.
The PowerFlex 755T family of products has a feature that is called Active
Damping that mathematically creates a virtual resistor in series with the filter
capacitor, which effectively reduces the resonance without de-tuning. To use
this feature, adjust the Active Damping Gain in parameter 13:81 [Actv Damping
Gn]. Lower the gain from the default value of 1.0 to reduce resonance between
the filter and the supply due to the high impedance. By itself, it does not
provide much help with resonances due to line notching caused by other
devices that are connected to the line.
This section covers the steps that are required to configure the PowerFlex 755T
drive for use with a backup generator. It is a guide to configuration only and
excludes recommendations for sizing or design.
Basic Configuration
Enter basic information about the AC Supply and the generator to configure
the PowerFlex 755T for use with a backup generator. This information is
needed so that the drive can calculate the system impedance and adjust the
current regulator gains accordingly.
1. Enter the nominal AC line frequency in 13:30 [Nom Line Freq].
2. Enter the apparent power rating of the mains AC Supply transformer in
13:32 [AC Line kVA A].
3. Enter the apparent power rating of the generator in 13:33
[AC Line kVA B].
4. Enter the percent impedance of the mains AC Supply transformer in
13:34 [AC Line Imped% A].
5. Enter the percent impedance of the generator in 13:35
[AC Line Imped% B].
There are two methods that can be used to switch between the two AC sources
that do not require using Connected Components Workbench software or the
drive HIM to change the value in 13:31 [AC Line Source]. The method that you
chose depends on your system.
IMPORTANT Don’t change the AC line source when the converter is modulating.
The first method is to configure 13:31 [AC Line Source] as one of the datalinks
and use a programmable controller to change the value to 0 for Source A (AC
Line) or 1 for Source B (Generator). Datalinks are setup using parameters 0:321
[DL From Net 01] through 0:336 [DL From Net 16]. You can use this method
with all firmware revisions.
The second method is to configure a digital input to switch between the two
sources. When the digital input is open or de-energized, the drive uses
Source A (AC Line) data. When the digital input is closed or energized, the
drive uses Source B (Generator). This method is only available for firmware
revision 4 and later.
6. Select the first unused datalink and configure it for ‘Port13: AC Line
Source’. For example, if 0:321 [DL from Net 01] was the first datalink that
was set to ‘Disabled’, change it to ‘Port13: AC Line Source’.
Or
Configure 0:136 [DI AC LineSource] for the digital input you want to use
to facilitate the switch between sources. For example, if you wanted to
use digital input 0 on the I/O card installed in Port 4, change 0:136 [DI AC
LineSource] from ‘Disabled’ to ‘Port 4: Dig In Sts.Input 0’.
The PowerFlex 755T regenerative and low harmonic products have a couple of
methods to address this additional capacitance. If the additional capacitance
value is known, it can be directly inputted into the inverter configuration. If
the actual value is not known, the Bus Observer feature can be enabled to
compensate for the additional capacitance automatically. For more
information on the Bus Observer feature, refer to the Bus Observer section in
the Adaptive Control chapter in this manual.
7. Enter the additional capacitance value in 13:52 [Ext Bus Cap]
And/or
Enable the Bus Observer Feature by setting 13:320 [BusObs Config] to
1 ‘BusObs Only’
Tuning
For many applications, the default settings work well. In installations with
higher system impedance, as in generator applications, the default settings
can cause resonance current in the LCL filters. There are two approaches for
reducing this resonance.
The first is to de-tune by adjusting the voltage and current bandwidths and the
second is to use the Active Damping feature. Both methods require that you
monitor the band pass filter current and adjust until the current is below the
fault threshold values that are specified in the tables in the AC Line Tuning
section of this manual. You can use a combination of de-tuning and Active
Damping for optimum performance.
IMPORTANT Consider tuning both sources. Ideally, there is a combination that works
for both the AC line and the generator. If not, the bandwidths and/or
Active Damping values can be changed based on the currently selected
AC source through datalinks.
Generator
8. Configure the drive to run from the generator.
9. Start the drive. It is preferable that the drive is run in a high load
condition.
10. Monitor the LCL resonance current in parameters 14:1216 [F0 Cap BPF
Cur R], 14:1217 [F0 Cap BPF Cur S], and 14:1218 [F0 Cap BPF Cur T], and
the bus voltage in parameter 14:109 [L0 DC BusVoltage].
11. Slowly adjust 13:55 [Volt Reg BW] and 13: 75 [Cur Reg BW] down by the
same percentage until the resonance current is below the fault levels.
Or
Slowly reduce 13:81 [Actv Damping Gn] until the resonance current is
below the fault levels.
12. Verify that the Bus Voltage is holding at the desired level without too
much fluctuation. If not, repeat step 9 but use the other method or a
combination of the two until the resonance current is below the fault
level and bus voltage maintains a steady level.
13. Stop the drive.
14. Record the values in 13:55 [Volt Reg BW], 13: 75 [Cur Reg BW], and 13:81
[Actv Damping Gn].
AC Line
15. Configure the drive to run from the AC Line.
16. Start the drive. It is preferable that the drive is run in a high load
condition.
17. Monitor the LCL resonance current in parameters 14:1216 [F0 Cap BPF
Cur R], 14:1217 [F0 Cap BPF Cur S], and 14:1218 [F0 Cap BPF Cur T], and
the bus voltage in parameter 14:109 [L0 DC BusVoltage].
18. If the bus voltage is at the desired level without too much fluctuation and
the LCL filter resonance current is below the fault levels, tuning is
complete, and you can skip ahead to the Exception Actions section. If
not, continue with the remaining steps to tune for the AC Line and then
programmatically change the bandwidths and Active Damping Gain
based on which source is selected.
19. Slowly adjust 13:55 [Volt Reg BW] and 13: 75 [Cur Reg BW] up by the same
percentage until the bus voltage is at the desired level without too much
fluctuation.
20. Slowly reduce 13:81 [Actv Damping Gn] until the resonance current is
below the fault levels.
21. Record the values in 13:55 [Volt Reg BW], 13: 75 [Cur Reg BW], and 13:81
[Actv Damping Gn].
22. Select the first three unused datalinks and configure them for ‘Port13:
Cur Reg BW’, ‘Port13: Volt Reg BW’, and ‘Port13: Actv Damping Gn’. For
example, if 0:321 [DL from Net 01] was the first datalink that was set to
‘Disabled’, change 0:321 [DL from Net 01] to ‘Port13: Cur Reg BW’, 0:322
[DL from Net 02] to “Port13: Volt Reg BW” and 0:323 [DL from Net 03] to
‘Port13: Actv Damping Gn’.
23. Write logic to switch between the values that are recorded for the
Generator and the AC Line based on which source is selected.
Exception Actions
One of the things to consider when using a backup generator is how the drive
responds to a power loss. While the default settings for power loss work in
many applications, you can customize them for your application.
Converter
24. Review parameter 13:170 [PwrLoss Det Actn] to make sure it is set
correctly for your application and modify as required.
25. Review parameter 13:172 [RideThrough Time] to make sure it is set
correctly for your application and modify as required.
Inverter
26. Review parameter 10/11:270 [Power Loss Actn] to make sure it is set
correctly for your application and modify as required.
27. Review parameter 10/11:273 [Pwr Loss A Time] to make sure it is set
correctly for your application and modify as required.
The PowerFlex 755TR and 755TM products can limit the amount of
regenerative energy that gets transmitted back to the supply. This capability
makes them an option when it is desirable to regenerate back to the line when
connected to AC Line but limit regeneration when being supplied by a
generator. The recommendation is to set the Regenerative Power Limit to 5%
when being supplied by a generator. Through datalinks or DeviceLogix
functionality, the limits can be adjusted programmatically to allow full
regeneration when connected to the AC Line but still limit to 5% when
connected to the generator.
If you are using a PowerFlex 755TL, you can skip this section. If you are using a
PowerFlex 755TR or 755TM, follow the remaining steps to configure the
Regenerative Power Limit.
Static Limit
28. Set parameter 13:104 [Regen Power Lmt] to 5%.
Dynamic Limit
29. Select the first unused datalink and configure it for ‘Port13: Regen Power
Lmt’. For example, if 0:321 [DL from Net 01] was the first datalink that
was set to “Disabled”, change 0:321 [DL from Net 01] to ‘Port13: Regen
Power Lmt’.
30. Write logic to switch between 5% for the Generator and the desired
regeneration level for the AC Line based on which source is selected.
Topic Page
High Speed Trending 157
Faults and Alarms 164
Input Phase Loss Detection 168
High Speed Trending The high speed trending wizard configures the onboard trending feature
providing high sample rate data capture. The wizard allows you to download
the trend configuration to the drive, and uploads the trended data from the
drive when finished. This information is saved as a comma-delimited *.csv file
for use with Microsoft® Excel® or any other spreadsheet program.
The high speed trending can be configured to trend either four, eight, or
sixteen parameters. The number of parameters that are trended effects the
sample size and sample rate. See Table 40 to determine the high speed
trending tool capabilities are based on the number of parameters being
trended.
The PowerFlex 755T drive can only run one instance of the onboard high speed
trending tool. Once the wizard has downloaded the high speed trend
configuration to the drive, you do not have to stay connected to the drive with
the software tool. The drive automatically captures data based on the triggered
event in the wizard configuration. You reconnect to the drive to upload the
trended data.
The configurable sample rate of the onboard high speed trending tool makes it
an alternative option to other trending tools available in Logix or Connected
Components Workbench™ software. The RPI (requested packet interval) of the
device defines the software tool sample rates. The PowerFlex 755T has a
minimum RPI of 2 ms. The onboard high speed trend tool in the PowerFlex
755T is a useful resource to:
• Determine application specific tuning characteristics
• Troubleshoot nuisance trip conditions
• Capture data before and after a triggered event
• Capture data when a user is not actively connected to the drive
Configuration Example
1. Connect to the PowerFlex 755T with the Connected Components
Workbench software tool.
2. Navigate to the Wizards on the left panel.
3. Select the High Speed Trend Wizard from the options.
The Configuration Trend window lets you customize the following high-speed
trend details:
• Trend Mode – dictates number of trend butters, total number of samples,
and the minimum interval sample rate
• Pre-Trigger samples – dictates number of samples to include in the trend
before the trigger
• Sample Interval – the time interval between trend data samples
• Trigger Setup – dictates how the data trend is triggered
- Compares two parameters
- Compares a parameter against a constant
- A test bit in a parameter
• Trend Buffers – dictates the drive and/or peripheral parameters and
diagnostic items that are trended
5. To configure the Trigger Setup and Trend Buffers, click the Ellipse.
If you do not see the ellipse for the Trend Buffers, click in the first
row of ‘Not Used’, and the ellipse populates the row.
6. Select the parameter that you want to log by selecting the port, and then
scroll through the parameter lists, file folders, diagnostic items, or use
the find function. Once a parameter is selected, click Apply.
In the example below, the trend buffers are configured with five drive
parameters consisting of Output Frequency, Pri Vel Feedback, DC Bus
Volts, Output Current, and Output Voltage parameter values. The trend
is configured for a total of 4096 samples that include 500 samples before
the trigger, at a sample rate of 1 millisecond. The trigger of the high speed
trend is the Motor Velocity Feedback greater than zero.
8. Click Start to start the trend tool. The ‘Trend Status’ changes to
‘Running.’ Upload and Start are unavailable when the trend is running.
Depending on the trigger configuration, the trend tool may not
start storing data until the trigger is tripped.
The ‘Trend Status’ changes to ‘Finishing’ after the buffers for all
parameters have filled, and the trend is processing the data. Press Stop at
any point to start the trend before the buffers are filled.
9. Click Upload. The wizard uploads the trend data from the drive and saves
the information as a comma-delimited *.csv file for use with Microsoft®
Excel® or any other spreadsheet program.
For more information on the High Speed Trend Wizard, reference the
block diagram that is published in the PowerFlex Drives with
TotalFORCE Control programming manual, publication 750-PM100.
Rockwell Automation Publication 750-RM100C-EN-P - August 2022 163
Chapter 4 Diagnostics and Troubleshooting
Faults and Alarms This chapter provides information about the faults and alarms that are
accessible through software or the HIM, and status indicators that are used to
report the current operating condition of the PowerFlex product.
Faults
Faults are events or conditions occurring within and/or outside of the drive.
These events or conditions by default are considered to be of such significant
magnitude that drive operation is discontinued. The STS (Status) indicator on
the drive, a HIM, communications network, and/or contact outputs
annunciate faults.
With frames 7…15 drives and bus supplies, the power and precharge modules
use status indicators and a 7-segment display to report conditions. The fiber-
optic interface and transceiver circuit boards also use a status indicator to
report conditions.
When a fault occurs, the fault condition is latched, which requires that you or
the application perform a fault reset to clear the latched condition. The
condition that caused the fault determines the user response. If the condition
that caused the fault still exists after a fault reset, the drive faults again and the
fault condition is latched.
The fault code is entered into the first buffer of the fault queue (see the Fault
Queue section for rules). Additional data on the status of the drive at the time
that the fault occurred is recorded. This information is always related to the
most recent fault queue entry captured by 0:610[Last Fault Code]. When
another fault occurs, this data is overwritten.
The following data/conditions are captured and latched into non-volatile drive
memory.
• Port 10/11:461[Fault Status A]
• Port 10/11:462 [Fault Status B]
• Port 13:240 [Fault Status A]
• Port 13:241 [Fault Status B]
Fault Queue
Faults are also logged into a fault queue, such that a history of the most recent
fault events is retained. Each recorded event includes a fault code (with
associated text) and a fault ‘time of occurrence.’ PowerFlex 755T drives have a
100-event queue.
The fault queue records the occurrence of each fault event that occurs while no
other fault is latched. Each fault queue entry includes a fault code and a time
stamp value. New fault events are not logged to the fault queue if a previous
fault has already occurred but has not yet been reset. Only faults that actually
trip the drive are logged. Faults that occur while the drive is faulted are not
logged.
The fault queue is a first-in, first-out (FIFO) queue. Fault queue entry 1 is
always the most-recent entry (newest). Entry 100 is always the oldest. As a new
fault is logged, each existing entry shifts by one. The previous entry 1 moves to
entry 2, previous entry 2 moves to entry 3, and so on. If the queue is full when a
fault occurs, the oldest entry is discarded.
The fault queue is saved in nonvolatile storage at power loss and its content is
retained when power is cycled.
The fault code with descriptive text for each entry can be viewed with a HIM or
by software tools like Connected Components Workbench software (CCW) or
Logix Designer application.
Once the fault code is displayed, pressing the enter key again on the HIM
displays the time stamp that is associated with that fault code. The time stamp
is the elapsed time since the fault occurred. When using one of the available
software tools, the fault code, descriptive text, and time stamp are displayed
simultaneously.
• Cycle power to the drive such that the control board goes through a
power-up sequence.
A fault reset clears the faulted status indication. If any fault condition still
exists, the fault is relatched and another entry is made in the fault queue.
A fault reset does not clear the fault queue. Clear the fault queue from a menu
selection on the HIM or click Clear Queue in the Fault/Alarms section of CCW
or Logix Designer application tools.
Event Actions
The drive can be configured such that some events or conditions do not trip
the drive.
The following is a list of the options that are available for the drive configurable
event actions.
• ‘Ignore’ – No action is taken.
• ‘Alarm’ – Type 1 alarm indicated.
• ‘Flt Minor’ – Minor fault indicated. If running, drive continues to run.
• ‘FltCoastStop’ – Major fault indicated. Coast-to-stop.
• ‘Flt RampStop’ – Major fault indicated. Ramp to Stop.
• ‘Flt CL Stop’ – Major fault indicated. Current Limit Stop.
The following is a brief list of configurable event actions that are listed by port.
Accessories such as encoder or I/O modules have additional configurable event
actions.
Alarms
Alarms are indications of situations that are occurring within the drive or
application that are annunciated to the user. These situations can affect the
drive operation or application performance. Conditions such as power loss or
analog input signal loss can be detected and displayed for drive or operator
action.
The alarm queue is accessible through a HIM or through CCW and Logix
Designer application tools, provide you with a history of faults, alarms, and
events. You can also access diagnostic file parameters for additional
information.
Input Phase Loss Detection Occasionally, three-phase power sources can fail on one phase while
continuing to deliver power between the remaining two phases (single-phase).
Operating above 50% output under this single-phase condition can damage the
drive. The 755T product has two separate methods dependent on hardware
configuration to detect this condition.
• For drives without active front end technology, the input phase loss
detection is implemented by hardware that measures DC bus voltage
harmonics. This protection is implemented in port 10.
• For drives with active front end technology, input phase loss detection is
implemented by hardware that measures the input line voltage and
current. This protection is implemented in port 13.
The drive can be programmed to turn on an alarm bit or issue a drive fault
(minor or major). Active front end drives can also be programmed to ride
through.
• For Powerflex 755T and 755TS, we recommend that input phase loss
detection is enabled in port 10 if this condition is likely to occur.
• For Powerflex 755Tand 755TS products with DC input we recommend
that input phase loss detection is enabled in port 10 if the bus supply is a
simple rectifier with limited diagnostics.
• For Powerflex 755T with active front end technology, we recommend
implementing input phase loss detection in port 13 if the condition is
likely to occur. Ride through can be enabled if the condition is short
duration.
The following bits configure the port 10 input phase loss action.
• ‘Ignore’ (0) – No action is taken.
• ‘Alarm’ (1) – Type 1 alarm indicated. Type 1 alarms are notifications. They
do not prevent starting. They do not stop modulation.
• ‘Flt Minor’ (2) – Minor fault indicated. Minor faults prevent the drive
from starting. They do not stop the drive, if it is already running. You
must clear the fault to start or run.
• ‘FltCoastStop’ (3) – Major fault indicated. The motor side inverter
executes a Coast Stop. You must clear the fault to start or run.
• ‘Flt RampStop’ (4) – Major fault indicated. The motor side inverter
executes a Ramp Stop. You must clear the fault to start or run.
• ‘Flt CL Stop’ (5) – Major fault indicated. The motor side inverter executes
a Current Limit Stop. You must clear the fault to start or run.
If a fault action has been selected because of port 10 input phase loss, 10/11:461
[Fault Status A] bit 4 ‘InPhaseLoss’ is set.
If an alarm action is selected because of port 10 input phase loss, 0:465 [Alarm
Status A] bit 4 ‘InPhaseLoss’ is set.
For drives with an active front end, input phase loss is configured in port 13. In
this instance, 10/11:289 [InPhase LossActn] can be set to ignore. The following
two parameters configure the input phase loss action.
Select the action taken when the port 13 input phase loss condition is detected.
• ‘Ignore’ (0) – No action is taken.
• ‘Type 2 Alarm’ (1) – A Type 2 Alarm occurs. Type 2 Alarms prevent the line
side converter from starting its modulation.
• ‘Ride Thru’ (2) – The line side converter pauses modulation for the
duration of the Ride Thru Timer. If the Input Phase Loss condition clears
before the timer expires, it resumes operation. During the Ride Thru
attempt, it logs a Type 2 Alarm.
• ‘Major Fault’ (3) – A Major Fault occurs immediately. Major Faults stop
the line side converter from modulating.
If an alarm or fault action is selected by the firmware as a result for the input
phase loss, 13:225 [Line Side Sts 1] bit 22 ‘InPhaseLoss’ is set.
If a fault action is selected by the firmware as a result for the input phase loss,
13:240 [Fault Status A] bit 20 ‘InPhaseLoss’ is set.
Sets the threshold for the Input Phase Loss detection function. Decreasing this
value increases sensitivity, increasing the value decreases sensitivity. When all
three input phases are connected, the sixth harmonic is dominant. When one
phase is disconnected, the second harmonic is dominant If the ratio exceeds
this threshold, the function detects an Input Phase Loss count. A certain
number of events are required to enact the Input Phase Loss action.
This is just a different way of saying that if you know you are going to run
single phase, derate the drive by 50%.
Test points are available to assist in adjusting the phase loss level.
• Test point 105 indicates the active ratio of second harmonics amplitude
to sixth harmonics
• Test point 106 indicates the active input phase loss counts
Notes:
Application References
Topic Page
PowerFlex 755T Lifting/Torque Proving 173
Anti-Sway Applications 191
Dynamic Braking 201
Dynamic Bus Control 212
Carrier (PWM) Frequency 221
Analog Inputs 222
Analog Outputs 230
Digital Inputs 235
Digital Outputs 246
PTC Motor Thermistor Input 255
PowerFlex 755T Lifting/ TorqProve™ is a PowerFlex 755T drive feature that is intended for applications
Torque Proving that require proper coordination between motor control and a mechanical
brake. Before releasing a mechanical brake, the drive checks motor output
phase continuity and verifies proper motor control (torque proving). The drive
also verifies that the mechanical brake has control of the load before releasing
drive control (brake proving). After the drive sets the brake, it monitors motor
movement to confirm that the brake can hold the load.
Overview
• Micro positioning
• Fast Stop
• Speed Deviation Fault, Output Phase Loss Fault, Encoder Loss Fault.
IMPORTANT Brake Slip detection and Float capability (ability to hold load at zero
speed) are no available in encoderless TorqProve.
Torque Proving Flow Diagram
Operator Run Run
Commands Command Command Released
Time
Drive Running
9:60 [Brk Release Time] 9:72 [ZeroSpdFloatTime] 9:61 [Brk Set Time]
All times between Drive Actions are programmable and can be made very
small (for example, Brake Release Time can be 0.1 seconds)
(1) For torque proving to function properly, wire a mechanical brake to a Brake
relay output on a digital I/O option module. On the I/O module, set nn:10 Relay
[RO0 Sel] to 9:52 [Trq Prove Status] Bit 4 ‘Brake Set’ and set nn:6 [Dig
Out Invert] Bit 0 ‘Relay Out 0’ = 1. R0NO
R0C
Control
Voltage
If an encoder is being used, by default, the drive does a brake slip test on every
stop. The brake slip test is outlined in the following steps.
1. A stop command is initiated
2. The drive ramps to zero speed. A snap shot (one time recording) of the
command torque 10/11:2087 [Trq Ref Limited] is taken.
3. The drive runs at zero speed for the time that is defined in 9:72
[ZeroSpdFloatTime].
4. The drive engages the brake.
5. The drive continues to command the snap shot torque that is found in
step 2 for the time that is allotted in 9:61 [Brk Set Time].
6. The PowerFlex 755T drive begins to slew (lower) the torque down.
Parameters 10/11:2083 [Torque Limit Pos] and 9:53 [Trq Lmt SlewRate]
define the rate at which the torque is lowered. The starting point of the
ramp is the commanded torque that is found in step 2 plus 20% torque.
The drive continues to command the torque that is defined in step 2 until
the ramp goes below this torque.
7. During the torque slew defined in step 6, the drive is monitoring the
encoder counts. If the drive detects a delta (change) in encoder counts
greater than 9:63 [Brk Slip Thresh], the drive brings the torque back up to
the torque level that is defined in step 2.
8. The PowerFlex 755T drive repeats steps 6 and 7 until the drive no longer
sees a change in encoder counts that is greater than the threshold in 9:63
[Brk Slip Thresh].
9. If no brake slip is found, the drive turns off and sits stopped and ready,
and waits for the next run command. If a brake slip is found in step 7,
once the drive lowers the load to the floor, the drive enunciates a 11012
‘Brake Slipped Stop’ alarm. The drive does not accept a run command
again until it’s reset or power is cycled to the drive.
To add additional brake control capabilities to the PowerFlex 755T drive when
using an encoder, see Brake Proving Configuration on page 176.
Configuration
You must configure the PowerFlex 755T drive before you access any TorqProve
parameters for configuration and commissioning. you can configure the drive
through Connected Components Workbench™ software or via parameter
settings in the HIM.
To configure the PowerFlex 755T drive via the HIM, follow these steps.
1. Navigate to 0:70 [Application Sel].
2. Click the ‘edit’ soft key and change 0:70 [Application Sel] = 2 ‘Torque
Prove’
3. To accept changes, click the ‘enter’ soft key.
4. Power cycle the drive.
Bus Regulation
By default, the drive is testing for brake slip only during Brake Slip Test, step 7
(see Brake Slip Test on page 174). If the brake fails while the drive is stopped,
the load can suddenly drop to the floor. To have the drive monitor for brake slip
while the drive is stopped, set 9:50 [Trq Prove Cfg] bit 6 ‘BrkSlipStart’. With this
bit set, if the drive detects a brake slip while the drive is stopped, the drive
starts up and takes control of the load, goes into a brake slip test, and lowers
the load to the floor. When the drive detects a brake slip in this manner (from a
stopped state), the drive allows one start after the load reaches a safe position
to move the load. After this point, the drive enunciates a Brake Slipped alarm
and a power cycle is required to restart the drive.
If the drive is set up for encoderless torque proving, there’s no brake slip test.
After stopping, the drive engages the brake when the motor speed falls below
the setting in 9:70 [Float Tolerance].
It’s important that you enter all motor data correctly. When using PowerFlex
755T Autotune features, it’s recommended to disconnect the motor from the
hoist/crane equipment during the tests. It’s recommended that Parameter 10
of the I/O card that is wired to the brake control is set to 10/11:354 [Motor Side
Sts 1] bit 1 ‘Active’, so that the brake releases when the motor starts to run.
Permanent Magnet motor control mode isn’t compatible with the TorqProve
feature.
5. To accept the change to the motor control selection, click OK.
7. Click OK.
IMPORTANT You must cycle power or reset the drive (Reset Device) to load
the value of these parameters.
2. Re-establish a connection with Connected Components Workbench
software. Navigate to port 0.
3. To verify the configuration, navigate to ‘Actual’ feedback parameters:
0:34 [VoltageClass Act] 0:47 [Vel Units Act] 0:71 [Application Act]
0:36 [Duty Rating Act] 0:66 [Pri MtrCtrl Act]
Parameters 5:1 [Encoder Cfg] and 5:2 [Encoder PPR] when using a
20-750-ENC-1 in slot 5.
6. Confirm the value of parameter 5:3 [Fdbk Loss Cfg] is 3 ‘FltCoastStop’.
When the motor is connected to a load, verify that there’s enough travel
distance for the Rotate Motor ID Test sequence to complete. If necessary, run
out the crane hook for more travel distance in the opposite direction.
We recommend that you run the Rotate Motor ID Test. If you can’t perform the
Rotate test to completion, perform the Static Motor ID Test instead.
IMPORTANT Confirm that the Rotate Motor ID Test can be stopped if an end travel
condition is likely to occur.
Confirm that the crane has control of the load at the end of the test.
Manually engage the brake at the end to prevent the load from
dropping.
1. Verify that the brake is disengaged.
2. Navigate to parameter 10/11:1898 [Vel Limit Pos] and enter a value of 40%
of maximum speed.
3. Navigate to parameter 10/11:910 [Autotune] and enter a value of 3 ‘Rotate
MtrID’.
4. Start the drive.
5. When the test is complete, manually engage the brake.
6. Navigate to parameter 10/11:510 [MtrParam C/U Sel]. Select a value of 1
‘User Entered’. This selects the measured results from the Rotate Motor
ID test, instead of the values estimated from the motor nameplate data.
Perform this test if you can’t perform the Rotate Motor ID Test. If you can
perform that test, skip to Confirm Flux-up Time.
1. Set the brake.
2. Navigate to parameter 10/11:910 [Autotune] and enter a value of 2 ‘Static
MtrID’.
3. Start the drive.
4. When the test is complete, navigate to parameter 10/11:510 [MtrParam C/
U Sel]. Select a value of 1 ‘User Entered’. This selects the measured results
from the Static Motor ID test, instead of the values estimated from the
motor nameplate data.
‘Active High’ control sets or engages the brake when the signal is
energized.
‘Active Low’ control sets or engages the brake when the signal is de-
energized.
2. Navigate to the port that contains the IO option card.
For ‘Active High’ control, set the value to 9:52 [Trq Prove Status] bit 4
‘Brake Set’
or
For ‘Active Low’ control, set the value to 9:52 [Trq Prove Status] bit 8
‘BrakeRelease’.
Confirm Configuration
1. Check brake control.
2. Run the crane up and down without the load.
3. Run the crane up and down with the load.
4. If necessary, adjust the acceleration and deceleration times.
10/11:1915 [VRef Accel Time1] 10/11:1917 [VRef Decel Time1]
5. If the 10007 TorqPrv Spd Band fault occurs, investigate the following:
• Verify that the brake is disengaging properly. A faulty brake rectifier
can cause this fault.
• Verify that the current limit isn’t impeding acceleration and
deceleration. The drive is undersized or the acceleration and
deceleration times are too short.
• Verify or adjust parameter 9:54 [Speed Dev Band] and/or parameter
10/11:906 [System BW].
• Verify that the position, velocity, and torque loops are tuned properly.
See the PowerFlex 755T Flux Vector Tuning Manual, publication
750-AT006.
Crane Setup—Encoderless
Review the Attention statement that follows if you intend to use the TorqProve
feature without an encoder.
ATTENTION: You must read the following information before you can use
TorqProve with no encoder.
Encoderless TorqProve must be limited to lifting applications where personal
safety isn’t a concern. Encoders offer additional protection and must be used
where personal safety is a concern. Encoderless TorqProve can’t hold a load
at zero speed without a mechanical brake and does not offer additional
protection if the brake slips/fails. Loss of control in suspended load
applications can cause personal injury and/or equipment damage.
It is your responsibility to configure drive parameters, test any lifting
functionality, and meet safety requirements in accordance with all applicable
codes and standards. If encoderless TorqProve is desired, you must certify
the safety of the application. To acknowledge that you have read this
‘Attention’ and properly certified the encoderless application, set bit 3
‘EnclsTrqProv’ of parameter 10/11:420 [Mtr Cfg Options] to a value of 1. This
action removes Alarm 9014 ‘TP Encls Config’ and allows bit 1 ‘Encoderless’ of
parameter 9:50 [Trq Prove Cfg] to be changed to 1 enabling encoderless
TorqProve.
Permanent Magnet motor control mode isn’t compatible with the TorqProve
feature.
7. Click OK.
IMPORTANT You must cycle power or reset the drive (Reset Device) to load
the value of these parameters.
2. Re-establish a connection with Connected Components Workbench
software. Navigate to port 0.
3. To verify the configuration, navigate to ‘Actual’ feedback parameters:
0:34 [VoltageClass Act] 0:47 [Vel Units Act] 0:71 [Application Act]
0:36 [Duty Rating Act] 0:66 [Pri MtrCtrl Act]
IMPORTANT During this test, the drive uses an internal reference that is positive
(forward). During operation and other tests, the drive uses an external
reference that you select. An external reference can include the HIM,
analog input, or communicated reference. The direction of rotation
depends on the polarity (direction) of that external reference. Make
sure the external reference moves the motor in the intended direction.
1. Stay at port 10, which is the port for Motor Side Inverter Control.
2. Navigate to parameter 10/11:910 [Autotune] and enter a value of 1
‘Direction Test’.
3. Start the drive. You can use the control bar feature in Connected
Components Workbench software, the start key on the HIM or the
normal start signal.
4. Verify that the motor direction is forward.
5. Verify the polarity of the encoder feedback.
• Navigate to parameter 10/11:1832 [Enc VRef Sel] and select the encoder
feedback on the feedback card in port 5. The value would be 50004
‘Port 5: Enc 0 FB’ when using a 20-750-ENC-1 in slot 5.
• View the result in parameter 10/11:1834 [Enc VRef].
6. Stop the drive from the control bar feature in Connected Components
Workbench software, the stop key on the HIM, or the normal stop signal.
7. Address the direction.
• If the direction is forward, proceed to next step.
• If the direction is reverse, power down and physically reverse the
motor leads.
During the Rotate Motor ID Test, the motor rotates for around 15 seconds in
the commanded direction. It runs at speeds up to 75% of motor nameplate
speed. You can execute this test with the motor that is disconnected from the
crane or with a lightly loaded condition. Lightly loaded conditions include
motor that is connected to gearbox, cable drum, or cable and hook.
It’s preferable to run the Rotate Motor ID Test. If you can’t perform the Rotate
test to completion, perform the Static Motor ID Test instead.
IMPORTANT Verify that the Rotate Motor ID Test can be stopped if an end travel
condition is likely to occur.
Verify that the crane has control of the load at the end of the test.
Manually engage the brake at the end to prevent the load from
dropping.
IMPORTANT An alarm indicates that the drive is in the state that is described on
page 184. Carefully read the Attention statement and acknowledge it by
setting the required parameter.
3. Navigate to the following parameters and enter the data for the crane
application.
9:53 [Trq Lmt SlewRate] 9:54 [Speed Dev Band] 9:55 [SpdBand Intgrtr]
9:60 [Brk Release Time] 9:61 [Brk Set Time] 9:62 [Brk Alarm Travel]
9:63 [Brk Slip Thresh] 9:64 [Brake Test Torq] 9:68 [DI Brake Fdbk]
9:70 [Float Tolerance] 9:71 [MicroPsnScalePct] 9:72 [ZeroSpdFloatTime]
9:78 [DI FloatMicroPsn]
Confirm Configuration
1. Check brake control.
2. Run crane up and down without load.
3. Run crane up and down with load.
4. If necessary, adjust the acceleration and deceleration times.
10/11:1915 [VRef Accel Time1] 10/11:1917 [VRef Decel Time1]
5. If the 10007 TorqPrv Spd Band fault occurs, investigate the following:
• Verify that the brake is disengaging properly. A faulty brake rectifier
can prevent the brake from disengaging.
• Verify that the current limit isn’t impeding acceleration and
deceleration. The drive is undersized or the acceleration and
deceleration times are too short.
• Verify or adjust parameter 9:54 [Speed Dev Band] and/or parameter
10/11:906 [System BW].
• Verify that the position, velocity, and torque loops are tuned properly.
See the PowerFlex 755T Flux Vector Tuning Manual, publication
750-AT006.
Anti-Sway Applications Anti-Sway is a PowerFlex 755T drive feature that helps to minimize the
pendulum effect that can occur when a trolley/gantry of a crane/hoist system
moves a suspended load. The distance between the trolley and the load
determines the sway frequency. This frequency can be notched from the
velocity/position command of the drive so that the pendulum effect on the load
isn’t excited because of a horizontal move. The pendulum can still be excited
from external disturbances such as wind or from nonzero initial conditions
like picking up a load off center.
Reference notch filters are the main feature that is used to control sway by
suppressing the sway frequency during position/velocity reference changes.
There are two notch filters in the reference path that modify the ramped
reference profile. Values of notch filter parameters can be entered manually or
calculated automatically based on hoist cable length.
Velocity Reference (%)
Ramped Ref
Filtered Ref
Time (ms)
The reference notch filters are applied to the horizontally moving axes, that is
the trolley and gantry sections of a crane.
• Reference notch filters can be applied to V/Hz, Sensorless Vector, and
Flux Vector motor control modes
• Reference notch filters only affect the motion of the axis due to changing
speed references.
• Reference notch filters can be applied to velocity, position, and process
control reference sources.
• Anti-sway control doesn’t use any load sway feedback sensors.
• Anti-sway control can’t compensate for sway induced by external forces
such as wind or unbalanced loads.
Trolley Motion
Trolley
Gantry
Hoist
Payload
Payload Trajectory
Gantry Motion
Gantry Track
The PowerFlex 755T with TotalFORCE control includes tunable reference notch
filters that are in the velocity, position, and process control reference paths
after the ramp generator.
Two separate reference notch filters (NF1 and NF2) are provided to tune the
anti-sway control more closely for varying or unknown sway frequencies.
931 One
1017
Ref NF2 Freq 948 Ref Move Type Scan
Ref NF2 Width 949 Delay Virtual EncDelay
Virtual Encoder
PRef 1 [C5]
Ref NF2 Depth 950 1
Ref NF2 Gain 951
VRef Filtered
VRef NF In
1925
36
Ref NF2 Ref NF1
Accel FF Output
Velocity Comp
2070
Vel Comp Sel
0
1927
Accel FF Output Not Used
1 0
0 Trq Ref [A2] Vel Comp Out
Ramped Ref 1 d 1930 From Anti-Sway [D2]
140 Cur Lmt Stop dt VRef Psn FF
OR Rate Ref 2 35 1760 c Vel FF Gain
1931 Speed 954 Ref NF1 Freq Act
0
130 LineLoss Act Comp
956 Ref NF1 Depth Act
x 1761 u Vel FF Gain
FF Vel Rate Ref
c Vel Comp Gain 1928 1 Vel FF
957 Ref NF1 Gain Act 0
u Vel Comp Gain 1929 943 Ref NF1 Width PRef 1 [I5]
354 17 1752
Notch Filters are band attenuating filters that allow frequencies above and
below the filter center frequency to pass unattenuated. Frequencies near the
center frequency are sharply attenuated.
Notch Filter
Bandwidth
Amplitude
Notch Filter
Frequency
Frequency
-3 dB
Notch Filter
Damping
The reference notch filter frequency (f) calculation in [Hz] is a function of cable
length (L) and the acceleration of gravity (g).
1 g
f = ------ --
2 L
Where…
f = filter center frequency in Hertz
g = acceleration due to gravity 9.81 m/sec2, 32.17 ft/sec2, 386.09 in/sec2
L = length from cable pivot point to load center of gravity (meters, feet, or
inches)
Motion
Load
The mass or weight of the Load does not affect the notch filter frequency
calculation.
When performing this calculation, you can use any set of consistent unit
systems.
Based on the application, the cable length can vary between a minimum and
maximum length (Lmin and Lmax), which results in a varying sway frequency.
The range of such length change can determine the system configuration.
Lmin
Load
Lmax
Load
The following experimental result shows how deviation from the actual cable
length affects the sway magnitude when the filter frequency does not
accurately match the sway oscillation frequency. The sway magnitude
increases as the cable length error becomes higher as shown in Figure 65.
5
4
3
2
1
0
-60% -40% -20% 0% 20% 40% 60%
Cable Length Implied by Notch Filter / True Cable Length
In this configuration, one of the reference notch filters is set to match the
maximum crane length (Lmax).
This method provides good anti-sway compensation and fast settling time for
moderate variations in hoist cable length.
NF1 reference notch filter frequency calculation.
1 g
f NF1 = ------ -------------
2 Lmax
Load
Lmax
Load
With this configuration, one of the reference notch filters is set to match the
average cable length (Lavg).
The other reference notch filter is set to match the maximum cable length
(Lmax).
This method provides better anti-sway compensation than the single filter but
can cause longer move times.
1 g
f NF1 = ------ ------------------------------------------
2 Lmin + Lmax 2
1 g
f NF2 = ------ -------------
2 Lmax
Lmin
Load
(Lmin + Lmax)/2
Lmax
Load
1 g 1 9.81
f NF2 = ------ ------------- = ------ -------- = 0.111Hz
2 Lmax 2 20
1 g
f NF1 = ------ --
2 L
Lmin
Load
Lmax
Load
Where…
g = acceleration due to gravity 9.81 m/sec2
L = actual cable length in meters
E M E M E M
Within the Logix controller program task, calculate the cable length from hoist
motor encoder feedback. We can assume a linear relationship between the
crane length (L) and the encoder counts (X), as:
Xcurrent – Xoffset
CraneLength L = ------------------------------------------
CalConst
Where…
L = current crane length in meters
Xcurrent = current hoist motor encoder feedback counts
Xoffset = hoist motor encoder offset counts
Cal Const = encoder calibration constant in counts/meter
The value of Xoffset must be set such that when the hoist is at maximum
operating height the crane length (L) is equal the measured Lmin from the pivot
point in meters.
It’s important that the crane length (L) isn’t equal to or less than zero.
To find the calibration constant (Cal Const), two given points are required: L1
and L2, which can be obtained by measuring the cable length at two arbitrary
points and capturing the corresponding hoist encoder counts, X1 and X2.
CalConst = ---------------------
X2 – X1
-
L2 – L1
Load
L1
Corresponding to X1 counts
L2
Corresponding to X2 counts
Load
Where…
Cal Const = encoder calibration constant in counts/meter
X1 = encoder counts at L1
X2 = encoder counts at L2
L1 = crane length at X1 in meters
L2 = crane length at X2 in meters
Within the trolley and/or gantry drives, the instantaneous cable length
DataLink is assigned to parameter 10/11:966 [Crane Length 1]
1 g ≠0
NF1 freq = 954 Ref NF1 Freq Act
2π Crane Length1
0
g = earth acceleration gravity (i.e. 9.81 m/s^2) Ref NF1 Freq 942
≠0
0 956 Ref NF1 Depth Act
0
Ref NF1 Depth 944
1 ≠0
957 Ref NF1 Gain Act
0
Ref NF1 Gain 945
The trolley and/or gantry drives use the data in parameter 10/11:966 [Crane
Length 1] to calculate the frequency for reference notch filter NF1 dynamically.
1 g
10/11:954 [Ref NF1 Freq Act = -----
- --
2 L
Where…
g = acceleration due to gravity 9.81 m/sec2
L = 10/11:966 [Crane Length 1] in meters
Dynamic Braking When an induction motor’s rotor is turning slower than the synchronous
speed set by the drive’s output power; the motor is transforming electrical
energy that is obtained from the drive into mechanical energy available at the
drive shaft of the motor. This process is referred to as motoring.
When the rotor is turning faster than the synchronous speed set by the drive’s
output power, the motor is transforming mechanical energy available at the
drive shaft of the motor into electrical energy that can be transferred back into
the utility grid. This process is referred to as regeneration.
On most AC PWM drives, the AC power available from the fixed frequency
utility grid is first converted into DC power with a diode rectifier bridge or
controlled SCR bridge, before being inverted into variable frequency AC
power. These diode or SCR bridges are cost-effective, but can handle power in
only one direction, and that direction is the motoring direction. If the motor is
regenerating, the bridge is unable to conduct the necessary negative DC
current, and the DC bus voltage increases until the drive trips on an over
voltage fault.
There are bridge configurations that use either SCRs or transistors that can
transform DC regenerative electrical energy into fixed frequency utility
electrical energy but are expensive. A more cost-effective solution is to provide
a transistor chopper on the DC bus of the AC PWM drive that feeds a power
resistor, which transforms the regenerative electrical energy into thermal heat
energy, which is dissipated into the local environment.
This process is called dynamic braking, with the chopper transistor and related
control and components that are called the chopper module, and the power
resistor called the dynamic brake resistor. The entire assembly of a chopper
module with dynamic brake resistor is sometime referred to as the dynamic
brake module. More modern AC PWM drives have a dedicated IGBT built into
the package for dynamic braking. The rest of this topic discusses drives that
have a seventh IGBT.
How it Works
There are two different types of control for dynamic braking, hysteretic control
and PWM control. Each used by themselves in a standard, standalone product
has no advantage over the other. The preferred control is the PWM method
when the application is a common DC bus. A description of this advantage
follows.
Hysteretic Control
Vdc_on
Vdc_off
on
off t
PWM Control
This type of control that operates the brake IGBT is similar to the way the
output voltage to the motor is controlled. As the DC bus voltage increases and
reaches some predetermined limit, the brake IGBT is turned on/off according
to a control algorithm switched at 1 kHz. This type of control virtually
eliminates bus ripple. The significant advantage is when this type of control is
used in a common bus configuration.
Vdc
Vdc_on+25
Vdc_on+25 –2.5
Vdc_on
t
Brake IGBT
on
off t
Duty Cycle
Linear PWM Hysteretic Full on
100%
90%
Duty Cycle
Vdc_on
Vdc_off
DB IGBT
Drive #1
on
off t
DB IGBT
Drive #2
on
off t
Here are two drives with PWM DB control on a common bus. Because one
drive turns on at a certain duty cycle, the bus voltage is likely to continue to rise
guaranteeing that the other drive’s IGBT turns on (at another duty cycle).
Vdc
Drive #2
Vdc_on
Vdc_off
Vdc
Drive #1
DB IGBT
Drive #1
on
off t
DB IGBT
Drive #2
on
off t
In general, the dynamic brake resistor value can be estimated by using the
motor power rating, speed, torque, and regenerative mode of operation. A rule
of thumb to use is that a dynamic brake module resistor can be specified when
regenerative energy is dissipated on an occasional or periodic basis. When a
drive is consistently operating in the regenerative mode of operation, consider
using equipment that transforms the electrical energy back to the fixed
frequency utility.
The peak regenerative power of the drive must be calculated to determine the
maximum Ohmic value of the dynamic brake resistor. A range of allowable
dynamic brake ohmic values is now known. These values exist from the
minimum value set by the transistor current rating to a maximum value set by
the peak regenerative power that the drive develops to decelerate or satisfy
other regenerative applications. If a dynamic brake resistance value less than
the minimum imposed by the AC drive’s specification is applied, damage can
occur to the transistor. If a dynamic brake resistance value greater than the
maximum imposed by the choice of the peak regenerative drive power is
applied, the drive can trip due to transient DC bus overvoltage problems. Once
the choice of the approximate Ohmic value of the dynamic brake resistor is
made, the wattage rating of the dynamic brake resistor can be determined.
The wattage rating of the dynamic brake resistor is estimated by applying the
knowledge of the drive motoring and regeneration modes of operation. The
average power dissipation of the regeneration mode must be estimated and
the wattage of the chosen dynamic brake resistor to be slightly greater than the
average power dissipation of the drive. If the dynamic brake resistor has a
large thermodynamic heat capacity, the resistor element is able to absorb a
large amount of energy without the temperature of the resistor element
exceeding the operational temperature rating. Thermal time constants of 50
seconds and higher satisfy the criteria of large heat capacities for these
applications. If a resistor has a small heat capacity, the temperature of the
resistor element could exceed the maximum temperature limits during the
application of pulse power to the element and could exceed the safe
temperature limits of the resistor.
The following figure is a typical dynamic braking application. The top trace
represents speed and is designated by the omega symbol. In the profile, the
motor is accelerated to a speed, it holds that speed, and is then decelerated.
This deceleration isn’t necessarily to zero speed. The cycle is then repeated.
The middle trace represents motor torque. Torque starts out high as the motor
is accelerated then drops down to maintain the commanded speed. Then the
torque turns negative as the motor is decelerated. The cycle is then repeated.
The bottom trace represents motor power. Power increases as the motor speed
increases. Power decreases some to maintain the commanded speed then goes
negative when deceleration starts. Point -Pb is the first value that must be
calculated. The cycle is then repeated.
w(t)
0 t1 t2 t3 t4 t1 + t4 t
T(t)
0 t1 t2 t3 t4 t1 + t4 t
P(t)
0 t1 t2 t3 t4 t1 + t4 t
-Pb
The equations that are used for calculating dynamic braking values use the
following variables.
2N
w(t) = The motor shaft speed in radians/second, or Rad s = ----------
60
T(t) = The motor shaft torque in Newton-meters, 1.0 lb•ft = 1.355818 N•m
JT = Jm + GR2 x JL
GR = The gear ratio for any gear between motor and load, dimensionless
JT 2
P b = ---------------
-
t3 – t2
Compare the peak braking power to that of the rated motor power, if the peak
braking power is greater that 1.5 times that of the motor, then the deceleration
time, (t3 - t2), needs to be increased so that the drive does not go into current
limit. Use 1.5 times because the drive can handle 150% current maximum for 3
seconds.
Peak power can be reduced by the losses of the motor and inverter.
Vd = The value of DC bus voltage that the drive regulates at and is equal to
375V DC, 750V DC, or 937.5V DC depending on input voltage
Rdb1 = The maximum allowable value for the dynamic brake resistor
Choose a dynamic brake resistance value that is less than the value calculated
in step 3. If the value is greater than the calculated value, the drive can trip on a
DC bus overvoltage fault. Remember to account for resistor tolerances.
Each drive with an internal dynamic brake IGBT has a minimum resistance
that is associated with it. The dynamic brake resistor can be damaged if a
resistance lower than the minimum value for a given drive is connected. The
following is a table of minimum resistances for PowerFlex 755TS drives,
frames 1...7.
Brake Resistance for 400/480V Drives
400V 480V
Frame Min Max DB Max Duty Min Max DB Max Duty
ND kW Catalog Code ND Hp Catalog Code
Resistance Current Cycle Resistance Current Cycle
0.75 C2P1 79.0 10 0.453 1.0 D2P1 79.0 10 0.453
1.5 C3P5 79.0 10 0.453 2.0 D3P4 79.0 10 0.453
2.2 C5P0 79.0 10 0.453 3.0 D5P0 79.0 10 0.453
1
4 C8P7 52.7 15 0.453 5.0 D8P0 52.7 15 0.453
5.5 C011 31.6 25 0.453 7.5 D011 31.6 25 0.453
7.5 C015 31.6 25 0.453 10 D014 31.6 25 0.453
0.75 C2P1 31.6 25 0.4844 1.0 D2P1 31.6 25 0.4844
1.5 C3P5 31.6 25 0.4844 2.0 D3P4 31.6 25 0.4844
2.2 C5P0 31.6 25 0.4844 3.0 D5P0 31.6 25 0.4844
2 4 C8P7 31.6 25 0.4844 5.0 D8P0 31.6 25 0.4844
5.5 C011 31.6 25 0.4844 7.5 D011 31.6 25 0.4844
7.5 C015 31.6 25 0.4844 10 D014 31.6 25 0.4844
11 C022 22.6 34.9 0.5603 15 D022 22.6 34.9 0.5603
15 C030 31.6 25 0.9857 20 D027 31.6 25 0.9857
18.5 C037 31.6 25 0.9857 25 D034 31.6 25 0.9857
3
22 C043 16.6 47.6 0.9857 30 D040 16.6 47.6 0.9857
37 (2) C075 (2) 7.9 100 0.8279 50 (2) D065 (2) 7.9 100 0.8279
5 45 C085 7.9 100 0.8279 60 D077 7.9 100 0.8279
55 C104 7.9 100 0.8279 75 D096 7.9 100 0.8279
(2) C104 (2) 3.3 239.4 0.912 75 (2) D096(2) 3.3 239.4 0.912
55
75 C140 3.3 239.4 0.912 100 D125 3.3 239.4 0.912
6 90 C170 3.3 239.4 0.912 125 D156 3.3 239.4 0.912
110 C205 3.3 239.4 0.912 150 D186 3.3 239.4 0.912
132 C260 3.3 239.4 0.912 200 D248 3.3 239.4 0.912
132 (2) C260 (2) 2.4 329 0.78 200 (2) D248 (2) 2.4 329 0.78
160 C302 2.4 329 0.78 250 D302 2.4 329 0.78
7 200 C367 2.4 329 0.78 300 D361 2.4 329 0.78
250 C456 1.65 478.8 0.78 350 D415 1.65 478.8 0.78
270 C477 1.65 478.8 0.78 400 D477 1.65 478.8 0.78
(1) IP20/IP00, NEMA/UL Open Type (enclosure code N).
(2) IP54, NEMA/UL Type 12 (enclosure code G).
To avoid damage to this transistor and get the desired braking performance,
select a resistor with a resistance between the maximum resistance that is
calculated in step 3 and the minimum resistance of the drive IGBT.
t3 – t2 Pb
P av = ----------------- -----
t4 2
The dynamic brake resistor power rating in watts that is chosen will be equal to
or greater than the value calculated in step 6.
Dynamic Bus Control Applications with cyclic speed and load fluctuations such as servo presses and
high-speed cut-to-length systems often have high motoring and regenerative
peak torque demands applied within one cycle of machine operation. This type
of load typically has a fixed mass (inertia) and low losses. To reduce the power
converter peak power demand, large DC bus capacitor banks are employed
that are designed to absorb regenerative (deceleration) energy from the load
then transfer energy to the load during motoring (acceleration) periods of the
cycle.
Typical active front end converter systems attempt to regulate the DC Bus
voltage to a setpoint. When in this mode the active front end converter
attempts to control the DC Bus to this level whether the drive is motoring or
regenerating. The following illustrative plots show a typical cyclical load speed/
torque profile with standard internal DC bus capacitance and DC bus voltage
regulation enabled. This results in high peak motoring and regenerative
Converter AC Input Power peak demands required to regulate the DC bus
voltage.
Load Velocity
t
0
Motor %
Load Torque
t
0
Regen %
t
0
Motor %
Converter AC
Input Power
t
0
Regen %
Applications with cyclic speed and load profiles, such as servo presses and
rotary shears can use additional DC bus capacitance to soften the peak
motoring and regeneration AC line power demand.
Dynamic bus control was designed to allow the active front end converter to
tolerate cyclic fluctuations in DC bus voltage due to energy exchanging from
the load to the DC bus capacitor bank with minimal converter motoring or
regenerative power exchange with the AC line. Because the converter is
supplying system losses the rating of the bus supply converter and AC supply
may be reduced. The following illustrative plots show the same load speed/
torque profile as the example above but with an external DC bus capacitor
bank and Dynamic Bus Control enabled. The peak Converter AC Input Power
is significantly reduced compared to the DC Bus Voltage Regulation depicted
in Figure 67.
Load Velocity
t
0
Motor %
Load Torque
t
0
Regen %
DC Bus Voltage
Motor %
Converter AC
Input Power
t
0
Regen %
• Dynamic bus control for PowerFlex 755TL low harmonic drives adjusts
the motoring power limits based on DC bus voltage.
• Dynamic bus control for the PowerFlex 755TM regenerative bus supply
and PowerFlex 755TR regenerative drives adjusts the motoring and
regeneration power limits based on the DC bus voltage.
• Dynamic bus control has ‘Linear’ and ‘Non-linear’ modes to tailor the
control for different applications. There are three DC bus voltage
thresholds that are used as transition points to change the converter
power limits. These points are defined steps in the linear mode and a
curve that is based on power limits and voltage setpoints in non-linear
mode. Depending on the DC bus voltage feedback, Dynamic Bus Control
selects the high or low voltage thresholds as the DC bus voltage regulator
setpoints.
Linear Mode
Select Linear Mode for applications that require a rapid transition from low
power limits to maximum power limit, such as when the bus supply is used as a
regenerative brake.
The setpoints for motor and regen are Low, Nominal, and High for
determining the motoring or regeneration power limits.
• For motoring at or below 13:62 [DBC V Thresh Lo] bus limit, use 13:105
[Motor Power Lmt].
• For motoring above 13:62 [DBC V Thresh Lo] and up to 13:64 [DBC V
Thresh Nom], use 13:330 [DBC NomMtrPwrLm].
• For motoring above 13:64 [DBC V Thresh Nom], use 13:331 [DBC
IdleMtrPwrLm].
• For regeneration at or above 13:63 [DBC V Thresh Hi], use 13:104 [Regen
Power Lmt].
• For regeneration from 13:63 [DBC V Thresh Hi] to 13:64 [DBC V Thresh
Nom], use 13:332 [DBC NomRgnPwrLm].
• For regeneration below 13:64 [DBC V Thresh Nom], use 13:333 [DBC
IdleRgnPwrLm].
The Dynamic Bus Control is most stable if the motoring and regenerative
power limit parameters are not set numerically less than 5%.
The following graphic shows the Linear mode of Dynamic Bus Control. This
could be used with a large DC bus capacitor bank application. With a DC bus
capacitor bank, the setpoints for power would be used for both motoring and
regeneration. In this example the motoring and regeneration power transfer is
limited in range between DC bus voltage low and high thresholds.
• The DC bus voltage is allowed to fluctuate due to energy transfer to and
from the load and the capacitor bank with minimal allowed power
transfer to/from the AC line (grey filled area).
• If the DC bus voltage drops below the low threshold maximum motoring
power is allowed to transfer from the AC line (blue filled area).
• If the DC bus voltage rises above the high threshold the maximum
regeneration power is allowed to transfer to the AC line (yellow filled
area).
Recommended Settings:
• 13:105 [Motor Power Lmt] = 100%
• 13:330 [DBC NomMtrPwrLm] = 25%
• 13:331 [DBC IdleMtrPwrLm] = 5%
• 13:104 [Regen Power Lmt] = -100%
• 13:332 [DBC NomRgnPwrLm] = -25%
• 13:333 [DBC IdleRgnPwrLm] = -5%
• Low bus voltage threshold, parameter 13:62 [DBC V Thresh Lo] = 13:25
[Rated Volts] × √2 × 0.98 (Rated Volts is based on PowerFlex 755TM
Voltage Class). For 480V AC = 480V AC √2 × 0.98 = 665V DC
• High bus voltage threshold, parameter 13:63 [DBC V Thresh Hi] = Default
DC Bus Voltage × 0.95 (Default is based on PowerFlex 755TM Voltage
Class). For 480V AC, 790V DC × 0.95 = 750V DC
• Nominal bus voltage threshold, parameter 13:64 [DBC V Thresh Nom] =
Default DC Bus Voltage × 0.93 (Default is based on PowerFlex 755TM
Voltage Class). For 480V AC, 741V DC × 0.93 = 689V DC
(+) Motoring Power Limit
Maximum Allowed
Power Transfer to AC
Line (Regeneration)
For a Regen Brake mode operation, you would set the motoring idle, nominal
and high power limits to minimum (5%). The regenerative idle and nominal
power limits would be set to -5% and the high power set to the desired
regenerative brake level (-100%). The converter supports minimal motoring
power in this configuration. All motoring power must be supplied by the non-
regenerative bus supply converter.
Recommended Settings:
• 13:105 [Motor Power Lmt] = 13:330 [DBC NomMtrPwrLm] = 13:331 [DBC
IdleMtrPwrLm] = 5%
• 13:104 [Regen Power Lmt] = -100%
• 13:332 [DBC NomRgnPwrLm] = 13:333 [DBC IdleRgnPwrLm] = -5%
• Low bus voltage threshold, parameter 13:62 [DBC V Thresh Lo] = 13:25
[Rated Volts] × √2 × 0.98 (Rated Volts is based on PowerFlex 755TM
Voltage Class). For 480V AC = 480V AC √2 × 0.98 = 665V DC
• High bus voltage threshold, parameter 13:63 [DBC V Thresh Hi] = Default
DC Bus Voltage × 0.95 (Default is based on PowerFlex 755TM Voltage
Class). For 480V AC, 790V DC × 0.95 = 750V DC
• Nominal bus voltage threshold, parameter 13:64 [DBC V Thresh Nom] =
Default DC Bus Voltage × 0.93 (Default is based on PowerFlex 755TM
Voltage Class). For 480V AC, 741V DC × 0.93 = 690V DC
The following graphic shows the Dynamic Bus Control settings for Regen
Brake control. In this example the regenerative bus supply motoring and
regeneration power transfer is limited in range below the DC bus voltage high
threshold.
• If the DC bus voltage is below the high threshold, minimum motoring
and regeneration power transfer is allowed from/to from the AC line
(gray filled area).
• If the DC bus voltage rises above the high threshold regeneration power
is allowed to transfer to the AC line (yellow filled area).
Maximum Allowed
Power Transfer to AC
Line (Regeneration)
Non-Linear Mode
Non-linear Dynamic Bus Control is similar to linear mode except the DC bus
voltage and power limit transition points are based on a curve instead of
discrete switching points. Non-linear bus control provides a smoother
converter AC input current during DC bus voltage reference and power limit
transitions. Select non-linear mode for applications that have large external
DC bus capacitor banks and controlled requirements for limiting power such
as a servo press or rotary shear.
The combination of the low, nominal, and high voltage thresholds and the idle,
nominal, and high motor/regen power limits shape the curve of the non-linear
operation of the Dynamic Bus Control.
Allowed Power
Transfer to AC Line
(Regeneration)
13:332 [DBC NomRgnPwrLm]
Nominal power limits and nominal voltage level parameters have the largest
effect on the power curves. Changing the values can create curves as in the two
curve examples that follow. The dynamic bus control is most stable if the
motoring and regenerative power limit parameters are not set numerically less
than 5%.
DC Bus Voltage
DC Bus Voltage
Carrier (PWM) Frequency Parameter 10/11:425 [PWM Frequency] sets the carrier frequency at which the
inverter output IGBTs (insulated gate bipolar transistors) switch. In general,
the lowest possible switching frequency that is acceptable for any particular
application is the one to use. An increased carrier frequency causes less motor
heat and lowers the audible noise from the motor. However, an increased
carrier frequency does cause the IGBTs to heat up faster than by using the
factory default PWM frequency of 4 kHz or 2 kHz depending on the frame size.
The higher switching frequency smooths the current waveform and therefore
creates less vibration in the motor windings and laminations and lower
audible noise. Lower audible noise is desirable in some applications such as
motors installed close to control rooms or in domestic environments. Because
a higher carrier frequency creates more IGBT heating, derating is required.
See Figure 68 and Figure 69. Note the output current at 2 kHz and 4 kHz. The
“smoothing” of the current waveform continues up to 12 kHz. The maximum
carrier frequency per frame size and the derating guidelines according to
PWM frequency can be found in the product technical data.
• For PowerFlex 755T products see the PowerFlex 750-Series Products with
TotalFORCE Control Technical Data, publication 750-TD100.
• For PowerFlex 755TS products see the PowerFlex 755TS Products with
TotalFORCE Control, publication 750-TD104.
Figure 68 - Current at 2 kHz PWM Frequency
Analog Inputs Analog Inputs for the PowerFlex 755TS drive are available with user installed
option modules. There are two analog inputs per I/O module. Up to four I/O
modules can be mounted in the drive ports. There is also an eight input option
module available from Spectrum Controls. See the PowerFlex 750-Series I/O,
Feedback, and Power Option Modules Installation Instructions, publication
750-IN111, for valid ports. Accessing the analog input parameters is done by
selecting the port that the module is mounted in, then accessing the Analog
Input group of parameters. See the PowerFlex Drives with TotalFORCE
Control Parameters Reference Data, publication 750-RD101, for parameter
descriptions.
Inputs are isolated, bipolar, differential, with 11 bit and sign resulting in 2048
steps.
• 4.88 mV resolution for 0…10v signals
• 0.0078125 mA resolution for 4…20 mA signals
Option modules provide the analog input value for use within the drive as well
as performing several basic functions.
• Analog Input type selection
• Analog Input Filter
• Analog Input Loss Detection
• Analog Input Square Root function
• Analog Scaling
Ai1 Ai1
Ai0 Ai0
A filter is provided for each analog input signal using parameters for filter
Gain and Bandwidth(rad/s). A gain value of zero results in first order low pass
filter behavior. Gain values between zero and one result in a lag type filter. A
gain value of one will disable the filter. Bandwidth sets the frequency range of
the filter. A value of zero will disable the filter. By default this filter is disabled
and can be enabled by changing option module parameters nn:55 [Anlg In0 Filt
Gn], nn:56 [Anlg In0 Filt BW], nn:65 [Anlg In1 Filt Gn], and nn:66 [Anlg In1 Filt
BW].
• For a light filter use a gain of 0.7 and a bandwidth of 35
• For a heavy filter use a gain of 0.5 and a bandwidth of 20
Signal loss detection can be enabled for each analog input. Parameter nn:47
[Anlg In Loss Sts] bits 0, 1, 2 indicate if the signal is lost. Bit 0 indicates that one
or both signals are lost. Parameters nn:53 [Anlg In0 LssActn] and nn:63 [Anlg
In1 LssActn] define what action the drive takes when loss of any analog input
signal occurs. Signal loss is defined as an analog signal that is less than 1V or 2
mA. The signal loss event ends and normal operation resumes when the input
signal level is greater than or equal to 1.5V or 3 mA.
• ‘Ignore’ (0) – No action is taken.
• ‘Alarm’ (1) – Type 1 alarm indicated.
• ‘Flt Minor’ (2) – Minor fault indicated. Minor faults prevent the drive
from starting. They do not stop the drive, if it is already running. You
must clear the fault to start or run.
• ‘FltCoastStop’ (3) – Major fault indicated. Coast to Stop.
• ‘Flt RampStop’ (4) – Major fault indicated. Ramp to Stop.
• ‘Flt CL Stop’ (5) – Major fault indicated. Current Limit Stop.
• ‘Hold Input’ (6) – Holds input at last value.
• ‘Set Input Lo’ (7) – Sets input to nn:52 [Anlg In0 Lo] or nn:62 [Anlg In1 Lo].
• ‘Set Input Hi’ (8) – Sets input to nn:51 [Anlg In0 Hi] or nn:61 [Anlg In1 Hi].
Square Root
The square root function can be applied to each analog input through the use
of nn:46[Anlg In Sqrt]. The function should be enabled if the input signal varies
with the square of the quantity (e.g. drive speed) being controlled. A common
If the mode of the input is bipolar voltage (-10V…+10V), then the square root
function returns 0 for all negative voltages.
The function takes square root of the raw analog value as compared to its full
scale as defined in the following equation. Note this function does not scale
based on Anlg In Hi or Anlg In Lo, so the full range of the input is expected.
Ana log InRawValue
Ana log InValue = ---------------------------------------------- 10Vor20mA
10Vor20mA
10
Analog Scaling
Example 1
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:60 [Anlg In1 Value]
• 10/11:1802 [VRef A AnlgHi] = 60 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In1 Hi] = 10V
• nn:62 [Anlg In1 Lo] = 0V
Input Volts
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hertz
Example 2
Command Frequency
nn:62 [Anlg In1 Lo]
0V
0 Hz 15 Hz 45 Hz 60 Hz
10/11:1803 [VRef A AnlgLo] Slope defined by (Analog Volts)/(Command Frequency) 10/11:1802 [VRef A AnlgHi]
Example 3
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:60 [Anlg In1 Value]
• 10/11:1802 [VRef A AnlgHi] = 30 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In1 Hi] = 10V
• nn:62 [Anlg In1 Lo] = 0V
10
9
8
7
6
Analog In Value
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hz
Example 4
• nn:45 [Anlg In Type], bit 0 = 1 ‘Current’
• 10/11:1800 [VRef A Sel] = nn:60 [Anlg In1 Value]
• 10/11:1802 [VRef A AnlgHi] = 60 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In1 Hi] = 20 mA
• nn:62 [Anlg In1 Lo] = 4 mA
20
18
16
14
12
Analog In Value
10
8
6
4
2
0
0 10 20 30 40 50 60
Output Hz
Example 5
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:60 [Anlg In1 Value]
• 10/11:1802 [VRef A AnlgHi = 0 Hz
• 10/11:1803 [VRef A AnlgLo] = 60 Hz
• nn:61 [Anlg In1 Hi] = 10V
• nn:62 [Anlg In1 Lo] = 0V
This configuration is used to invert the operation of the input signal. Here,
maximum input (10V) represents 0 Hz and minimum input (0V) represents 60
Hz.
10
9
8
7
Analog IN Value 6
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hz
Example 6
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:60 [Anlg In1 Value]
• 10/11:1802 [VRef A AnlgHi = 60 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In1 Hi] = 5V
• nn:62 [Anlg In1 Lo] = 0V
This configuration is used when the input signal is 0…5V. Here, minimum
input (0V) represents 0 Hz and maximum input (5V) represents 60 Hz. This
provides full scale operation from a 0…5V.
5
4.5
4
3.5
3
Analog In Value
2.5
2
1.5
1
0.5
0
0 10 20 30 40 50 60
Output Hz
Example 7
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:2000 [Trq Ref A Sel] = nn:60 [Anlg In1 Value]
• 10/11:2002 [Trq Ref A AnlgHi] = 200%
• 10/11:2003 [Trq Ref A AnlgLo] = 0%
• nn:61 [Anlg In1 Hi] = 5V
• nn:62 [Anlg In1 Lo] = 0V
This configuration is used when the input signal is 0…10V. The minimum
input of 0V represents a torque reference of 0% and maximum input of 10V
represents a torque reference of 200%.
10
9
8
7
Input Volts 6
5
4
3
2
1
0
0 20 40 60 80 100 120 140 160 180 200
Torque Ref %
Example 8
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:50 [Anlg In0 Value]
• 10/11:1802 [VRef A AnlgHi] = 60 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In0 Hi] = 10V
• nn:62 [Anlg In0 Lo] = 0V
• nn:46[Anlg In Sqrt] bit 0 = 1
This configuration is used to perform the square root function on the input
signal. Here, 0V represents 0 Hz and 10V represents 60 Providing a square root
action throughout the input range. Note that Anlg In Value maintains a linear
relationship with Output Hz.
Analog In Value Analog In Raw Value
10
9
8
7
6
Analog In Value
5
4
3
2
1
0
0 10 20 30 40 50 60
Output Hz
Example 9
• nn:45 [Anlg In Type], bit 0 = 0 ‘Voltage’
• 10/11:1800 [VRef A Sel] = nn:50 [Anlg In0 Value]
• 10/11:1802 [VRef A AnlgHi] = 60 Hz
• 10/11:1803 [VRef A AnlgLo] = 0 Hz
• nn:61 [Anlg In0 Hi] = 5V
• nn:62 [Anlg In0 Lo] = 0V
• nn:46[Anlg In Sqrt] bit 0 = 1
This configuration is used to perform the square root function on the input
signal. Here, 0V represents 0 Hz and 10V represents 120 Providing a square
root action throughout the input range. Note the output Hz are limited by
combination of nn:61 [Anlg In0 Hi] and 10/11:1802 [VRef A AnlgHi].
nn:50 [Anlg In0 Value] nn:54 [Anlg In0 Raw]
10
9
8
7
6
5
Volts
4
3
2
1
0
0 10 20 30 40 50 60
Output Hz
Analog Outputs There are two analog outputs per I/O module. Up to five I/O modules can be
mounted in the drive ports. See the PowerFlex 750-Series I/O, Feedback, and
Power Option Modules installation instructions, publication 750-IN111 for
valid ports. Accessing the analog output parameters by selecting the port that
the module is mounted in then accessing the Analog Output group of
parameters.
Table 41 - Analog Output Specifications
Related
Terminal Name Description
Param (4)
Sh Terminating point for wire shields when
Shield an EMC plate or conduit box is not
Sh installed.
Ptc– Motor PTC (–) Motor protection device (Positive 40
Ptc+ Motor PTC (+) Temperature Coefficient). on Port X
Ao0– Analog Out 0 (–) 75
Bipolar, ±10V, 11 bit & sign, 2 k ohm on Port X
Ao0+ Analog Out 0 (+) minimum load.
Ao1– Analog Out 1 (–) 4-20 mA, 11 bit & sign, 400 ohm maximum
load. 85
Ao1+ Analog Out 1 (+) on Port X
Sh
Sh
–10V –10 Volt Reference 2k ohm minimum.
PTC–
PTC+
Ao0–
10VC 10 Volt Common For (–) and (+) 10 Volt references.
Ao0+
Ao1–
Ao1+ +10V +10 Volt Reference 2k ohm minimum.
–10V
10VC
+10V Ai0– Analog Input 0 (–) Isolated (2), bipolar, differential, 11 bit & 50, 70
sign. on Port X
Ai0–
Ai0+
Ai0+ Analog Input 0 (+)
Voltage mode: ±10V @ 88k ohm input
Ai1–
Ai1+
60, 70
+24V
on Port X
Di0
Di1
Di2 Ai1+ Analog Input 1 (+) impedance.
Di3
Di4
Di5
24VC 24 Volt Common Drive supplied logic input power.
200 mA max per I/O module
+24V +24 Volt DC 600 mA max per drive
Di C Digital Input Common Common for Digital Inputs 0…5
Di 0 Digital Input 0 (1)
24V DC - Opto isolated
Di 1 Digital Input 1 (1) Low State: less than 5V DC
Di 2 Digital Input 2 (1) High State: greater than 20V DC 11.2 mA
DC 1
on Port X
Di 3 Digital Input 3 (1) 115V AC, 50/60 Hz (3) - Opto isolated
Low State: less than 30V AC
Di 4 Digital Input 4 (1) High State: greater than 100V AC
Di 5 Digital Input 5 (1)
(1) Digital Inputs are either 24 Volts DC (2262C) or 115 Volts AC (2262D) based on module catalog number. Be sure applied voltage
is correct for I/O module.
(2) Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common
mode immunity.
(3) For CE compliance use shielded cable. Do not exceed 30 m (98 ft) cable length.
(4) I/O Module parameters also have a Port designation.
Parameters nn:75 and nn:85 [Anlg Outn Select] are use to specify the signal used
on Analog Outputs 1 and 2, respectively. These parameters can be programmed
to the following selections.
Scaling
The scaling for the analog output is defined by entering analog output voltages
into two parameters, nn:91 [Anlg Out1 Lo] and nn:90 [Anlg Out1 Hi]. These two
output voltages correspond to the bottom and top of the possible range
covered by the quantity being output. Scaling of the analog outputs is
accomplished with low and high analog parameter settings that are associated
with fixed ranges for each target function (see the PowerFlex Drives with
TotalFORCE Control Programming Manual, publication 750-PM101).
Additionally, PowerFlex 755T products contain an adjustable scale factor to
override the fixed target range. Parameter nn:77 [Anlg Out0 Data] and
nn:82 [Anlg Out0 Val] are described in the following charts.
Case 1…4
77 [Anlg Out0 Data] 78 [Anlg Out0 DataHi] 79 [Anlg Out0 DataLo] 82 [Anlg Out0 Val] 80 [Anlg Out0 Hi] 81 [Anlg Out0 Lo] 76 [Anlg Out0 Stpt]
Case 1: This shows nn:77 [Anlg Out0 Data] the units are consistent with the
selection of nn:75 [Anlg Out0 Sel]. In this case, the analog out select is set to 10/
11:1044 [Motor Vel Fb] and the units are in rpm. Parameter nn:80 [Anlg Out0
Hi], nn:81 [Anlg Out0 Lo], nn:78 [Anlg Out0 DataHi], and nn:79 [Anlg Out0
DataLo] are all at default. The motor was started and ramped to 1800 rpm.
Note that nn:82 [Anlg Out0 Val] remained zero.
Case 2: Here the nn:80 [Anlg Out0 Hi] is changed to 9 and nn:81 [Anlg Out0 Lo]
is changed to 1. As the motor ramps up and down, there is no change in the
value or scaling of nn:77 [Anlg Out0 Data]. Note that nn:82 [Anlg Out0 Val] is
still zero.
Case 3: Now nn:78 [Anlg Out0 DataHi] is changed to 1800 and nn:79 [Anlg Out0
DataLo] is left at zero. When started, nn:82 [Anlg Out0 Val] starts at 1 and
reaches 9 when the motor speed is at maximum.
Case 4: In this section the nn:80 [Anlg Out0 Hi] and nn:81 [Anlg Out0 Lo] were
reversed in value. Now when the motor ramps up and down nn:82 [Anlg Out0
Val] is just the opposite. It starts out at 9 and is at 1 at full speed.
Case 5
77 [Anlg Out0 Data] 78 [Anlg Out0 DataHi] 79 [Anlg Out0 DataLo] 82 [Anlg Out0 Val]
When the motor speed reaches 500 rpm, [Anlg Outn Val] begins to increase from 0.
When the motor speed reaches 1500 rpm, [Anlg Outn Val] is at maximum of 10.
Case 6
77 [Anlg Out0 Data] 78 [Anlg Out0 DataHi] 79 [Anlg Out0 DataLo] 82 [Anlg Out0 Val] 80 [Anlg Out0 Hi] 81 [Anlg Out0 Lo]
Absolute (Default)
Certain quantities used to drive the analog output are signed, for example the
quantity can be both positive and negative. You have the option of having the
absolute value (value without sign) of these quantities taken before the scaling
occurs. Absolute value is enabled separately for each analog output via the bit
enumerated nn:71 [Analog Out Abs].
Setpoint
Digital Inputs Physical inputs are programmed to desired digital input functions. These
parameters cannot be changed while the drive is running.
Technical Information
The PowerFlex 755T drive has one digital input on its main control board:
• Di0 - configured for 115V AC or 24V DC
- Shared common (Di C) between Di 0ac and Di 0dc terminals
- TB1 - bottom of the main control board
There are also PowerFlex 750-Series option modules that expand the amount
of digital inputs that can be used.
20-750-2262C-2R / 20-750-2263C-1R2T
• Six 24V DC input terminals:
- Labeled as Di 0, Di 1, Di 2, Di 3, Di 4, and Di 5
- Shared common (Di C)
- TB1 - front of the option module
20-750-2262D-2R
• Six 115V AC input terminals:
- Labeled as Di 0, Di 1, Di 2, Di 3, Di 4, and Di 5
- Shared common terminal (Di C)
- TB1 - front of the option module
PowerFlex 750-Series Option Modules I/O TB1 wiring examples are included in
the PowerFlex 750-Series I/O, Feedback, and Power Option Modules
Installation Instructions, publication 750-IN111.
Configuration
Operation for DI Run type parameters can be defined by 0:101 [Digital In Cfg]:
• ‘Run Edge’ (0) – Control function requires a rising edge (open to close
transition) for the drive to run.
• ‘Run Level’ (1) – As long as a separate "Stop" command is not issued, the
level alone (no rising edge required) determines whether the drive runs.
When set to 1 ‘Run Level’ the absence of a run command is indicated as a
stop asserted and 10/11:354 [Motor Side Sts 1] bit 0 is low.
Functional Descriptions
DI M Enable
Closing this input lets the drive run when a Start command is issued. If the
drive is already running when this input is opened, the drive will coast stop
and indicate ‘not enabled’ on the HIM (if present). This is not considered a
fault condition, and no fault is generated. If this function is not configured,
the drive is considered enabled.
IMPORTANT If the ENABLE Jumper on the main control board is removed, the
Di 0 becomes a hardware enable. Di 0 is found on TB1 on the main
control board.
DI L Enable
Closing this input allows the line side converter to modulate when a Start
command is issued. If it opens or resets while it is modulating, the line side
converter ceases modulating.
DI M Stop
An open input causes the drive to stop and become Not Ready. A closed input
lets the drive run when given a Start or Run command.
DI M Stop Mode B
This input is used to select which Stop mode is used when stop command is
issued. If the input is open or de-energized, the drive uses the stop mode
configured by parameter 10/11:110 [Mtr Stop Mode A]. If the input is closed or
energized, the drive uses the stop mode configured by parameter 10/11:111 [Mtr
Stop Mode B].
DI M CurLmt Stop
With this digital input function, an open input causes the drive to current limit
stop. The drive acknowledges the stop command by setting the motor speed
reference to zero, causing the drive to bring the motor down to zero speed as
fast as the power limits, torque limits, and current limits allow. When the drive
output reaches zero, the output transistors are shut off.
DI M Coast Stop
With this digital input function, an open input causes the drive to Coast-to-
Stop. The drive acknowledges the stop command by shutting off the output
transistors and releasing control of the motor. The load/motor will coast or
free spin until the mechanical energy is dissipated.
DI L Stop
An open input causes the converter to stop modulating. A closed input lets the
converter modulate when given a Start or Run command.
DI Clear Fault
The Clear Fault digital input function lets an external device reset drive faults
through the terminal block. An open to closed transition on this input causes
an active fault (if any) to be reset.
DI Aux Fault
This input function is normally closed and lets external equipment fault the
drive. When this input opens, the drive faults on a code 1 ‘Auxiliary Input’ and
stops modulating. The motor will coast to a stop. If this input function is not
configured, the fault will not occur.
DI Regen OK
This input only applies to common bus inverters. It is used to let the inverter
know when there is a fault on the bus supply. When the input is open or reset,
the fault prevents the drive from starting or running until it is cleared. If the
input opens or resets while the drive is running, the drive faults on code 72
‘Digin Regen Fail’ and stops modulating. The motor will coast to a stop.
DI M Start
An open to closed transition while the drive is stopped causes the drive to run
in the current direction, unless the Stop input function is open. If Start is
Rockwell Automation Publication 750-RM100C-EN-P - August 2022 237
Chapter 5 Application References
configured, then a Stop must also be configured or the drive fault with code 171
‘No Stop Source’. The Stop does not have to be a digital input. The drive counts
the HMI and active network connections as a stop source.
DI M HOA Start
This digital input function provides Hand-Off-Auto control. It functions like a
three-wire start signal; with the exception, that it does not require the DI Stop
to be high for a full input cycle before the drive looks for a rising edge on DI
HOA Start.
DI L Start
An open to closed transition while the converter is stopped causes the
converter to start modulating. If it goes low after the line side converter is
modulating, the line side converter continues to run until it receives a Stop
command.
DI M Run
This digital input runs the drive when closed or energized. If the drive is
running, opening or de-energizing the input will stop the drive. This input
does not prevent starting the drive if open or de-energized.
DI L Run
This digital input modulates the converter when closed or energized. If the
converter is modulating, opening or de-energizing the input will stop the
converter. This input does not prevent starting the converter if open or de-
energized.
DI M Jog 1, DI M Jog 2
Jog is a non-latched command similar to Run, but overrides the normal speed
reference and uses 10/11:1894 [Jog Speed 1] or 10/11:1895 [Jog Speed 2]
respectively. An open to closed transition while the drive is stopped causes the
drive to jog unless the Stop input function is configured and open. Direction is
determined by another input or another device's command (HIM or
communication adapter). In Unipolar mode, the absolute value is used along
with a separate direction command. In Bipolar mode, the polarity of 10/
11:1894 [Jog Speed 1] or 10/11:1895 [Jog Speed 2] determines the direction of jog.
DI M Fwd Reverse
This digital input function is one of the ways to provide direction control when
the Start or Run functions (not combined with direction) are used. An open
input sets direction to forward. A closed input sets direction to reverse. If state
of input changes and drive is running or jogging, the drive changes direction.
DI M Manual Ctrl
The digital input function works in conjunction with the overall Auto/Manual
function. When this input is closed, it overrides other speed references, but
only if another device (HIM) did not have ownership of the Manual state. If the
digital input is successful in gaining manual control, the speed reference
comes from 0:147 [DI ManRef Sel], which can be set to any of the Analog
Inputs, Preset Speeds, MOP Reference, or an applicable Port Reference.
Associated with this digital input function, there is the ability to configure the
drive to switch smoothly from an automatic (communicated) speed reference
to manual speed reference produced by the Human Interface Module (HIM).
238 Rockwell Automation Publication 750-RM100C-EN-P - August 2022
Chapter 5 Application References
DI EmergencyOVRD
This digital input is used to enable and disable the Emergency Override
Function. When the input is closed or energized, Emergency Override is
enabled. For information about the Emergency Override Function, Emergency
Override Function on page 106.
DI Energy Pause
This digital input is used to send the product to and from the Paused (low
energy) state. When the input is closed or energized, device will transition to
the Paused state. For information about Energy Pause, see Energy Pause
Function on page 71.
DI AC LineSource
This digital input is used to switch between two AC line sources that have
different power and impedance values. When the input is open or de-
energized, the Line Side Converter uses parameters 13:32 [AC Line kVA A] and
13:34 [AC Line Imped% A]. When the input is closed or energized, the Line Side
Converter uses parameters 13:33 [AC Line kVA B] and 13:35 [AC Line Imped%
B]. When this digital input is configured, the product ignores parameter 13:31
[AC Line Source].
DI M BusRegMode
This digital input function selects how the drive regulates excess voltage on the
DC bus. If the input is open, then 10/11:116 [Bus Reg Mode A] selects which bus
regulation mode to use. If the input is closed, then 10/11:117 [Bus Reg Mode B]
selects which bus regulation mode to use. If this input function is not
configured, then 10/11:116 [Bus Reg Mode A] always selects which bus
regulation mode to use.
DI M PwrLossMode
This digital input function selects between two different drive power loss
modes. If the input is open, 10/11:271 [Pwr Loss Mode A] dictates the drive’s
action during the Power Loss mode. If the input is closed, 10/11:275 [Pwr Loss
Mode B] dictates the drive’s action during the power loss. If this input function
is not configured, 10/11:271 [Power Loss Mode A] always dictates the drive’s
action during the power loss.
DI M Pwr Loss
The drive contains a sophisticated algorithm to manage initial application of
power as well as recovery from a partial power loss event. This digital input
function is used to force the drive into a power loss condition. If this input is
open, the drive’s internal algorithm dictates the power loss condition. If the
input is closed, the algorithm is overridden and the drive is externally forced
into a power lost condition. Parameter 10/11:270 [Power Loss Actn] configures
the drive's response to a power loss time out condition and 10/11:273 [Pwr Loss
A Time] or 10/11:277 [Pwr Loss B Time] set the time that the drive remains in
Power Loss mode before a fault occurs. 10/11:272 [Pwr Loss A Level] or 10/11:276
[Pwr Loss B Level] are used to calculate the power loss threshold.
DI M TorqueStptA
This digital input function is used to force 10/11:2001 [Trq Ref A Stpt] as the
source for Torque Reference A, regardless of the setting in 10/11:2000 [Trq Ref
A Sel]. Used when the drive is in a mode that is commanding torque. Refer to
10/11:30 [PsnVelTrq Mode A], 10/11:31 [PsnVelTrq Mode B], 10/11:32 [PsnVelTrq
Mode C], and 10/11:33 [PsnVelTrq Mode D].
DI Find Home
This digital input function starts the Find Home function. Closing or
energizing the input initiates the Find Home function. If the drive is not
running, a start command is needed after this input goes high, to execute the
Find Home function. If this input is configured, it will take the place of
parameter 10/11:1640 [Home Ctrl Opts] bit 0 ‘Find Home’.
DI Return Home
This digital input function activates the Return Home function. losing or
energizing the input initiates the Return Home function. f the drive is not
running, a start command is needed after this input goes high, to execute the
Return Home function. f this input is configured, it will take the place of
parameter 10/11:1640 [Home Ctrl Opts] bit 3 ‘Return Home’.
DI Redefine Psn
This digital input function starts the Redefine Position function. Closing or
energizing the input initiates the Redefine Position function. If the drive is not
running, a start command is needed after this input goes high, to execute the
Redefine Position function. If this input is configured, it will take the place of
parameter 10/11:1640 [Home Ctrl Opts] bit 4 ‘Psn Redefine’.
DI OL Home Limit
This digital input function is used to connect a home limit switch. The polarity
of the Open Loop Home Limit function is configured by parameter 10/11:1640
[Home Ctrl Opts] bit 6 ‘Home DI Inv’.
DI Indx Step
This digital input function starts the Index Position Move function. Closing or
energizing the input initiates the Index Move. This digital input will be
equivalent to setting parameter 10/11:1381 [PTP Control] bit 1 ‘Move’ when the
point-to-point mode 10/11:1382 [PTP Mode] is set to 0 ‘Absolute’ or 1 ‘Index’.
DI Indx StepRev
This digital input function starts the Index Position Reverse Move function.
Closing or energizing the input initiates the Reverse Index Move. This digital
input will be equivalent to setting parameter 10/11:1381 [PTP Control] bit 2
‘Reverse Move’ when the point-to-point mode 10/11:1382 [PTP Mode] is set to 1
‘Index’.
DI Indx StepPrst
This digital input function starts the Index Preset Position Move function.
Closing or energizing the input initiates the Index Preset Move. This digital
input will be equivalent to setting parameter 10/11:1381 [PTP Control] bit 3
'Preset Psn' when the point-to-point mode 10/11:1382 [PTP Mode] is set to 1
'Index'.
DI FwdEndLimit, DI RevEndLimit
These digital input functions are used to trigger a Forward End Limit and/or a
Reverse End Limit. The resulting action depends on whether the drive is
operating as a speed, torque or position regulator. The mode of operation is
indicated by 10/11:354 [Motor Side Sts 1] bit 21 ‘Speed Mode’, bit 22
‘PositionMode’, and bit 23 ‘Torque Mode’. When the drive is operating as a
speed regulator, the resulting action is to execute a ‘Fast Stop’ command. After
the drive stops in this case, it only restarts in the opposite direction (if given a
new start command). This function is usually used with a limit switch near the
point where the drive needs to stop.
DI FwdDecLimit, DI RevDecLimit
These digital input functions are used to trigger a Forward Decel Limit and/or
a Reverse Decel Limit. The resulting action depends on whether the drive is
operating as a speed, torque or position regulator. The mode of operation is
indicated by 10/11:354 [Motor Side Sts 1] bit 21 ‘Speed Mode’, bit 22
‘PositionMode’, and bit 23 ‘Torque Mode’. When the drive is operating as a
speed regulator, the resulting action is to override the speed reference and
decelerate to 10/11:1814 [Preset Speed 1]. This function is usually used with a
limit switch and initiates the slowing down process prior to encountering the
End Limit.
When the drive is operating as a torque regulator, the drive ignores this signal
and continues operating at its torque reference.
When the drive is operating as a position regulator, the drive ignores this
signal and continues moving towards its position reference.
DI Precharge
This digital input function is used to manage disconnection from a common
DC bus. If the input is closed, this indicates that the drive is connected to
common DC bus and normal precharge handling can occur, and that the drive
can run (start permissive). If the physical input is open, this indicates that the
drive is disconnected from the common DC bus, and the drive enters the
precharge state and initiates a coast stop immediately to prepare for
reconnection to the bus. If this input function is not configured, then the drive
assumes that it is always connected to the DC bus, and no special precharge
handling is done.
DI Prchrg Seal
This digital input function is used to force a unique fault when an external
precharge circuit opens. 0:39 [Prchrg Err Cfg] dictates the action taken when
an external precharge circuit has opened.
DI Hold Step
This digital input function sets a digital input port for the hold step in profile/
indexer control logic. The digital input that this parameter assigns is
equivalent to 10/11:1202 [Profile Command] bit 8 ‘Hold Step’. Parameter
0:850 [Prof DI Invert] bit 0 'Hold Step' defines the polarity of the active state.
DI Abort Step
This digital input function sets a digital input port for the abort profile in
profile/indexer control logic. 0:850 [Prof DI Invert] bit 1 ‘Abort Step’ defines
the polarity of the active state.
DI Abort Profile
This digital input function sets a digital input port for the hold step in profile/
indexer control logic. 0:850 [Prof DI Invert] bit 2 ‘AbortProfile’ defines the
polarity of the active state.
DI Vel Override
This digital input function sets a digital input port for the velocity override in
profile/indexer control logic. The digital input this parameter assigns is
equivalent to 10/11:1202 [Profile Command] bit 9 ‘Vel Override’. 0:850 [Prof DI
Invert] bit 3 ‘Vel Override’ defines the polarity of the active state.
DI Step 1 thru 16
This digital input function sets digital input source for the corresponding step
in profile/indexer control logic. The input is only required if the index step is
configured as one of the following:
1. [Type] Position Absolute [Action] Wait DigIn
2. [Type] Position Incremental [Action] Wait DigIn
3. [Type] Speed Profile [Action] DigIn Blend
4. [Type] Speed Profile [Action] Wait DigIn
0:850 [Prof DI Invert] bit 9 ‘Step 1’ to bit 24 ‘Step 16’ define the polarities of the
active state.
DI PCAM Start
This digital input function starts the CAM in the position reference planner.
Closing or energizing the input starts the CAM sequence but not the drive. A
separate run command is required to start the drive.
DI VCAM Start
This digital input function starts the CAM in the velocity reference planner.
Closing or energizing the input starts the CAM sequence but not the drive. A
separate run command is required to start the drive.
DI TqCAM Start
This digital input function starts the CAM in the torque reference planner.
Closing or energizing the input starts the CAM sequence but not the drive. A
separate run command is required to start the drive.
Status
For the PowerFlex 755T main control board Digital Inputs (Di) 0, 0:100 [Digital
In Sts] Bit 0 represents its respective digital input status. For the PowerFlex
750-Series Option Module Digital Inputs (Di) 0, 1, 2, 3, 4, and 5, nn:1 [Dig In Sts]
Bits 0, 1, 2, 3, 4, and 5 represents its respective digital input status. When the bit
associated with the digital input is on, depicted by a 1, this means that the drive
recognizes that the digital input is on. When the bit associated with the digital
input is off, represented by a 0, this means that the drive recognizes that the
digital input is off.
Configuration Conflicts
If you configure the digital inputs so that one or more selections conflict with
each other, one of the digital input configuration alarms is asserted. As long as
the Digital Input Conflict exists, the drive will not start. These alarms are
automatically cleared by the drive as soon as the parameters are changed to
remove the conflicts. These are examples of configurations that cause an
alarm:
• Configuring both the ‘Start’ input function and the ‘Run Forward’ input
function at the same time. ‘Start’ is used only in ‘3-wire’ Start mode, and
‘Run Forward’ is used only in ‘2-wire’ Run mode, therefore, do not
configure at the same time.
• Configuring the same toggle input function (for instance ‘Fwd Reverse’)
to more than one physical digital input simultaneously.
These alarms, called Type 2 Alarms, are different from other alarms in that it is
not possible to start the drive while the alarm is active. It is not possible for any
of these alarms to occur while the drive is running, because all digital input
configuration parameters can only be changed while the drive is stopped.
Whenever one or more of these alarms is present, the drive ready status
becomes ‘not ready’ and the HIM displays a conflict message. In addition, the
drive status light flashes yellow. See the PowerFlex Drives with TotalFORCE
Control Conditions Reference Data, publication 750-RD102 for a complete list
of Faults and Alarms.
DigIn Cfg B
Digital input conflict. Input functions that cannot exist at the same time have
been selected. Correct Digital Input configuration.
DigIn Cfg C
Digital input conflict. Input functions that cannot be assigned to the same
digital input have been selected. Correct Digital Input configuration.
Block Diagrams
Figure 71 - PowerFlex 755T
[Dig In Sts]
220 0
Com
1 5 4 3 2 1 0
[Dig In Fltr]
3
In5
Filter
Com 2 0
Digital Outputs The PowerFlex 755T has no outputs embedded on its Main Control Board.
There are PowerFlex 750-Series Option Modules that expand the amount of
digital outputs that can be used.
See the PowerFlex 750-Series I/O, Feedback, and Power Option Modules
Installation Instructions, publication 750-IN111 for PowerFlex 750-Series
Option Module I/O wiring examples.
Configuration
Each digital output can be programmed to change state based on one of many
different conditions. These conditions can fall into different categories.
• Drive status conditions (fault, alarm, and reverse).
• Level conditions (DC bus voltage, current, and frequency)
• Controlled by a digital input.
• Controlled by the network.
• Controlled by DeviceLogix software.
For PowerFlex 750-Series drives utilizing an option module, the table below
shows an overview of the selectable configurations for the drive’s digital
output selection parameters.
Parameter No. Parameter Name Description
0:59 Energy Status Status of the Energy Pause Function.
Status of the digital inputs resident on the main control board
0:100 Digital In Sts (Port 0).
0:456 EmergMode Status Status of the Emergency Override Function
(1) Dig In Sts Status of the option module digital inputs.
nn:1
Controls Relay or Transistor Outputs when chosen as the
nn:7 (1) Dig Out Setpoint source. Can be used to control outputs from a communication
device using DataLinks.
Status of the level compare, and a possible source for a relay
nn:13 (1) RO0 Level CmpSts
or transistor output.
Provides the individual on/off status of the DLX Boolean
9:1100… 9:1103 (2) DLX Bool SP1- SP4 scratchpad 1…4 memory locations. Each scratchpad location
contains 32 bits.
Indicates which condition is preventing the inverter from
10/11:351 M Start Inhibits starting or running. (examples Faulted, Alarm, Enable, and so
on)
10/11:354 Motor Side Sts 1 Present operating condition of the inverter.
See the PowerFlex Drives with TotalFORCE Control Parameters Reference Data,
publication 750-RD101 for specific parameter bit level details.
Example
Level Conditions
A desired level function needs to be programmed into the ‘Level Sel’ parameter,
depending on the output being used. If the value for the specified function
(frequency, current, and so forth) is greater than equal to or less than the
programmed limit dictated by the ‘Level’ parameter, the output activates or
deactivates depending on how the ‘Sel’ parameter is configured.
Notice that the Level Select parameters do not have units. The drive assumes
the units and the minimum/maximum values from the selected parameter
function. For example, if the ‘Level Sel’ is programmed for 10/11:362 [Heatsnk
Temp Pct], which indicates operating temperature of the drive power section
(heat sink), its units are in percentage of the maximum heat sink temperature
with minimum/maximum values of -200/+200 percent.
For the PowerFlex 750-Series drives utilizing an Option Module, the table
below shows an overview of the selectable configurations for the drive’s Digital
Output ‘Level Sel’ parameters.
Parameter No. Parameter Name Description
0:3 DC Bus Volts DC bus voltage.
Value of the Analog input after filter, square root, and loss
nn:50 (1) Anlg In0 Value action.
Value of the Analog input after filter, square root, and loss
nn:60 (1) Anlg In1 Value action.
Eight 32-bit Real scratchpad registers for DLX program
9:1120…9:1127 (2) DLX Real Out SP1 - SP8 output use.
Output frequency present at terminals T1, T2, and T3 (U, V &
10/11:1 Output Frequency W).
10/11:2 Output Voltage Output voltage present at terminals T1, T2, and T3 (U, V & W).
The total output current present at terminals T1, T2, and T3 (U,
10/11:3 Output Current V & W).
10/11:4 Output Power Output power present at terminals T1, T2, and T3 (U, V & W).
10/11:5 Output Pwr Factr Output power factor.
Based on the motor, the amount of current that is in phase
10/11:8 Torque Cur Fb with the fundamental voltage component.
Amount of current that is out of phase with the fundamental
10/11:9 Flux Cur Fb voltage component.
10/11:207 Mtr OL Counts Accumulated percentage of motor overload.
10/11:208 Mtr OL Trip Time Displays the inverse of the motor overload time.
10/11:357 Drive OL Count Indicates power unit overload (IT) in percentage.
Indicates operating temperature of the drive inverter section
10/11:362 Heatsnk Temp Pct (heat sink) in percentage of the maximum heat sink
temperature.
10/11:1044 Motor Vel Fb Estimated or actual motor speed, with feedback.
Displays the filtered velocity reference from the Encoder
10/11:1834 Enc VRef Velocity Reference function.
10/11:1914 VRef Commanded Value of the active Speed/Frequency Reference.
Displays the load observer torque estimate signal.
10/11:2036 LdObs Torque Est This value includes load disturbances relative to an ideal
unloaded motor.
Displays the torque reference output of the Friction
10/11:2057 FrctnComp Out Compensation function.
Final torque reference value after limits and filtering are
10/11:2073 Trq Commanded applied. Percent of motor rated
Displays total 3-phase average AC voltage.
13:2 (3) AC Line Voltage Parameter 13:23 [Display Filter] determines whether the value
is filtered or unfiltered.
Example
To configure RO0 on the option module located in port 7 to energize when the
drive's operating temperature of the drive power section (heat sink) in
percentage of the maximum heat sink temperature is greater than 50 percent,
set parameter 7:10 [RO0 Sel] to 7:13 [RO0 Level CmpSts] bit 1 ‘Grt Than Equ’,
7:11 [RO0 Level Sel] to 10/11:362 [Heatsnk Temp Pct], and 7:12 [RO0 Level] to 50.
Example
Controlled by Network
This configuration is used when it is desired to control the digital outputs over
network communication instead of a drive related function. In the case the
PowerFlex 750-Series Option Module, nn:7 [Dig Out Setpoint] is utilized. To
complete the configuration for control over a network, a datalink must be
configured for the Digital Output Setpoint parameter.
Example
To turn on physical outputs using DeviceLogix (DLX), you utilize the 32 bit
Boolean scratchpad memory locations 9:1100 [DLX Bool SP1] thru 9:1103 [DLX
Bool SP4]. These are User Selectable tags that can be added to the DLX
database via the DLX Tag Editor.
Example
The DeviceLogix program has been written to turn on 9:1102 [DLX Bool SP3],
bit 7 when a conveyor photoeye is blocked for more than 5 seconds. We need to
turn on a stack light wired to RO0 on the option module installed in port 5, to
indicate to the operator that there is a backup on the conveyor. To accomplish
this, set 5:10 [RO0 Sel] to 9:1102 [DLX Bool SP3], bit 7.
Invert
There is a logical invert function associated with the PowerFlex 750-Series
drive's digital outputs. It is configured by nn:6 [Dig Out Invert]. This invert
function changes the output status bit from a zero, false state, to a one, true
state, and vice versa.
This logical invert function requires power to be applied to the drive’s control
module for the drive’s logic to be active. This can be obtained from powering
up the drive’s control module by either applying power to the drive’s input
section or from an external 24V DC being wired into the Auxiliary Power
Supply Option Module.
Example
On/Off Time
Each digital output has two user-controlled timers associated with it. The On
timer defines the delay time between a False-to-True transition (condition
appears) on the output condition and the corresponding change in state of the
digital output. The Off timer defines the delay time between a True-to-False
transition (condition disappears) on the output condition and the
corresponding change in the state of the digital output. Either timer can be
disabled by setting the corresponding delay time to zero.
Example
For example, in the following diagram, a digital output is configured for 10/
11:354 [Motor Side Sts 1], bit 27 ‘Cur Limit’, the On Time is programmed for two
seconds and the Off Time is programmed for 0 seconds.
Relay Activates
On Delay = 2 Seconds
0 5 10
Status
The nn:5 [Dig Out Sts] parameter displays the status of the digital outputs and
can be used for troubleshooting the digital outputs. When the bit in associated
with the digital output is on, this means that the logic in the drive is telling that
digital output to turn on. When the bit associated with the digital input is off,
this means that the logic in the drive is telling that digital output to turn off.
Block Diagrams
Figure 73 - PowerFlex 750-Series Option Module Outputs
Outputs
RO0 Off Time
15 Dig Out Sts
Dig Out Invert
5 0 NC
6 0
Relay Out0 0
Timer Common
Source
Parameter 1
Selection Inv
NO
10 14
20 24
NO
RO1/TO0 Sel RO1/TO0 On Time
Transistor Out1 0
Timer
Source NO
Parameter 1
Selection Inv
30 34
TO1 Level 32 B
PTC Motor Thermistor Input A PTC (Positive Temperature Coefficient) sensing device, also known as a
motor thermistor, embedded in the motor windings can be monitored by the
drive for motor thermal protection. The motor windings are typically equipped
with three PTC sensors (one per phase) wired in series as shown in schematic
below. The miniaturized sensors have a low resistance below the rated
response temperature, and increase their resistance (exponentially) in the
rated response temperatures range. The rated response temperature is defined
by the PTC sensor. Motors with different thermal insulation classes (Class F or
H) are equipped with different PTC sensors, each with its own response
temperature such as 120, 130, and 140 degrees C. Unlike the PT100 or KTY
thermistors, which have a linear relation between temperature and resistance,
the PTC thermistor is used for a temperature level indication rather than a
direct measurement in degrees C.
- Temperature
1,330
250
Defined cutoff values
100
R[ǜ]
20
10
-20 ʞC TNF – 20K TNF + 15K
0 ʞC TNF – 5K TNF + 5K
TNF
The PTC thermistor leads are connected to the PTC+ and PTC- terminals on
TB1 of one of the optional I/O cards, catalog numbers 20-750-2262C-2R, 20-
750-2263C-1R2T, 20-750-2262D-2R.
Parameter nn:40 [PTC Cfg] = 0 ‘Ignore’, 1 ‘Alarm’, 2 ‘Flt Minor’, 3 ‘Flt CoastStop’,
4 ‘Flt RampStop’, or 5 ‘Flt CL Stop’
Status is shown in nn:41 [PTC Sts] and nn:42 [PTC Raw Value].
Status is shown in nn:41 [ATEX Sts] The fault action is not configurable when
the ATEX module is used.
Numerics conditions 29
needed to start 29
24V DC power source 41
control circuitry power 41
control features
A adaptive tuning 58
autotune 58
AC line source load observer 57
bus regulators 144 current regulator adjustment 147
configuration 143
external bus capacitance 144
parameter data 143
phase loss 168
D
switching 148 DC bus voltage
tuning 143 bus observer 59
AC motor types 48 feed forward power 61
accel/decel time derating 35
configure 7 DeviceLogix 99
adaptive tuning 58 digital outputs 252
alarms 167 digital inputs 235
analog inputs 222 discrete wired 74
functional descriptions 236
analog outputs 230 digital outputs 246
anti-sway 191
dynamic braking 201
automatic device configuration applications 204
activation 10 module and resistor 205
compatibility 9 PWM control 203
autotune 58 resistance 209
motor side inverter 188
E
B energy saving 71
braking methods 19 explicit messaging, predictive maintenance
coast 20 96
current limit stop 21
DC brake 24
decel to hold 23
fast brake 25
F
flux braking 26 faults 164
ramp 21 override 106
ramp to hold 23 queue 165
bus control 212 reset or clear 165
bus observer 59 response to 164
block diagram 61 feed forward power 61
limitations 60 parameters 62
bus regulation 59 feedback modes 56
bus supplies 138
derating 142 G
operation modes 139
generators
configuration 152
C considerations 150
calculate sway frequency 193 drive features 151
exception actions and limits 155
carrier frequecy external capacitance 153
derating 35 selection 150
carrier frequency 221 tuning 154
configuration 33
low speed 32
CIP security 66 H
high frequency variation 37
Additional Resources
These documents contain additional information concerning related products from Rockwell Automation.
Resource Description
Provides detailed information on:
PowerFlex 750-Series Products with TotalFORCE Control Technical Data, publication • Drive and bus supply specifications
750-TD100 • Option specifications
• Fuse and circuit breaker ratings
Provides detailed information on:
• Kit selection
PowerFlex 755TM IP00 Open Type Kits Technical Data, publication 750-TD101 • Kit ratings and specifications
• Option specifications
PowerFlex 750-Series Products with TotalFORCE Control Installation Instructions, Provides the basic steps to install PowerFlex 755TL low harmonic drives,
publication 750-IN100 PowerFlex 755TR regenerative drives, and PowerFlex 755TM drive systems.
PowerFlex 755TM IP00 Open Type Kits Installation Instructions, publication 750-IN101 Provides instructions to install IP00 Open Type kits in user-supplied enclosures.
Provides detailed information on:
PowerFlex Drives with TotalFORCE Control Programming Manual (firmware revision 6.xxx • I/O, control, and feedback options
and earlier), publication 750-PM100 • Parameters and programming
• Faults, alarms, and troubleshooting
PowerFlex TotalFORCE Firmware Documentation Set: Provides detailed information on:
• PowerFlex Drives with TotalFORCE Control Programming Manual, publication • Startup, control algorithms, and status indicators
750-PM101
• PowerFlex Drives with TotalFORCE Control Parameters Reference Data, publication • Parameters and programming
750-RD101
• PowerFlex Drives with TotalFORCE Control Conditions Reference Data, publication • Faults, alarms, events, and troubleshooting
750-RD102
Provides basic information to properly wire and ground the following products in
Drives in Common Bus Configurations with PowerFlex 755TM Bus Supplies Application common bus applications:
Techniques, publication DRIVES-AT005 • PowerFlex 755TM drive system for common bus solutions
• PowerFlex 750-Series AC and DC input drives
• Kinetix 5700 servo drives
Provides guidance on how to tune Flux Vector position and velocity loops, filters,
and other features to achieve the level of performance that is required for a
PowerFlex 755T Flux Vector Tuning, publication 750-AT006 given application. This publication is intended for novice drives users and users
with advanced skills.
PowerFlex Drives with TotalFORCE Control Built-in EtherNet/IP Adapter User Manual, Provides information on how to install, configure, and troubleshoot applications
publication 750COM-UM009 for the PowerFlex drives with the built-in EtherNet/IP adapter.
Provides detailed information on:
PowerFlex 750-Series Products with TotalFORCE Control Hardware Service Manual, • Preventive maintenance
publication 750-TG100 • Component testing
• Hardware replacement procedures
PowerFlex 750-Series Safe Speed Monitor Option Module Safety Reference Manual,
publication 750-RM001
PowerFlex 750-Series Safe Torque Off Option Module User Manual, publication
750-UM002
These publications provide detailed information on installation, set-up, and
PowerFlex 750-Series ATEX Option Module User Manual, publication 750-UM003 operation of the 750-Series safety option modules.
PowerFlex 755 Integrated Safety - Safe Torque Off Option Module User Manual,
publication 750-UM004
PowerFlex 755/755T Integrated Safety Functions Option Module User Manual, publication
750-UM005
PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Module) User Manual, 20HIM-UM001 Provides detailed information on HIM components, operation, and features.
Provides detailed set-up and operating instructions for the module service cart
PowerFlex 750-Series Service Cart Instructions, publication 750-IN105 and DC precharge module lift.
PowerFlex 755TM Power and Filter Module Storage Hardware Instructions, publication Provides detailed installation and usage instructions for this hardware
750-IN106 accessory.
PowerFlex 755T Module Service Ramp Instructions, publication 750-IN108 Provides detailed usage instructions for the module service ramp.
Provides basic information on enclosure systems, considerations to help protect
Industry Installation Guidelines for Pulse Width Modulated (PWM) AC Drives, publication against environmental contaminants, and power and grounding considerations
DRIVES-AT003 for installing Pulse Width Modulated (PWM) AC drives.
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication Provides basic information to properly wire and ground PWM AC drives.
DRIVES-IN001
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.
Rockwell Automation Knowledge Base The Rockwell Automation Support Forum
You can view or download publications at rok.auto/literature.
Technical Support Center Find help with how-to videos, FAQs, chat, user forums, and product notification updates. rok.auto/support
Knowledgebase Access Knowledgebase articles. rok.auto/knowledgebase
Local Technical Support Phone Numbers Locate the telephone number for your country. rok.auto/phonesupport
Literature Library Find installation instructions, manuals, brochures, and technical data publications. rok.auto/literature
Product Compatibility and Download Center Download firmware, associated files (such as AOP, EDS, and DTM), and access product rok.auto/pcdc
(PCDC) release notes.
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Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our
content, complete the form at rok.auto/docfeedback.
At the end of life, this equipment should be collected separately from any unsorted municipal waste.
Rockwell Automation maintains current product environmental information on its website at rok.auto/pec.
Allen-Bradley, Connected Components Workbench, DeviceLogix, expanding human possibility, FactoryTalk, PowerFlex, Rockwell Automation, RSLogix 5000, Stratix, Studio 5000 Logix Designer,
and TotalFORCE are trademarks of Rockwell Automation, Inc.
EtherNet/IP is a trademark of ODVA, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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