750 Rm100 - en P (Predictive Maintenance)

Reference Manual
Original Instructions
PowerFlex 750-Series Products with TotalFORCE Control

Catalog Numbers 20G, 20J
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Table of Contents
Preface
Overview Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Adaptive Control Load Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Adaptive Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Position and Velocity Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bus Observer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Feed Forward Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reference Notch Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
AC Line Tuning Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
AC Source Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
External Bus Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bus Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AC Line Source Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 3
Precharge Sequence Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frames 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frames 7…15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 4
Secondary Motor Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Secondary Motor Control Configuration . . . . . . . . . . . . . . . . . . . . . . . 27
Application Use Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chapter 5
Energy Pause Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Monitor Status with Energy Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Activate Energy Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Rockwell Automation Publication 750-RM100A-EN-P - August 2019 3

Table of Contents
Chapter 6
Predictive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Setting the Event Levels and Event Actions . . . . . . . . . . . . . . . . . . . . . . 40
Monitor Elapsed Life and Remaining Life . . . . . . . . . . . . . . . . . . . . . . . 41
Predictive Maintenance Function Details . . . . . . . . . . . . . . . . . . . . . . . 42
Resetting the Meters After Component Replacement . . . . . . . . . . . . 47
Reset Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Monitoring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 7
DeviceLogix Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DeviceLogix Configuration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DeviceLogix Tag Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Download and Enable the Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chapter 8
Emergency Override Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Activate the Emergency Override Feature . . . . . . . . . . . . . . . . . . . . . . . 65
Decide Which Protections to Override. . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 9
Reference Motion Planners New Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Position Reference Motion Planner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Velocity Reference Motion Planner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chapter 10
Droop Control for Parallel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Operation of PowerFlex 755TM Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Derating for Voltage Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
AFE Bus Supplies
Chapter 11
Application References PowerFlex 755T Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . 101
Anti-Sway Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Preface
Overview
The purpose of this manual is to provide detailed information about configuring

PowerFlex® 750-Series products with TotalFORCE® control for common
applications.
Who Should Use This 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
Manual an understanding of the parameter settings and functions.
Manual Conventions In this manual we refer to the PowerFlex 750-Series products with TotalFORCE
control as:
• PowerFlex 755T products when referring to the group of drives, bus
supplies, and common bus inverters.
• PowerFlex 755TL drive when referring to the low harmonic drive product.
• PowerFlex 755TR drive when referring to the regenerative drive product.
• PowerFlex 755TM drive system when referring to regenerative bus supply
and common bus inverter products.
Additional Resources The following table lists publications that provide general drive-related
information.
Resource Description
PowerFlex 750-Series Products with TotalFORCE Control Provides detailed information about:
Technical Data, publication 750-TD100 • Drive and bus supply specifications
• Option specifications
• Fuse and circuit breaker ratings
PowerFlex 755TM IP00 Open Type Kits Technical Data, Provides detailed information about:
publication 750-TD101 • Kit selection
• Kit ratings and specifications
• Option specifications
PowerFlex 755TM IP00 Open Type Kits Installation Provides instructions to install IP00 Open Type kits in
Instructions, publication 750-IN101 user-supplied enclosures.
PowerFlex 750-Series I/O, Feedback, and Power Option Provides instructions to install and wire 750-Series
Modules Installation, publication 750-IN111 option modules.
PowerFlex Drives with TotalFORCE Control Programming Provides detailed information about:
Manual, publication 750-PM100 • I/O, control, and feedback options
• Parameters and programming
• Faults, alarms, and troubleshooting
Drives in Common Bus Configurations with PowerFlex Provides basic information to wire and ground the
755TM Bus Supplies Application Techniques, publication following products in common bus applications:
DRIVES-AT005 • PowerFlex 755TM drive system for common bus
solutions
• PowerFlex 750-Series AC and DC input drive
• Kinetix® 5700 servo drives

Preface
Resource Description
PowerFlex 755T Flux Vector Tuning, publication 750-AT006 Provides guidance about how to tune Flux Vector
position and velocity loops, filters, and other features
to achieve the level of performance that is required
for a given application. This publication is intended
for novice drives users and users with advanced skills.
PowerFlex Drives with TotalFORCE Control Built-in Provides information about how to install, configure,
EtherNet/IP Adapter User Manual, publication 750COM- and troubleshoot applications for the PowerFlex
UM009 drives with the built-in EtherNet/IP™ adapter.
PowerFlex 750-Series Products with TotalFORCE Control Provides detailed information about:
Hardware Service Manual, publication 750-TG100 • Preventive maintenance
• Component testing
• Hardware replacement procedures
PowerFlex 750-Series Safe Speed Monitor Option Module These publications provide detailed information
Safety Reference Manual, publication 750-RM001 about installation, setup, and operation of the 750-
Series safety option modules.
PowerFlex 750-Series Safe Torque Off Option Module User
Manual, publication 750-UM002
PowerFlex 750-Series ATEX Option Module User Manual,
publication 750-UM003
PowerFlex 755 Integrated Safety - Safe Torque Off Option
Module User Manual, publication 750-UM004
PowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Provides detailed information about HIM
Module) User Manual, 20HIM-UM001 components, operation, and features.
PowerFlex 755TM AC Precharge Modules Unpacking and These publications provide detailed information
Lifting Instructions, publication 750-IN102 about:
• Component weights
PowerFlex 755TM DC Precharge Modules Unpacking and • Precautions and recommendations
Lifting Instructions, publication 750-IN103 • Hardware attachment points
PowerFlex 755TM Power and Filter Modules Unpacking • Lifting the component out of the packaging
and Lifting Instructions, publication 750-IN104
PowerFlex 750-Series Service Cart Instructions, publication Provides detailed setup and operating instructions for
750-IN105 the module service cart and DC precharge module lift.
PowerFlex 755TM Power and Filter Module Storage Provides detailed installation and usage instructions
Hardware Instructions, publication 750-IN106 for this hardware accessory.
PowerFlex 755T Module Service Ramp Instructions, Provides detailed usage instructions for the module
publication 750-IN108 service ramp.
Industry Installation Guidelines for Pulse Width Modulated Provides basic information about enclosure systems,
(PWM) AC Drives, publication DRIVES-AT003 considerations to help protect against environmental
contaminants, and power and grounding
considerations for installing Pulse Width Modulated
(PWM) AC drives.
Wiring and Grounding Guidelines for Pulse Width Provides basic information to properly wire and
Modulated (PWM) AC Drives, publication DRIVES-IN001 ground PWM AC drives.
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

http://www.rockwellautomation.com/global/literature-library/overview.page.

Chapter 1
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
When load observer is enabled with autotuned control loop gains:

• Load disturbances are compensated for automatically
• Tracking errors, machine vibration, and power consumption are
minimized
• Bandwidth and line speeds can be increased
• Tighter control of moving parts reduces wear and saves material costs

Chapter 1 Adaptive Control
Adaptive Tuning The adaptive tuning feature is an algorithm that continuously monitors and, if
necessary, adjusts filter parameters and control loop gains to compensate for
unknown and changing load conditions. Adaptive tuning performs the following
functions:
• Monitors motor-side resonances
• Automatically adjusts torque loop notch and low pass filter parameters to
suppress resonances
• Automatically tunes control loop gains to avoid instability
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.

Adaptive Control Chapter 1
Position and Velocity The PowerFlex 755T utilizes a series form of a Proportional-Integral (PI)
controller for the Position Regulator (PReg) and the Velocity Regulator (VReg).
Regulators The proportional and integral gains are expressed in units of Hz. The
proportional gains have been normalized by removing inertia and represent
bandwidth which is a readily understood and measureable value. Relating the
proportional gains to bandwidth makes the tuning experience more intuitive.
Figure 1 - Regulator Schemes
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 755T regenerative and low
harmonic AFE 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.
Bus Observer Limitations

• If the external capacitance is greater than three times the supply, DC bus
regulation can become unstable.
• Do not enter an external capacitance value greater than what is connected
or stability can be affected. It is recommended to use the lowest estimated
value. Bus observer can compensate for increased line capacitance, but it
cannot reduce line capacitance.
• Cannot be enabled or disabled while the converter is active (running).
Figure 2 and Figure 3 show the Bus Observer function.
Figure 2 - Voltage Control (VoltCtrl) Block Diagram

Volt Reg C/U Sel Selector:
0- Calculated
1- User Entered
Port 0,DC Bus Volts

Metering [D5]
BusObsMode (320): 3
BusObsMode BusCompMode
0- BusObs Only
1- BusObsVltEst 320 300 BusRegIntegTerm
0,2
0 DC Bus Command BusRegPropTerm
1 50 VbusErr
BusObs Volt Est 1 IqRefVbusReg
BusDistRejMode(300): DC Bus Obs DC Bus Obs
VoltRefGen [G3] PI Regulator
[H5] A[2]
0- Disabled
1-BusObserver.
2- FF Power. Volt Reg C/U Sel 54
VbusRegKi
c Volt Reg Ki 60
Volt Reg BW 55 0
Volt Reg Damping 56

u Volt Reg Ki 59 1
Auto Gain
Calculation
VbusRegKp
c Volt Reg Kp 58
0
u Volt Reg Kp 57 1
Internal Bus Capacitance Total Sys Cap

DcBusObs [C1]
Ext Bus Cap 52

Figure 3 - DC Bus Observer Block Diagram

Total Sys Cap
VoltCtrl [C4]
LscCtrlCfg [C5]
IqRefVbusReg
IqRefDcBusObs
+ X
- Limit
Cur Lmt Command

101
BusDistRejMode(300): -1
BusObs Curr Est
0- Disabled X 325
1-BusObserver.
2- FF Power. X
0
0,2 1 0,2 1
DistRejMode 300
1.0
VoltCtrl [F3]
1 BusObs Volt Est
Port 0
DC Bus Volts
3 + X
-
c BusObs Kp 321 323 cBus Obs Ki

u BusObs Kp 322 324 u BusObs Ki
X X
Feed Forward Power 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 bus supply because it does
not have the inverter control on the same control board.

Figure 4 - Feed Forward Power Block Diagram

40 2
Conv Options Cfg

CurRefGen [F2]
PFC [A2,E2,A4,E4]
VoltCtrl [H2]
Converter Mode Select
FF Power Gain 13:44
X
Output Power 10:4
DC Bus Obs[H2]
IqRefDcBusObs
Table 1 - Feed Forward Power Parameters

Parameter No. Parameter Name Setting Description
13:300 BusDistRej Mode 0 = ‘Disabled’ The control uses no special method.
1 = ‘Bus Observer’ The control applies Bus Observer.
This setting is recommended for 755TM bus supplies.
2 = ‘FF Power’ The control applies the feed forward power method.
This setting is recommended for 755TL/TR drives.
13:320 BusObs Mode 0 = ‘BusObs Only’ Bus Observer Only mode.
Use this setting when the bus capacitance is known.
1 = ‘BusObsVltEst’ Bus Observer with voltage estimate mode.
Use this setting when the bus capacitance is unknown.
Reference Notch Filters 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 121 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 5 and Figure 6 show that the notch filters are located in the reference
command of both the position and velocity command paths.
Figure 5 - Position Reference 2 (PRef2) Block Diagram

PRef EGR Out
PRef NF Out
15
Ref NF 1 Ref NF 2 ¦ 1731 Position Command
PRef NF Out
PReg [C3]
942 Ref NF1 Freq 948 Ref NF2 Freq
943 Ref NF1 Width 949 Ref NF2 Width
944 Ref NF1 Depth 950 Ref NF2 Depth
945 Ref NF1 Gain 951 Ref NF2 Gain
Figure 6 - Velocity Reference – Flux Vector (VRef Vect)

Start/Stop
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)
Cubic 1018 1046
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
Figure 7 - Process PID (Proc1) Block Diagram Block Diagram

PID Ref Sel
9:25 Ref NF1 Freq 942 948 Ref NF2 Freq
Option
Ref NF1 Width 943 949 Ref NF2 Width
Port:
PID Ref PID Ref Ref NF1 Depth 944 950 Ref NF2 Depth Digital In
AnlgHi AnlgLo
Ref NF1 Gain 945 951 Ref NF2 Gain
PID
9:29 9:30
Deadband
9:9
Option Parameter
Port: Selection 9:1 1 PID Cfg
Analog In (Ramp Ref)
Analog Types
0 Ref Ref
x NF1 NF2 +-
MOP [G3] Scale Error Deadband
MOP Reference 1
1823 9:27 0
Float Types Ramp
PID Ref
PID Setpoint Mult
9:28 Default 9:26 9:3 0
9:10
PID Ref PID Status Filter
PID LPF
Meter (PID Enabled)
LPass BW

Table 2 - Notch Filter Parameters

Parameter No. Parameter Name Setting Min/Max Description
10/11:942 Ref NF1 Freq 0.00/32767.00 Hz Reference Notch Filter Frequency
10/11:948 Ref NF2 Freq Enter the center frequency of the first reference notch
filter in units of Hz.
10/11:943 Ref NF1 Width 0.000/10000.000 Reference Notch Filter Width
Enter the width of the first reference notch filter
10/11:949 Ref NF2 Width around the center frequency.
This value determines the denominator damping of its
second order transfer function.
A typical value of 0.4 produces a narrow width and a
value of 1.0 produces a wide width.
10/11:944 Ref NF1 Depth 0.000/10000.000 Reference Notch Filter Depth
Enter the depth of the first reference notch filter at the
10/11:950 Ref NF2 Depth center frequency.
This value determines attenuation level and the
numerator damping of its second order transfer
function.
The minimum depth occurs when this value is the
same value as the width, turning off the filter. The
maximum depth occurs when this value is zero.
10/11:945 Ref NF1 Gain -20.00/+20.00 Command (Reference) Notch Filter Gain
Enter the gain of the first reference notch filter.
10/11:951 Ref NF2 Gain
This value sets the mode of the filter and gain of its
second order transfer function.
For a notch filter, enter a value of 1.
For a second order low pass filter, enter a value of 0.
For a second order lag-lead filter, enter a value from 0
to 1.
For a second order lead-lag filter, enter a value greater
than 1.
Notch Filters Examples
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.

Figure 8 - Velocity Command – Before Reference Notch Filter
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
Figure 9 - Velocity Command – After Reference Notch Filter

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

Notes:

Chapter 2
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.
Technical 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.

Chapter 2 AC Line Tuning
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 3 shows the basic AC line source information required.
Table 3 - 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 impedance is derived from this information. The converter operates best
when system impedance is less than 10%. Use this equation to calculate system
impedance.
PowerFlex 755T KV A
System Impedance = × Transformer % Impedance
Transformer KV A
The Line Source A and Line Source B parameters accommodate situations where
the system is powered by two separate sources. An example is when the 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.
External Bus Capacitance When tuning the converter, some analogies can be made to tuning the inverter.
One analogy is the similarity between external bus capacitance and load inertia.
Just like inertia resists changes in velocity on the motor side, bus capacitance
resists changes in DC Bus Voltage on the line side. Having the correct external
bus capacitance is as important to the Voltage Regulator gains as having the
correct load inertia is to the Velocity Regulator gains.
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.
IMPORTANT Do not overstate the external bus capacitance.

AC Line Tuning Chapter 2
Specifying an external capacitance value that is higher than the actual connected
capacitance can cause instability. Also, incorrect values cause a noticeable
performance degradation. If you don’t know the exact capacitance, specify the
value on the low side and use the Bus Observer feature to account for the
remaining capacitance. See Bus Observer on page 9 for more information. If the
external bus capacitance is largely unknown, enter a zero and enable the bus
observer to estimate the entire value.
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.
Voltage and Current Regulator Tuning
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).
If an application has a high impedance supply, the default bandwidths can cause
the LCL filter to resonate and requires the converter to be de-tuned. To de-tune,
adjust 13:55 [Volt Reg BW] and 13:75 [Cur Reg BW] down by the same
percentage. As a rule, the current regulator bandwidth is 10 times larger than the
voltage regulator bandwidth (10:1 ratio) to avoid interaction and possible
resonance. However, in applications that require a fast dynamic response with a
soft line supply, you can reduce the ratio down to 6:1.
A good indication that the converter needs to be de-tuned is the presence of

14117 ‘CapResonanceArm’ and 14118 ‘CapResonanceFlt’ alarms. Monitor
14:1216 [F0 Cap BPF Cur R], 14:1217 [F0 Cap BPF Cur S], and 14:1218 [F0
Cap BPF Cur T] to observe the LCL filter resonance. When de-tuning, lower the
bandwidths until these parameters are below the capacitor resonance fault
threshold. The thresholds are listed in the following tables.

Table 4 - Capacitor Resonance Fault Thresholds—400/480V Products

Frame 400V ND Rating Codes (1) 480V ND Rating Codes (1) Resonance Current [A]
Alarm Fault
5 C015…C043 D014…D040 3 4
C060…C104 D052…D096 6 7
6 C140, C176 D125, D156 11 14
C205, C260 D186, D248 18 23
7 C302…C585 D302…D617 23 31
8 C302…C540 D302…D505 23 31
C585…C770 D545…D740 31 41
9 C920, C1K0 D800, D960 46 62
C1K1…C1K4 D1K0…D1K3 62 82
10 C1K6…C2K1 D1K4…D2K0 62 82
11 C2K8 D2K6 62 82
12 C3K5 D3K4 62 82
13 C4K2 D4K0 62 82
14 C5K6 D5K4 62 82
15 C7K0 D6K7 62 82
(1) Catalog number positions 7…10.
Table 5 - Capacitor Resonance Fault Thresholds—600/690V Products

Frame 600V ND Rating Codes (1) 690V ND Rating Codes (1) Resonance Current [A]
Alarm Fault
5 E011…E062 F015…F061 5 6
6 E077…E144 F082…F142 10 13
7 E192…E395 F171…F370 23 31
8 E242…E545 F215…F505 23 31
9 E595…E760 F565…F735 31 41
E825, E980 F820, F920 46 62
10 E1K1…E1K5 F1K0…F1K4 46 62
11 E2K0 F1K8 46 62
12 E2K4 F2K3 46 62
13 E2K9 F2K7 46 62
14 E3K9 F3K6 46 62
15 E4K9 F4K5 46 62
(1) Catalog number positions 7…10.
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 6 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 6 - Resonance Current Thresholds
LCL Module Parameters Resonance Current by Frame 400V/480V (600V/690V) [A]
10 11 12 13 14 15
0 14:1216…14:1218 82 (62) 82 (62) 82 (62) 82 (62) 82 (62) 82 (62)
1 14:1316…14:1318 — — — — — —
2 14:1416…14:1418 41 (31) 82 (62) 82 (62) 41 (31) 82 (62) 82 (62)
3 14:1516…14:1518 — — — 82 (62) — —
4 14:1616…14:1618 — — 41 (31) — 82 (62) 41 (31)
5 14:1716…14:1718 — — — 41 (31) — 82 (62)
6 14:1816…14:1818 — — — — 82 (62) —
7 14:1916…14:1918 — — — — — 82 (62)
8 14:2016…14:2018 — — — — — —
9 14:2116…14:2118 — — — — — 41 (31)
Voltage Regulator Gains—Manual Adjustment
PowerFlex 755T products allow individual manual adjustment of the

proportional and integral terms that are used by the voltage regulator. To enable
manual adjustment of the proportional and integral terms, set 13:54 [Volt Reg
C/U Sel] to 1 ‘User Entered’. This setting switches the gains that are used by the
voltage regulator from the calculated values to values that are entered in
parameters 13:57 [u Volt Reg Kp] and 13:59 [u Volt Reg Ki].
It is recommended to begin manual adjustment with the suggested gain start

points. To initiate the transfer of these values, toggle 13:54 [Volt Reg C/U Sel] to
2 ‘LoadCalcData’. When this option is selected, the calculated gains values are
copied to the user entered gain parameters. When the transfer is complete, 13:54
[Volt Reg C/U Sel] will automatically set to 1 ‘User Entered’ for manual
adjustment.
Proper adjustment of the individual proportional and integral terms is more

difficult than adjusting the bandwidth because the ideal spacing between the
proportional and integral terms is not maintained. The theoretical ideal spacing
between the proportional and integral terms is where Z = 1 is the desired
damping factor. This creates a 4:1 spacing.

Figure 10 - Voltage Regulator and Gains Block Diagram

Volt Reg C/U Sel Selector:
0- Calculated
1- User Entered
Port 0,DC Bus Volts

Metering [D5]
BusObsMode (320): 3
BusObsMode BusCompMode
0- BusObs Only
1- BusObsVltEst 320 300 BusRegIntegTerm
0,2
0 DC Bus Command BusRegPropTerm
1 50 VbusErr
BusObs Volt Est 1 IqRefVbusReg
BusDistRejMode(300): DC Bus Obs DC Bus Obs
VoltRefGen [G3] PI Regulator
[H5] A[2]
0- Disabled
1-BusObserver.
2- FF Power. Volt Reg C/U Sel 54
VbusRegKi
c Volt Reg Ki 60
Volt Reg BW 55 0
Volt Reg Damping 56

u Volt Reg Ki 59 1
Auto Gain
Calculation
VbusRegKp
c Volt Reg Kp 58
0
u Volt Reg Kp 57 1
Internal Bus Capacitance Total Sys Cap

DcBusObs [C1]
Ext Bus Cap 52

13:54 Volt Reg C/U Sel 0 = Calculated, 1 = User Entered, 2 = Load Calculated Data
13:55 Volt Reg BW Voltage regulator bandwidth in Hz
13:56 Volt Reg Damping Voltage regulator damping factor
13:57 u Volt Reg Kp User entered voltage regulator proportional gain
13:58 c Volt Reg Kp Calculated voltage regulator proportional gain
13:59 u Volt Reg Ki User entered voltage regulator integral gain
13:60 c Volt Reg Ki Calculated voltage regulator integral gain
Current Regulator Gains—Manual Adjustment
PowerFlex 755T products allow individual manual adjustment of the

proportional and integral terms that are used by the current regulator. To enable
manual adjustment of the proportional and integral terms, set 13:74 [Cur Reg C/
U Sel] to 1 ‘User Entered’. This setting switches the gains that are used by the
current regulator from the calculated values to values that are entered in
parameters 13:77 [u Cur Reg Kp] and 13:79 [u Cur Reg Ki].
It is recommended to begin manual adjustment with the suggested gain start

points. To initiate the transfer of these values, toggle 13:74 [Cur Reg C/U Sel] to
2 ‘LoadCalcData’. When this option is selected, the calculated gains values are
copied to the user entered gain parameters. When the transfer is complete, 13:54
[Volt Reg C/U Sel] will automatically set to 1 ‘User Entered’ for manual
adjustment.

Proper adjustment of the individual proportional and integral terms is more

difficult than adjusting the bandwidth because the ideal spacing between the
proportional and integral terms is not maintained. The theoretical ideal spacing
between the proportional and integral terms is where Z = 1 is the desired
damping factor. This creates a 4:1 spacing.
Figure 11 - Current Control (CurrCtrl) Regulator and Gains Block Diagram

Cur Reg C/U Sel Selector:
0- Calculated
1- User Entered IqSyncErr CurRegqOut
Active Cur Cmd 67
CurPwrLmt [G3] PI Regulator
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
LCL Data c Cur Reg Kp 78 CurRegKiId

VdSyncRef
0
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

13:74 Cur Reg C/U Sel 0 = Calculated, 1 = User Entered, 2 = Load Calculated Data
13:75 Cur Reg BW Current regulator bandwidth in Hz
13:76 Cur Reg Damping Current regulator damping factor
13:77 u Cur Reg Kp User entered current regulator proportional gain
13:78 c Cur Reg Kp Calculated current regulator proportional gain
13:79 u Cur Reg Ki User entered current regulator integral gain
13:80 c Cur Reg Ki Calculated current regulator integral gain
AC Line Source Switching 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.
IMPORTANT Do not switch AC line sources while the converter is modulating.
When switching between two AC line sources, it is important that the converter
is tuned to both sources. Individual AC line sources rarely have the same
electrical characteristics. Gains that work well for one source can cause resonance
when connected to the alternate source.

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.
Power Loss Source Switching
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.

Chapter 3
Precharge Sequence
This section defines the precharge sequence of the PowerFlex® 750-Series

products with TotalFORCE® control.
Overview PowerFlex 755T products use a precharge sequence to control powerup. 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.

Chapter 3 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.

Chapter 4
Secondary Motor Control
PowerFlex® 755T products support user-configuration of a secondary motor

control profile that provides application flexibility.
Overview 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.
Secondary Motor Control The Secondary Motor Control modular control profile in port 11 is defined in
0:67 [Sec MtrCtrl Mode]. The same motor control types that are available in the
Configuration primary motor control profile are configurable in the secondary motor control
profile. Motor control profiles include Induction VHz, Induction SV, Induction
Economizer, Induction FV, IPM FV, and SPM FV. The active motor control type
that is configured in the Secondary Motor Control profile port 11 is displayed in
0:68 [Sec MtrCtrl Act].
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.

Chapter 4 Secondary Motor Control
Switching Between Motor Control Profiles
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].
Discrete-Wired Digital Input
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.
Interaction between Logix and Digital Input
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.

Secondary Motor Control Chapter 4
Application Use Cases Secondary Motor Control profiles can be used for various applications.
Applications that require one drive to control two different-sized motors
independently, multi-axis storage and retrieval systems, or single motor to multi-
motor are several examples that can leverage the two motor control profiles.
One Drive, Two Independent Motors

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.
Figure 12 - One Drive, Two Independent Motors

PowerFlex 755T Drive
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
100 Hp 150 Hp
Power Structure
100 Hp 150 Hp

One Drive, Two Motor Control Types
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.
Figure 13 - One Drive, Two Motor Control Types

Port 10 Port 11
Induction Motor SPM Motor

Flux Vector Flux Vector
Power Structure
Induction SPM

Secondary Motor Control Chapter 4
One Drive, One Motor, and Multi-Motor Control
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.
Figure 14 - One Drive, One Motor, Multi-Motor

Port 10 Port 11
Induction Motor Induction Motor

Flux Vector Volts per Hertz

Notes:

Chapter 5
Energy Pause Function
This section provides instructions for configuring the Energy Pause function on
PowerFlex® 755T products.
Overview 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.
Components that save energy:

• LCL filter and line side converter heatsink fans
• Balancing resistors
• Power module power supplies
• LCL filter module inductors
For frame 5 and 6 products that are in the energy pause mode, an external input
contactor can be controlled to disconnect the drive from the AC line.
For frame 7…15 products that are in energy pause mode, line side converters are
disconnected from the AC line and the fans are in a low-energy state.
Table 7 - Total Energy Savings
Frame Drives [kW] Bus Supplies [kW]
5 (1) — —
(1)
6 — —
(1)
7 — —
8 1.31 1.11
9 2.22 1.83
10 3.53 2.49
11 4.45 3.66
12 5.76 4.77
13 7.07 5.89
14 8.90 7.32
15 11.52 9.55
(1) Data not available at publication.

Chapter 5 Energy Pause Function
System Requirements The Energy Pause function is available in PowerFlex 755TL low harmonic drives,
755TR regenerative drives, and 755TM bus supplies.
• Firmware revision 3 or later is installed.
• A customer-supplied 24V DC power source is connected to the control
bus at terminal TB5.
Monitor Status with Energy 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
Pause CIP Energy Power Management object. The names come from that object.
Monitor the status of the state machine with parameter 0:59 [Energy Status].
No. Display Name Values
FW Revision
Access Level
Read-Write
Data Type
Extended Name
Description
59 Energy Status RO Bit 3.x 2
Energy Status
Displays the state of the energy function.
Options
Cls Ext Cont
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
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.
Power Off Power up and AC precharge successful.
Energy Pause Command Owned
AC precharge successful.
Paused Energy Resume Command Resuming

(Not Energy Pause)

Energy Pause Function Chapter 5
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 not modulating.
You must set parameter 0:63 [LS Start Mode] to 2 ‘Conv Logic’ to use energy
pause.
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.
The function moves to the Owned state when AC precharge is complete.

Activate Energy Pause 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:

• Program the Logix project to set bit 21 ‘Energy Pause’ of the logic
command word to request an Energy Pause command. Link to
Communication of Option Module Logic Command/Status Words. See
the Communication section in the PowerFlex Drives with TotalFORCE
Control Programming Manual, publication 750-PM100.
• Program the project to clear the bit to request an Energy Resume
command.
For PowerFlex 755TL/TR drives:

• Set parameter 0:63 [LS Start Mode] to 2 ‘ConvLogic’
• Set an output datalink to parameter 0:64 [LS Manual Ctrl]
• Program the Logix project to set parameter 0:64 [LS Manual Ctrl] bit 21
‘Energy Pause]’of word to request an Energy Pause command.
• Program the project to clear the bit to request an Energy Resume
command.
Discrete-wired Digital Input—Frames 5 and 6

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.
Example: Connect a digital output function that energizes to close an external

contactor.
• Set I/O card parameter nn:10 [RO0 Sel] to 000059.16.
This value is the address of parameter 0:59 [Energy Status] bit 16.
• Connect the relay output to the contactor to energize the coil that closes
the contactor.
• The energy function clears this bit 16 in the Paused state.
Bit 16 is set in the Resuming and Owned states.

Energy Pause Function Chapter 5
Interaction Between Logic Command and Digital Input
Parameter 0:267 [EnergyPauseOwner] indicates which ports are issuing valid

energy pause commands. By default, bit 15 = 1, which is the embedded Ethernet
port.
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 8 - 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

Notes:

Chapter 6
Predictive Maintenance
This section provides instructions for configuring the predictive maintenance

function on PowerFlex® 755T products.
Overview The overall goal of the predictive maintenance function is to enable regular
maintenance of drives, motors, and machines.
The predictive maintenance function monitors the lifespan of various

components that are used in PowerFlex 755T products. The function uses prior
usage patterns to calculate the component lifespan.
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.
The Predictive maintenance function can monitor the following components:

• Insulated-gate bipolar transistors (IGBTs)
• Fans and blowers
• DC bus capacitors
• Circuit breaker
• LCL capacitors
• Filters (airflow health)
The predictive maintenance function calculates the remaining life of

components. The calculation is based on the following application factors:
• Temperature
• Air quality
• Airflow
• Voltage
• Runtime
• Cycles
• Drive size
In each of the predictive maintenance functions, there are several parameters that
are used to configure levels, actions, inputs, and outputs. The following sections
describe those functions and parameters. The following descriptions are the same
for all parameters. For example, Event Level functions are the same for all
parameters, in that it determines when the event that it is monitoring occurs
based on percentage of life used.

Chapter 6 Predictive Maintenance
Setting the Event Levels 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
and Event Actions 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.

Predictive Maintenance Chapter 6
Monitor Elapsed Life and There is an elapsed life and a remaining life parameter for each component that is
covered by predictive maintenance.
Remaining Life
Elapsed Life
The values of these parameters represent the accumulated damage that the
components experience.
The unit of measure is unique for each type of component.

• Hours for fans, bus capacitors, and filter capacitors.
• Cycles for relay contacts, IGBTs, precharge contactors, switches, and
breakers.
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 value of this parameter represents a prediction of how much life is remaining
in the component. Changes you make to the event level for each predictive
maintenance function directly affect this value.
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.

Predictive Maintenance This section describes the details of the predictive maintenance functions of
PowerFlex 755T products.
Function Details
IGBT Modules
Table 9 - Event Level and Event Action Parameters
Parameter No. Parameter Name Units Definition
0:566 IGBT Event Level % Enter a value to determine when a Predictive
Maintenance IGBT event in the power modules takes
place. The event notifies you to replace the power
module.
0:567 IGBT Event Actn 0 = ‘Ignore’ Select the action taken when the Predictive Maintenance
1 = ‘Alarm’ IGBT event in the power modules takes place.
Output Parameters (Port 12 and 14)
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
occured. 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 10 - Output Parameters
Units Definition Parameters
Hours Displays the remaining life for the IGBTs in the line side power module.
IGBTs in power module L0 14:140 [L0IGBT RemainLif]
… …
Hours Displays the unprocessed elapsed life of the IGBTs in the line side power module.
IGBTs in power module L0 14:139 [L0IGBT ElpsdLife]
… …
Cycles Displays the unprocessed elapsed life of the IGBTs in the motor side power module.
IGBTs in power module M0 12:139 [M0IGBT 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)
The firmware calculates by averaging the measured ambient temperature

parameters from the power modules in the motor side inverter and the line side
converter.
Table 11 - Input Parameters
Units Definition Motor Side Power Module Fans Line Side Power Module Fans LCL Filter Module Fans
°C Temperature Module M0 = 12:131 [M0 Meas Amb Tmp] Module L0 = 14:131 [L0 Meas Amb Tmp] Module LCL0 = 14:1241 [F0 Meas Amb Tmp]
Module M1 = 12:231 [M1 Meas Amb Tmp] Module L1 = 14:231 [L1 Meas Amb Tmp] Module LCL1 = 14:1441 [F2 Meas Amb Tmp]
… … …
Module M1 = 12:1031 [M9 Meas Amb Tmp] Module L9 = 14:1031 [L9 Meas Amb Tmp] Modlue LCL5 = 14:2141 [F9 Meas Amb Tmp]
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 Heatsink Fans Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
% Event Level 0:562 0:514 0:534 0:524 0:554 0:544
[HSFan EventLevel] [PodFan Event Lvl] [PwrRfFanEventLvl] [In Fan EventLvl] [CtrlFanEventLvl] [WrgFanEventLvl]
1 or 0 Event Action 0:563 0:515 0:535 0:525 0:555 0:545
[HSFan EventActn] [PodFan EventActn] [PwrRfFanEvntActn] [In FanEventActn] [CtrlFanEvntActn] [WrgFanEvntActn]

Hours Remaining Module M0 = 12:136 [M0HSFanRemainLif] Module L0 = 14:136 [L0HSFanRemainLif] Module LCL0 = 14:1246 [F0HSFanRemainLif]
Life Module M1 = 12:236 [M1HSFanRemainLif] Module L1 = 14:236 [L0HSFanRemainLif] Module LCL1 = 14:1446 [F2HSFanRemainLif]
… … …
Module M9 = 12:1036 [M9HSFanRemainLif] Module L9 = 14:1036 [L0HSFanRemainLif] Module LCL5 = 14:2146 [F9HSFanRemainLif]
Hours Remaining 0:513 0:533 0:523 0:553 0:543
Life [PodFan RemainLif] [PwrRfFanRem Life] [In FanRemainLif] [CtrlFanRem Life] [WrgFanRem Life]
Hours Elapsed Life Module M0 = 12:135 [M0HSFanElpsdLife] Module L0 = 14:135 [L0HSFanElpsdLife] Module LCL0 = 14:1245 [F0HSFanElpsdLife]
Module M1 = 12:235[M1HSFanElpsdLife] Module L1 = 14:235 [L1HSFanElpsdLife] Module LCL1 = 14:1445 [F2HSFanElpsdLife]
… … …
Module M9 = 12:1035 [M9HSFanElpsdLife] Module L9 = 14:1035 [L9HSFanElpsdLife] Module LCL5 = 14:2145 [F9HSFanElpsdLife]
Hours Elapsed Life 0:512 [PodFan ElpsdLife] 0:532 [PwrRfFanElpsdLif] 0:522 [In FanElpsdLife] 0:552 [CtrlFanElpsdLif] 0:542 [WrgFanElpsdLif]

DC Bus Capacitors
To help support planned maintenance schedules, predictive parameters issue an

alarm when it is time to replace bus capacitors.
°C Temperature Module M0 = 12:131 [M0 Meas Amb Tmp] Module L0 = 14:131 [L0 Meas Amb Tmp] Module LCL0 = 14:1241 [F0 Meas Amb Tmp]
… … …

Units Definition Heatsink Fans
% Event Level 0:570 [Bus Cap EventLvl]
1 or 0 Event Action 0:571 [BusCap EventActn]

Units Definition Motor Side Power Module Line Side Power Module
Hours Remaining Module M0 = 12:143 [M0BusCapRmngLife] Module L0 = 14:143 [L0BusCapRmngLife]
Life Module M1 = 12:243 [M1BusCapRmngLife] Module L1 = 14:243 [L1BusCapRmngLife]
… …
Module M9 = 12:1043 [M9BusCapRmngLife] Module L9 = 14:1043 [L9BusCapRmngLife]
Hours Elapsed Life Module M0 = 12:142 [M0BusCapElpsdLif] Module L0 = 14:142 [L0BusCapElpsdLif]
Module M1 = 12:242 [M1BusCapRmngLife] Module L1 = 14:242 [L1BusCapElpsdLif]
… …
Module M9 = 12:1042 [M9BusCapRmngLife] Module L9 = 14:1042 [L9BusCapElpsdLif]
Airflow Health
The goal of the predictive maintenance function is to be able to assess the health
of the airflow system with the ability to detect abnormal conditions that are
based on deviations from an expected temperature rise.
The following warnings are generated by comparing the actual temperature rise
with the upper and lower expected temperature rise limits.
• High Temperature Rise warning
• Low Temperature Rise warning
Several conditions can cause a high temperature rise warning, including:

• Blocked air filter
• Mismatch of air filter and IP class of drive
• Internal recirculation caused by damaged or missing baffles or gaskets
• Debris in the IGBT airflow path
• Excessive pre-heating of air

• Missing LCL filter or power module covers

• Roof fan failures
Several conditions can cause a low temperature rise warning, including:

• Missing air filter
• Mismatch of air filter and IP class of drive
Units Definition Motor Side Power Module Fans Line Side Power Module Fans Motor Side Heatsink Line Side Heatsink
°C Temperature M0 = 12:131 [M0 Meas Amb Tmp] L0 = 14:131 [L0 Meas Amb Tmp] M0 = 12:118 [M0 HeatsinkTempV] L0 = 14:118 [L0 HeatsinkTempS]
M1 = 12:231 [M1 Meas Amb Tmp] L1 = 14:231 [L1 Meas Amb Tmp] M1 = 12:218 [M1 HeatsinkTempV] L1 = 14:218 [L1 HeatsinkTempS]
… … … …
M9 = 12:1031 [M9 Meas Amb Tmp] L9 = 14:1031 [L9 Meas Amb Tmp] M9 = 12:1018 [M9 HeatsinkTempV] L9 = 14:1018 [L9 HeatsinkTempS]

Units Definition High Temperature Rise Low Temperature Rise
1 or 0 Event Action 0:590 [Hi TR EventActn] 0:591 [Lo TR EventActn]
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..
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]

Units Definition AC Precharge Main Circuit Breaker AC Precharge Contactor DC Precharge Molded Case Switch
Hours Remaining 14:1143 [ACP0 MCB RmngLif] 14:1146 [ACP0 PCC RmngLif] Module M0 = 12:146 [DCP0MCS Rem Life]
Life 14:1153 [ACP1 MCB RmngLif] 14:1156 [ACP1 PCC RmngLif] Module M1 = 12:246 [DCP1MCS Rem Life]
…
Module M9 = 12:1046 [DCP9MCS Rem Life]
Cycles Elapsed Life 14:1142 [ACP0 MCBElpsdLif] 14:1145 [ACP0 PCCElpsdLif] Module M0 = 12:145 [DCP0MCS ElpsdLif]
14:1152 [ACP1 MCBElpsdLif] 14:1155 [ACP1 PCCElpsdLif] Module M1 = 12:245 [DCP1MCS ElpsdLif]
…
Module M9 = 12:1045 [DCP9MCS ElpsdLif]

LCL Capacitors
The calculation of line capacitor life is simplified. The only operating parameter
is ambient temperature.
Units Definition Motor Side Power Module Fans
°C Ambient Module LCL0 = 14:1241 [F0 Meas Amb Tmp]
Temperature Module LCL1 = 14:1441 [F2 Meas Amb Tmp]
…
Module LCL5 = 14:2141 [F9 Meas Amb Tmp]
% Event Level 0:586 [LCL Cap EventLvl]
1 or 0 Event Action 0:587 [LCLCap EventActn]

Units Definition DC Precharge Molded Case Switch
Hours Remaining Module LCL0 = 14:1250 [F0 Cap RmngLife]
Life Module LCL1 = 14:1450 [F2 Cap RmngLife]
…
Module LCL5 = 14:2150 [F9 Cap RmngLife]
Hours Elapsed Life Module LCL0 = 14:1249 [F0 Cap ElpsdLif]
Module LCL1 = 14:1449 [F2 Cap ElpsdLif]
…
Module LCL5 = 14:2149 [F9 Cap ElpsdLif]

Resetting the Meters After Rockwell Automation has made the following components field replaceable: all
types of fans, DC bus capacitors, LCL filter capacitors, main circuit breakers in
Component Replacement 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 33 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 This section provides instructions about how to reset Predictive Maintenance
function parameters after you replace a component.
M0 Power Module Heatsink Fan Example
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.
Parameter 12:130 [M0PredMaintReset] returns to 0 ‘Ready’ after the reset

is performed.
4. Return to parameter 0:504 [PredMain Rst En] in port 0. Then clear bit 10
‘M0’.

Control Pod Fan Example
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 This section provides instructions for configuring the Predictive Maintenance
Event Level and Event Action.
Heatsink Fan Example
Go to the Predictive Maintenance group in the Protection file of port 0.
Go to parameter 0:562 [HSFan EventLevel]. Change the value to 70%.
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.
Go to parameter 0:563 [HSFan EventActn]. The value is set to ‘Alarm’ with an

internal value of 1.
When this parameter is set to alarm, a heatsink fan event results in a numbered
alarm with text to indicate which heatsink fan is affected.

IGBT Example
Go to parameter 0:566 [IGBT Event Level]. Change the value to 60%.
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
When set to alarm, an IGBT event results in a numbered alarm with text to
indicate which power module is affected.

Control Pod Fan Example
Go to parameter 0:514 [PodFan EventLevel]. Change the value to 70%.
Now the control pod fan event occurs when 70% of the fan life is consumed.
Go to parameter 0:515 [PodFan EventActn]. The value is set to ‘Alarm’ with an

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.
M0 Power Module Heatsink Fan Example
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.
2. Go to the Predictive Main group in the M0 Power Module file.
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.
L0 Power Module Bus Capacitor Example
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.

2. Go to the Predictive Main group in the L0 Power Module file.
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.

Chapter 7
DeviceLogix
Introduction PowerFlex® 755T products (firmware revision 4 or later) have embedded

DeviceLogix™ (DLX) capability that provides built-in control capacity for local
application and supplementary supervisory control. DeviceLogix functionality
enhances productivity for standalone applications or complimentary operation
to a controller. DeviceLogix is configured using either function block or ladder
logic programming.
Figure 15 - Function Block Programming
Figure 16 - Ladder Logic Programming
Some examples of DeviceLogix functionality are:

• Controls Logic Command bits and Speed Reference
• Monitors Logic Status bits and Speed Feedback
• Reads inputs
• Writes outputs
• Reads and writes to parameters

Chapter 7 DeviceLogix
DeviceLogix supports the most frequently used instructions in the industry to

build a logic program, including: Logical, Move, Timer, Counter, Compare, and
Math. You can configure up to 500 instruction blocks to support application
requirements.
DeviceLogix also supports custom instructions that encapsulate logic you

develop with the built-in instruction set. This feature is called a Macro
instruction, with which you can design application instructions for the target
device.
Tag Binding in PowerFlex 755T Products
Tag Binding is included in the most recent release of DeviceLogix. This tag-
mapping capability allows you to create tags for any parameter in the drive that is
needed for programming. This new feature provides a consistent programming
experience in DeviceLogix for PowerFlex 755T drives and option modules.
Benefits of DeviceLogix
Local control at the drive level allows for simple local control functions without
the need for programmable logic and automation controllers.
Some of the benefits of DeviceLogix include:

• Improves control system performance
• Performs logic on the drive that reduces loading on the centralized
controller and reduces drive-related traffic on the network
• Faster reaction. Capable of achieving response times of 2 ms (with 100
instructions blocks)
• Increases system reliability
• Improves diagnostics and reduces troubleshooting time
• Continues to run a process during network interruptions
• Increases system/machine modularity
• Divides control responsibility in the controller for smaller programs that
save memory and reduce scan times
DeviceLogix functionality can be powered through three-phase input power or

auxiliary 24V DC control power.
Some of the typical applications for DeviceLogix functionality include:

• Material handling
• Cascade pump control
• PID control
• Selector switch functions
• Signal conditioning and scaling
• Fault handling

DeviceLogix Chapter 7
DeviceLogix Configuration DeviceLogix functionality is set through the DeviceLogix Editor that runs on a
workstation. You can access the DeviceLogix editor through a Studio 5000® Add-
Tool on Profile (AOP) or Connected Components Workbench software.
Launch the DeviceLogix Editor Tool
1. In the Drive Properties, select Edit peripherals.
2. Add the Application DLX Only option module in the Peripherals list.

DeviceLogix (DLX) functionality is added in port 9.
3. To close the window, click OK.

4. Select DeviceLogix and click the Launch Editor icon.
5. When the editor starts, select the editor style.
6. To enter edit mode, click in the taskbar.

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.

DeviceLogix Tag Database Use the Tag Editor to add the tags to be used in the code.
There are four categories of tags within the database.

• Produced Network Data is the data that is to be sent to the drive, such as
Start and Stop.
• Consumed Network Data is the data that is read from the drive, such as
Faulted, Ready, and Direction.
• Status Input is the data that comes from the clock/calendar of the drive.
• User Defined Tag are local tags that you create.
1. Select the Show Tag Database option from the Tools menu.
The Tag Database window opens.
2. To open the editor, click Launch Tag Editor.

Use the Tag Editor to select any drive parameter needed for programming.
These tags are called User Selected Tags.

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.
3. To add other drive parameters to the Tag database, repeat step 1 and step 2.
4. To close the window, click OK.
All added tags appear in the DeviceLogix Editor workspace.

Download and Enable the 1. When the code is completed, click in the task bar to verify the logic.
Logic After the verification, a window appears with the result.
The message-log window displays any errors.
2. If there are no errors, click in the taskbar to exit edit mode.
3. To download the logic, click in the taskbar.

A confirmation window opens.
4. Click Yes.
5. To enable the logic, click in the taskbar.

The logic is executed in the drive.
To disable the logic, click in the taskbar.
See DeviceLogix Technology for Industrial Applications Application

Techniques, publication 193-AT001, for more information.

Chapter 8
Emergency Override Function
This section provides a description of the Emergency Override function and

configuration instructions for PowerFlex® 755T products.
Overview The purpose of the function is to allow the drive or bus supply to override its
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.
ATTENTION: The emergency override function allows you to configure the

drive to bypass internal protections when operating in emergency override
mode. When the emergency override mode is enabled and active,
protections that are selected are bypassed. Do not use the emergency
override function without considering applicable local, national, and
international codes, standards, regulations, or industry guidelines.
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.
The following parameters are used to configure the Emergency Override

function.
• 0:454 [Emerg OVRD Mode]
• 0:455 [Emerg Prot OVRD]
• 0:456 [EmergMode Status]
• 0:457 [Purge Frequency]
See PowerFlex Drives with TotalFORCE® Control Programming Manual,

publication 750-PM100, for full descriptions of these parameters.

Chapter 8 Emergency Override Function
Go to the Overrides group in the Protection file on port 0.
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
In the Purge Frequency mode, the product overrides faults to continue running.
It switches to velocity mode and uses the Purge Frequency as its velocity
reference. The function treats the Emergency Override command like a Run
command. The product runs at the Purge Frequency when the command is set,
and stops when the command is cleared.
To set the Purge Frequency, go to parameter 0:457 [Purge Frequency] and enter
the speed value.

Emergency Override Function Chapter 8
Activate the Emergency The Emergency Override function can be activated by setting a bit in the
controller, or by a discrete-wired digital input.
Override Feature
Logic Command
Program the Logix project to set bit 15 ‘Emerg OVRD’ to create an Emergency
Override command.
Program it to clear the bit to remove the Emergency Override command.
Discrete-Wired Digital Input

Use parameter 0:134 [DI EmergencyOVRD] to select a digital input on an I/O
option card in one of the option slots. To create an Emergency Override
command, wire the input to circuitry that closes or energizes. To remove the
Emergency Override command the circuitry opens or de-energizes.
Go to the Command group in the Feedback and I/O file on port 0.
Go to parameter 0:134 [DI EmergencyOVRD] and map the function to the

input on the option card you have wired to the circuit.
Interaction between Logic Command and Digital Input
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.

Chapter 8 Emergency Override Function
Decide Which Protections The person or company that designs the drive or bus supply configuration is
responsible for deciding which protections the function can override. That
to Override person or company takes responsibility for the damage to the product from the
conditions that would otherwise trigger the protections.
Go to the Overrides group in the Protection file on port 0.
Go to parameter 0:455 [Emerg Prot OVRD].
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.
The PowerFlex Drives with TotalFORCE Control programming manual,

publication 750-PM100, describes which faults are covered by each bit. See the
description for parameter 0:455 [Emerg Prot OVRD]. Also, see the fault and
alarm tables in the troubleshooting chapter.

Chapter 9
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 Overviews on how to use the Position Reference and Velocity Reference Motion
Planners are provided, each highlighting new features to:
• Provide a selection of useful move profile types with easy switching
between them
• Allow users to enter acceleration and deceleration times directly
• Complete decoupling of acceleration and deceleration profiles, making it
easier to generate asymmetric move profiles
• Smoothly transition in and out of velocity, acceleration, and jerk limits
• Create a simple way to balance smoothness, energy, and peak dynamics
• Automatically increase move final time for best performance when inputs
generate constrained circumstances
Benefits Leveraging these new features to balance energy efficiency, peak dynamics, and
smoothness in a simple way, Position Reference and Velocity Reference motion
planners do the following:
• Prevent steps in jerk that beat up mechanical components over time. This
often leads to less frequent re-tuning of servo loops and down time to
replace components.
• Steps in jerk and other discontinuities generate odd harmonics that excite
mechanical resonances. This leads to servo loops working harder to
remove these self-induced resonances. As a result, the drive consumes more
energy.
• Balance peak dynamics which translates to lower energy requirements for
some applications.
• Configure motion profiles to operate closer to machine limits, while
preserving high dynamics.
• Configure motion profiles to generate torque-speed curves that improve
motor utilization and use more of its operating range.

Chapter 9 Reference Motion Planners
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
Position Reference Motion 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
Planner features in the order they are listed in the first section. A block diagram of the
PTP Planner is given, showing relevant parameters.
Figure 17 - PTP Planner Block Diagram

Ref Move Type Point to Point parameter initializations
performed with Position Regulator
931 INACTIVE
Max Speed Fwd 1392 PTP Reference [1404], PTP Feedback

1393 [1396], PTP Command [1391] are
Max Speed Rev PTP Feedback
loaded with Position Actual [1745].
Virtual
PTP Vel Override 1402 Encoder
1396
These parameters apply to all Move Types
PTP Accel Time 1398 PTP PRef Status

1380 0 ZeroFFSpdRef
PTP Decel Time 1399 LinScurve (0)
1 Ref Complete
PTP S Curve 1403 2 PTP Int Hold
3 SpdFFRef En
PTP VRef Fwd

PTP 1405
Command
PRef 1 [E2] 1391 ¦ 1404 PRef 1 [G2]
Ref Time Base PTP Reference
933
0 = Rate
1406 PTP Vel Max
1 = Time 1407 PTP Accel Max

Ref Accel Time 934
1408 PTP Decel Max
0 = Rate 1409 PTP Move Time PTP Move Status
1410 0 Vel Limited
1 = Time
Ref Decel Time 935 1411 PTP Move Seg 1 AccelLimited
SineSquared (1)
0 = Rate Poly5 (2) 2 DecelLimited
Cubic (3) 0- Accel Decel
1- Dwell Decel 3 Zero Move
RefEnergyBalance 932
2- Decel
Ref Max Accel 936 3- Reversing 4 Move Failed
Ref Max Decel 937 24 PTP VelMax Time

25 PTP AccMaxTime
26 PTP DecMaxTime
27 PTP Time Left
28 PTP Iterations
Ref Fault Config 941

Reference Motion Planners Chapter 9
Step 1—Configure Move Type

Adjust parameters described in the following table to setup the base PTP move profile.
Table 23 - PTP Configuration Parameters

Parameter Description
10/11:931 Select the move type used for generating position and velocity reference commands.
[Ref Move Type] ‘LinScurve’ (0) – Selects the Linear move type with optional S-curve smoothing. This is the
LinScurve move type used in 750 series drives.
‘SineSquared’ (1) – Selects the Sine Squared move type. This produces the smoothest possible
motion to reduce mechanical wear.
‘Poly5’ (2) – Selects the Fifth Order Polynomial move type. This produces smooth motion, but
trades some smoothness at the beginning and end of each move for lower peak dynamics.
‘Cubic’ (3) – Selects the Cubic move type. This is Third Order Polynomial move type that is similar
to LinScurve, however it can leverage new features and can be adjusted by 10/11:932
[RefEnergyBalance] through 10/11:941 [Ref Fault Config].
10/11:941 Select the drive action for position and velocity reference commands when 10/11:1410 [PTP Move
[Ref Fault Config] Status], bit 4 [Move Failed] = 1 or 10/11:1938 [VRef Move Status], bit 4 [Move Failed] = 1.
‘Ignore’ (0) – No action is taken
‘Alarm’ (1) – A Type 1 Alarm is indicated
‘Flt Minor’ (2) – A minor fault is indicated. The drive continues to run if it is currently running.
‘FltCoastStop’ (3) - A major fault indicated. The drive coasts to a stop if it currently running.
‘Flt CL Stop’ (4) - A major fault indicated. The drive does a current limit to a stop if it currently
running.
This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
‘SineSquared’, ‘Poly5’, or ‘Cubic’.
10/11:1381 Sets and clear bits to control the point-to-point position planner.
[PTP Control] Bit 0 ‘Vel Override’ – Applies the velocity override in 10/11:1402 [PTP Vel Override] to the forward
velocity limit in 10/11:1392 [Max Speed Fwd] and the reverse velocity limit in 10/11:1393 [Max
Speed Rev] as a gain. When the velocity override in 10/11:1402 [PTP Vel Override] is 1.1 and the
forward velocity limit in 10/11:1392 [Max Speed Fwd] is 30 Hz, the bit sets the maximum forward
velocity to 33 Hz.
Bit 1 ‘Move’ – Sets scaled point-to-point position reference to the point-to-point point reference in
10/11:1391 [PTP Command]. When the point-to-point mode selection in 10/11:1382 [PTP Mode]
is absolute mode (Option 0), the absolute position is set to the point-to-point reference in 10/
11:1391 [PTP Command] when this bit rises. When the point-to-point mode selection in 10/
11:1382 [PTP Mode] is index mode (Option 1), the index position is set to the point-to-point
reference in 10/11:1391 [PTP Command] when this bit rises.
Bit 2 ‘Reverse Move’ – Changes direction of the index position when the point-to-point mode
selection in 10/11:1382 [PTP Mode] is index mode (1). Set the direction with this bit, then set bit 1
‘Move” to 1 to move.
Bit 3 ‘Preset Psn’ – Sets index preset 10/11:1386 [PTP Index Preset] to the point-to-point position
command 10/11:1391 [PTP Command] when the point-to-point mode
selection 10/11:1382 [PTP Mode] is index mode (1).
Bit 4 ‘Intgrtr Hold’ – Holds integrator in the velocity control.
Bit 5 ‘Ref Pause’ – Pauses the point-to-point control function. The point-to-point speed forward
reference becomes zero, and the position selected reference in 10/11:1684 [PRef Selected] keeps
the current position.
Bit 6 ‘Ref Sync’ – Sets initial value to the point-to-point feedback in 10/11:1396 [PTP Feedback].
When motor feedback reaches zero speed, the planner resets 10/11:1404 [PTP Reference] and 10/
11:1396 [PTP Feedback] to 10/11:1745 [Position Actual].
10/11:1382 Enter a value to select the mode of the Point to Point Position Planner function:
[PTP Mode] ‘Absolute’ (0) – selects the absolute position mode. When the move bit is set the planner moves
the scaled position reference to the position command.
‘Index’ (1) – Selects index position mode. When 10/11:1381 [PTP Control] bit 1 ‘Move’ is set, the
reference source, selected by 10/11:1383 [PTP Ref Sel], is multiplied by 10/11:1385 [PTP Ref Scale]
and 10/11:1391 [PTP Command] is incremented by the result.
‘Immediate’ (2) – Selects absolute immediate position mode. When 10/11:1381 [PTP Control] bit
1 ‘Move’ is set, and the reference source selected by 10/11:1383 [PTP Ref Sel] changes, 10/11:1391
[PTP Command] is immediately set.

10/11:931 [Ref Move Type] provides a selection of useful move profile types with easy
switching between them.
When 10/11:931 [Ref Move Type] = (0) ‘LinScurve’, it provides the standard motion
profile type used in 750 series drives. A similar move can be generated simply by selecting
a different move type. Figure 18 shows different move types for a 10,000 count index
move with 1 second acceleration and deceleration times and a maximum velocity of 150
RPM (5Hz for an 1800 RPM motor).
Figure 18 - Index Moves with Different Move Types

Compare Trajectories
10000
[counts]
Pos
Sine Squared
5000
Poly5
0 LinScurve and Cubic
[RPM] 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
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
-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]
Note the following relationships:

• Sine Squared is the smoothest. It trades maximum velocity and
acceleration for smoothness.
• Poly5 trades end point smoothness for lower maximum velocity, maximum
acceleration, minimum jerk, and energy.
• LinScurve and Cubic are the least smooth. They generate trapezoidal
moves and trade smoothness for lower maximum jerk.
Step 2—Configure Move Distance

Adjust parameters described in the following table to define your target distance. You can
enter a constant set point or select an input signal. Note that as an input signal changes,
the PTP reference motion planner acts as a filter with a combined cam-on-cam effect.

Table 24 - PTP Distance Parameters

10/11:1383 Select a source for the Point to Point Position Planner reference.
[PTP Ref Sel] Select the port and parameter of the source.
10/11:1384 Enter a value to set a constant Point to Point Position Planner reference.
[PTP Setpoint] You can select this parameter as a source for the Point to Point Position Planner reference in 10/
11:1385 [PTP Ref Scale].
10/11:1385 Enter a value to set the scale value for the Point to Point Position Planner reference.
[PTP Ref Scale] The planner multiplies this value with the reference selected by 10/11:1383 [PTP Ref Sel].
10/11:1386 Enter a constant value to set the Preset Index step size.
[PTP Index Preset] The planner uses this as the step size (in index mode) when 10/11:1381 [PTP Control] bit 3
‘Preset Psn’ is set.
10/11:1391 Displays the position command produced by the Point to Point Position function.
[PTP Command] The Point to Point Position Planner consumes this signal in order to produce the Velocity Feed
Forward signal and the final Point to Point Position Reference.
Step 3—Configure Move Time

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’.
Rate Based Move
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.
Table 25 - PTP Rate Based Move Parameters

10/11:933 Select how acceleration and deceleration times are calculated for position and velocity reference
[Ref Time Base] commands.
‘Rate’ (0) – Calculates acceleration and deceleration rates equivalent to LinScurve behavior.
10/11:1392 Enter the maximum forward speed limit coming from the position reference.
[Max Speed Fwd]
10/11:1393 Enter the maximum reverse speed limit coming from the position reference.
[Max Speed Rev]
10/11:1398 Enter the acceleration ramp time used by the Point to Point (PTP) position planner.
[PTP Accel Time] This value is the time to go from zero to the velocity in 10/11:1392 [Max Speed Fwd].

Table 25 - PTP Rate Based Move Parameters

10/11:1399 Enter the deceleration ramp time used by the Point to Point (PTP) position planner.
[PTP Decel Time] This value is the time to go from the velocities in 10/11:1392 [Max Speed Fwd] or 10/11:1393
[Max Speed Rev] to zero.
10/11:1402 Enter a value to set the multiplier to both forward parameters 10/11:1392 [Max Speed Fwd] and
[PTP Vel Override] 10/11:1393 [Max Speed Rev].
This parameter applies to the speed limits when Bit 0 ‘Vel Override’ of 10/11:1381 [PTP Control]
is set.
10/11:1403 Enter a value to set the S-curve duration for Point-to-Point (PTP) position reference commands.
[PTP S Curve] This value is used to calculate acceleration and deceleration rates equivalent to LinScurve
behavior when 10/11:933 [Ref Time Base] = ‘Rate’.
Figure 19 shows different distances for a LinScurve indexing move with 1 second
acceleration and deceleration rates and a maximum velocity of 150 RPM (5Hz for an
1800 RPM motor).
Figure 19 - Rate Based Index Moves with Different Distances

104 Compare Trajectories
2
3000 counts
[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
[rev/sec 2 ]
Accel
-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]

• Acceleration and deceleration times are calculated based on a constant
maximum acceleration (velocity rate).
• Once the move distance increases enough to hit maximum velocity 10/
11:1392 [Max Speed Fwd], the acceleration rate remains constant.
• Rate based move times are good when continually indexing to various
target distances.

Time Based Move
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’.
Table 26 - PTP Time Based Move Parameters

‘Time’ (1) – 10/11:934 [Ref Accel Time] and 10/11:935 [Ref Decel Time] are applied directly as
acceleration and deceleration times.
10/11:934 Enter the acceleration time that is directly applied to position and velocity reference commands
[Ref Accel Time] when P933 [Ref Time Base] = ‘Time’.
10/11:935 Enter the deceleration time that is directly applied to position and velocity reference commands
[Ref Decel Time] when P933 [Ref Time Base] = ‘Time’.
You can completely decouple acceleration and deceleration parts of a move, making it
easier to generate asymmetric move profiles.
Figure 20 - Asymmetric Index Moves

5000
[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
-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]

• Asymmetry trades maximum acceleration and jerk for minimum
acceleration and jerk
• Asymmetry lets you adjust maximum and minimum acceleration and jerk
times
• Asymmetry does not affect energy directly

Step 4—Configure Dynamic Limits (optional)

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] =
Table 27 - PTP Dynamic Limit and Balance Parameters

10/11:1392 Enter the maximum forward speed limit coming from the position reference.
[Max Speed Fwd]
10/11:1393 Enter the maximum reverse speed limit coming from the position reference.
[Max Speed Rev]
10/11:936 Enter the maximum acceleration limit for position and velocity reference commands.
[Ref Max Accel] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:937 Enter the maximum deceleration limit for position and velocity reference commands.
[Ref Max Decel] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:932 Enter a skew factor applied to position and velocity reference commands that shifts the
[RefEnergyBalance] acceleration and deceleration peaks forward or backward in time. A lower value allows the
acceleration peak to occur at lower velocity for saving energy. A higher value allows the
acceleration peak to occur at higher velocity for more aggressive moves. The deceleration peak
mirrors the acceleration peak.
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’.
The following example shows what happens when acceleration and deceleration limits are
lowered below what is required by an unconstrained 2 second move.

Figure 21 - Acceleration Limiting

5000
[counts]
Pos
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
0
-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]
Acceleration and deceleration times can be readjusted to make up for the added dwell
time if required. However, times quickly go to zero when the limit approaches about half
the required maximum acceleration because the area under the curve becomes square.
Any further lowering of the limit beyond this point forces a velocity dwell to be added,
which increases acceleration and deceleration times.
Figure 22 - Acceleration Limiting with Adjusted Times

5000
[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
-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
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]


• Acceleration Limiting trades maximum jerk for lower maximum
acceleration
• Acceleration Limiting automatically induces acceleration dwells with
smooth transitions, which extends the move time
• Acceleration Limiting does not affect energy directly
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.
Figure 23 - Velocity Limiting with Adjusted Times

5000
[counts]
Pos
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]

• Velocity Limiting trades maximum acceleration and jerk for lower
maximum velocity and energy
• Velocity Limiting automatically induces a velocity dwell with a smooth
transition, which extends the move time
• Velocity Limiting affects energy directly
The following example shows the effect of Energy Balance.

Figure 24 - Energy Balance

• Energy Balance moves the maximum acceleration point horizontally so
that it occurs lower or higher in velocity
• For PTP moves, Energy Balance adjusts maximum velocity to balance out
area under the curve, which affects energy directly
• For PTP moves, Energy Balance trades max jerk for lower maximum
velocity, maximum acceleration, and energy
• Energy Balance does not induce dwells or extend move time

Step 5—Monitor Outputs (optional)

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’.
Table 28 - PTP Output Parameters

10/11:1404 Displays the position reference output of the Point to Point Position Planner.
[PTP Reference] This is the final Point to Point Position Reference.
It becomes the position reference for the Position Regulator.
10/11:1405 Displays the velocity reference output of the Point to Point Position Planner.
[PTP VRef Fwd] It becomes the velocity reference for the Velocity Regulator.
10/11:1406 Displays the maximum velocity of the most recent position reference command.
[PTP Vel Max] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:1407 Displays the maximum acceleration of the most recent position reference command.
[PTP Accel Max] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:1408 Displays the maximum deceleration of the most recent position reference command.
[PTP Decel Max] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:1409 Displays the total time required to complete the most recent position reference command.
[PTP Move Time] This value only affects commands that are generated when 10/11:931 [Ref Move Type] =
10/11:1410 Displays the status of the most recent position reference command.
[PTP Move Status] Bit 0: ‘Vel Limited’ – Indicates velocity is limited.
Bit 1: ‘AccelLimited’ – Indicates acceleration is limited.
Bit 2: ‘DecelLimited’ – Indicates deceleration is limited.
Bit 3: ‘Zero Move’ – Indicates that the new command calculated is zero (no move).
Bit 4: ‘Move Failed’ – Indicates that the new command calculation failed. See 10/11:941 [Ref
Fault Config] to select the drive response when this condition is true.
10/11:1411 Displays the move segment composition (general shape) of the most recent position reference
[PTP Move Seg] command.
‘Accel Decel’ (0) – Indicates the command accelerates to a peak velocity with an optional dwell,
followed by decelerating to the specified value.
‘Dwell Decel’ (1) – Indicates the command is composed of a dwell at initial velocity, followed by
decelerating to the specified value.
‘Decel’ (2) – Indicates the command decelerates to the specified value.
‘Reversing’ (3) – Indicates the command decelerates past the specified value, then reverses
direction to the specified value. This condition typically occurs when a command currently in
progress is interrupted late by a new move command.
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’.

Figure 25 - Index Moves with Initial Velocity

5000
[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.
Figure 26 - Index Moves that Decelerate Only

5000
[counts]
Pos
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
[rev/sec 2 ]
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’.
Figure 27 - Index Move that Reverses

104 Compare Trajectories
2 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
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

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]

Velocity Reference Motion 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
Planner section. A block diagram of the Velocity Reference Planner is given, showing relevant
parameters.
Figure 28 - Velocity Reference Planner Block Diagram

Ref Move Type
Motor Side Sts 1 354 17 Jogging
931
0
VRef Accel Time1 1915 1,0 VelRamp Rate
2
0,1
VRef Accel Time2 1916 Vel Ctrl Options 1950
MS Logic Rslt (Ramp Hold) 0
0:200 8 9
(Accel Time 1, 2)
1 (Ramp Disable) 1
Jog Acc Dec Time 1896 (StpNoSCrvAcc) 2
0 (NoSCrvSpdChg) 9
Logic [H3] 1917 1,0
VRef Decel Time1
VRef Decel Time2 0,1
1918 LinScurve (0)
MS Logic Rslt
0:200 10 11
(Decel Time 1, 2)
Logic [H3]
VRef Accel Jerk 1919
VRef Decel Jerk 1920
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
1 = Time 1935 VRef AccJerk Max

Ref Accel Time 934
1936 VRef DecJerk Max
0 = Rate 1937 VRef Move Time VRef Move Status
1938 0 AccelLimited
1 = Time
Ref Decel Time 935 1939 VRef Move Seg 1 AccelJerkLim
SineSquared (1)
0 = Rate Poly5 (2) 2 DecelJerkLim
Cubic (3) 0- Accel Decel
1- Dwell Decel 3 Zero Move
RefEnergyBalance 932
2- Decel
Ref Max Accel 936 3- Reversing 4 Move Failed
Ref Max Decel 937 4 VRefAccelMaxTime

5 VRefAcJrkMaxTime
Ref Max AccJerk 938
6 VRefDcJrkMaxTime
Ref Max DecJerk 939 7 VRef Time Left
8 VRef Iterations
Ref Fault Config 941

Step 1—Configure Move Type

Adjust parameters described in the following table to setup the base Velocity Reference
move profile.
Table 29 - Velocity Reference Configuration Parameters

10/11:931 Select the move type used for generating position and velocity reference commands.
[Ref Move Type] ‘LinScurve’ (0) – Selects the Linear move type with optional S-curve smoothing. This is the
LinScurve move type used in 750 series drives.
‘SineSquared’ (1) – Selects the Sine Squared move type. This produces the smoothest possible
motion to reduce mechanical wear.
‘Poly5’ (2) – Selects the Fifth Order Polynomial move type. This produces smooth motion, but
trades some smoothness at the beginning and end of each move for lower peak dynamics.
‘Cubic’ (3) – Selects the Cubic move type. This is Third Order Polynomial move type that is
similar to LinScurve, however it can leverage new features and can be adjusted by 10/11:932
[RefEnergyBalance] through 10/11:941 [Ref Fault Config].
10/11:941 Select the drive action for position and velocity reference commands when 10/11:1410 [PTP
[Ref Fault Config] Move Status], bit 4 [Move Failed] = 1 or 10/11:1938 [VRef Move Status], bit 4 [Move Failed] = 1.
‘Ignore’ (0) – No action is taken
‘Alarm’ (1) – A Type 1 Alarm is indicated
‘Flt Minor’ (2) – A minor fault is indicated. The drive continues to run if it is currently running.
‘FltCoastStop’ (3) - A major fault indicated. The drive coasts to a stop if it currently running.
‘Flt CL Stop’ (4) - A major fault indicated. The drive does a current limit to a stop if it currently
running.
10/11:1950 Set and clear bits to configure options in the Velocity Regulator.
[Vel Ctrl Options] Bit 0 “Ramp Hold” – set this bit to stop the Velocity Reference Ramp from changing and to hold
constant. Clear this bit to allow the Velocity Reference Ramp to change. If this bit is set while 10/
11:1923 [VRef Ramped] is in an S-curve region, the S-curve completes before the output is held.
Bit 1 ‘Ramp Disable’ – Set this bit to bypass the Velocity Reference Ramp. 10/11:1923 [VRef
Ramped] tracks the Input to the ramp function.
Bit 2 ‘StpNoSCrvAcc’ – Set this bit to force the velocity regulator to immediately discontinue
acceleration when the drive receives a stop command. Clear this bit to finish accelerating, as part
of the S-curve profile, before decelerating in response to a stop command.
Bit 9 ‘NoSCrvSpdChg’ – Set this bit to interrupt the S-curve if the drive is accelerating and a new
velocity reference is commanded less than the current velocity. The drive will immediately
decelerate. Setting this bit will also interrupt the S-curve if the drive is decelerating when the
new velocity reference is more than the current velocity. Clearing this bit configures the drive to
complete the S-curve before decelerating or accelerating. Note to Tech Writing use
NoSCrvSpdChg figure.
Bit 10 ‘FastZeroCrs’ – Set this bit to allow the velocity command to cross zero without ramping to
zero acceleration. Clear this bit to generate two moves: a first move that ramps to zero
acceleration when approaching zero velocity and a second move to ramp from zero acceleration
after crossing zero velocity and move to the final velocity.
10/11:931 [Ref Move Type] provides a selection of useful move profile types with easy
switching between them.

When 10/11:931 [Ref Move Type] = (0) ‘LinScurve’, it provides the standard motion
profile type used in 750 series drives. A similar move can be generated simply by selecting
a different move type. Figure 29 shows different move types for an 1800 RPM velocity
move with a 10 second acceleration time.
Figure 29 - Velocity Moves with Different Move Types

• Sine Squared is the smoothest. It trades maximum jerk and snap for
smoothness.
• Poly5 trades end point smoothness for lower maximum acceleration,
maximum jerk, and minimum snap.
• LinScurve and Cubic are the least smooth. They generate trapezoidal
moves and trade smoothness for lower maximum snap.

Step 2—Configure Move Target Velocity

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.
Table 30 - Velocity Reference Distance Parameters

10/11:354 Displays the operating condition of the Motor Side Inverter:
[Motor Side Sts 1] Bit 9 ‘Manual’ indicates the Auto/Manual function is in the Manual mode.
Bit 10 ‘SpdRef Bit 0’ indicates the state of the Speed (Velocity) reference selection bit 0.
Bit 14 ‘SpdRef Bit 4’ indicates the state of the Speed (Velocity) reference selection bit 4. These
bits work together to select a velocity reference.
10/11:1800 Select a source for Velocity Reference A.
[VRef A Sel] Select the port and parameter of the source.
This is the typical Automatic reference.
Digital input functions for and bits in the Logic Command select between Velocity Reference A
and Velocity Reference B.
A Manual selection will override this.
10/11:1801 Enter a constant value to be used as a source for Velocity Reference A.
[VRef A Stpt] You can select this constant as a reference in 10/11:1800 [VRef A Sel]. This is similar to using a
Preset.
10/11:1804 Enter a value to define a multiplier for Velocity Reference A.
[VRef A Mult] The value from the source selected by 10/11:1800 [VRef A Sel] will be multiplied by this.
10/11:1914 Displays the value of the Velocity Reference after the Skip Speed function.
[VRef Commanded]

Step 3—Configure Move Time

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’.
Rate Based Move
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.
Table 31 - Velocity Reference Rate Based Move Parameters

‘Rate’ (0) – Calculates acceleration and deceleration rates equivalent to LinScurve behavior.
10/11:403 Enter the rated RPM shown on the motor nameplate.
[Motor NP RPM]
10/11:1915 Enter the first acceleration ramp time that is applied to velocity reference commands.
[VRef Accel Time1] This value is defined as the time to accelerate from zero to the value in 10/11:403 [Motor NP
RPM].
Digital input functions and bits in the Logic Command select between the first and second ramp
times.
10/11:1916 Enter the second acceleration ramp time that is applied to velocity reference commands.
[VRef Accel Time2] This value is defined as the time to accelerate from zero to the value in 10/11:403 [Motor NP
RPM].
times.
10/11:1917 Enter the first deceleration ramp time that is applied to velocity reference commands.
[VRef Decel Time1] This value is defined as the time to decelerate from the value in 10/11:403 [Motor NP RPM] to
zero.
times.
This value is also used for these stop modes: Ramp, Ramp to Hold, and DecelToHold.
10/11:1918 Enter the second deceleration ramp time that is applied to velocity reference commands.
[VRef Decel Time2] This value is defined as the time to decelerate from the value in 10/11:403 [Motor NP RPM] to
zero.
times.
This value is also used for these stop modes: Ramp, Ramp to Hold, and DecelToHold.
10/11:1919 Enter the percentage of acceleration time applied to the acceleration ramp of velocity reference
[VRef Accel Jerk] commands. Increasing this value softens changes in acceleration and reduce jerk. Half of the
time associated with this percentage is added at the beginning of the ramp and half is added at
the end of the ramp.
10/11:1920 Enter the percentage of deceleration time applied to the deceleration ramp of velocity reference
[VRef Decel Jerk] commands. Increasing this value softens changes in deceleration and reduce jerk. Half of the
time associated with this percentage is added at the beginning of the ramp and half is added at
the end of the ramp.

Figure 30 shows different target velocities for a LinScurve velocity move with a 10 second
acceleration time.
Figure 30 - Rate Based Velocity Moves with Different Distances

• Acceleration and deceleration times are calculated based on a constant
maximum jerk (acceleration rate).
• Rate based move times are good when continually indexing to various
target velocities.
Time Based Move
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’.
Table 32 - Velocity Reference Time Based Move Parameters

‘Time’ (1) – 10/11:934 [Ref Accel Time] and P935 [Ref Decel Time] are applied directly as
acceleration and deceleration times.
10/11:934 Enter the acceleration time that is directly applied to position and velocity reference commands
[Ref Accel Time] when 10/11:933 [Ref Time Base] = ‘Time’.
10/11:935 Enter the deceleration time that is directly applied to position and velocity reference commands
[Ref Decel Time] when 10/11:933 [Ref Time Base] = ‘Time’.

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.
Figure 31 - Velocity Moves that Accelerate and Decelerate

• Acceleration time is applied when moving away from zero velocity
• Deceleration time is applied when moving towards zero velocity
• When crossing zero velocity and 10/11:1950 [Vel Ctrl Options] bit 10
‘FastZeroCrs’ is not set, two independent moves are created: one move
decelerates to zero velocity and acceleration, while a second move
accelerates to the final velocity target. However, when 10/11:1950 [Vel
Ctrl Options] bit 10 ‘FastZeroCrs’ is set, one move will accelerate through
zero velocity from initial to final target.
• Both acceleration and deceleration times are applied when crossing zero
velocity. When 10/11:933 [Ref Time base] = ‘Time’, these times are
simply added during fast zero crossing.

Step 4—Configure Dynamic Limits (optional)

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’.
Table 33 - Velocity Reference Dynamic Limit and Balance Parameters

10/11:936 Enter the maximum acceleration limit for position and velocity reference commands.
[Ref Max Accel]
10/11:937 Enter the maximum deceleration limit for position and velocity reference commands.
[Ref Max Decel
10/11:938 Enter the maximum jerk limit during acceleration for velocity reference commands. It is the
[Ref Max AccJerk] change of acceleration with respect to time.
10/11:939 Enter the maximum jerk limit during deceleration for velocity reference commands. It is the
[Ref Max DecJerk] change of deceleration with respect to time.
10/11:932 Enter a skew factor applied to position and velocity reference commands that shifts the
[RefEnergyBalance] acceleration and deceleration peaks forward or backward in time. A lower value allows the
acceleration peak to occur at lower velocity for saving energy. A higher value allows the
acceleration peak to occur at higher velocity for more aggressive moves. The deceleration peak
mirrors the acceleration peak.
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] =

The following example shows what happens when minimum and maximum jerk limits
are lowered below what is required by an unconstrained 10 second move.
Figure 32 - Jerk Limiting
Acceleration and deceleration times can be readjusted to make up for the added dwell
time if required. However, times quickly go to zero when the limit approaches about half
the required maximum jerk because the area under the curve becomes square. Any further
lowering of the limit beyond this point forces an acceleration-dwell to be added, which
increases acceleration and deceleration times.
Figure 33 - Jerk Limiting with Adjusted Times


• Jerk Limiting trades maximum snap for lower maximum jerk
• Jerk Limiting automatically induces jerk dwells with smooth transitions,
which extends the move time
• Jerk Limiting does not affect energy directly
The following example shows what happens when acceleration limits are lowered below
what is required by an unconstrained move with adjusted acceleration time.
Figure 34 - Acceleration Limiting with Adjusted Times

• Acceleration Limiting trades maximum jerk and snap for lower maximum
acceleration
• Acceleration Limiting automatically induces an acceleration dwell with a
smooth transition, which extends the move time
• Acceleration Limiting does not affect energy directly

The following example shows the effect of Energy Balance.
Figure 35 - Energy Balance

• Energy Balance moves the maximum acceleration point horizontally so
that it occurs lower or higher in velocity
• For Velocity moves, target velocity is unaffected and, as a result, energy is
unaffected
• Energy Balance does not induce dwells or extend move time
• For Velocity moves, Energy Balance creates asymmetry
• Asymmetry trades maximum acceleration and jerk for minimum
acceleration and jerk
• Asymmetry lets you adjust maximum and minimum acceleration and jerk
times

Step 5—Monitor Outputs

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’.
Table 34 - Velocity Reference Output Parameters

10/11:1923 Displays the value of the Velocity Reference after the Ramp and Jerk functions.
[VRef Ramped]
10/11:1934 Displays the maximum acceleration of the most recent velocity reference command.
[VRef Accel Max] This value only affects commands that are generated when P931 [Ref Move Type] =
10/11:1935 Displays the maximum jerk in the acceleration region of the most recent velocity reference
[VRef AccJerk Max] command.
This value only affects commands that are generated when P931 [Ref Move Type] =
10/11:1936 Displays the maximum jerk in the deceleration region of the most recent velocity reference
[VRef DecJerk Max] command.
10/11:1937 Displays the total time required to complete the most recent velocity reference command.
[VRef Move Time] This value only affects commands that are generated when P931 [Ref Move Type] =
10/11:1938 Displays the status of the most recent velocity reference command.
[VRef Move Status] Bit 0: ‘AccelLimited’ – Indicates acceleration is limited.
Bit 1: ‘AccelJerkLim’ – Indicates acceleration jerk is limited.
Bit 2: ‘DecelJerkLim’ – Indicates deceleration jerk is limited.
Bit 3: ‘Zero Move’ – Indicates that the new command calculated is zero (no move).
Bit 4: ‘Move Failed’ – Indicates that the new command calculation failed. See P941 [Ref Fault
Config] to select the drive response when this condition is true.
10/11:1939 Displays the move segment composition (general shape) of the most recent velocity reference
[VRef Move Seg] command.
‘Accel Decel’ (0) – Indicates the command accelerates to a peak acceleration with an optional
dwell, followed by decelerating to the specified value.
‘Dwell Decel’ (1) – Indicates the command is composed of a dwell at initial acceleration,
followed by decelerating to the specified value
‘Decel’ (2) – Indicates the command decelerates to the specified value.
‘Reversing’ (3) – Indicates the command decelerates past the specified value, then reverses
direction to the specified value. This condition typically occurs when a command currently in
progress is interrupted late by a new move command.
Typical trajectories moving from constant velocity to constant velocity accelerate to a

peak acceleration and then decelerate back to zero. When this occurs, parameter 10/
11:1939 [VRef Move Seg] = ‘AccelDecel’. However, when a move profile is initiated
while another is in motion, the new move will start at an initial acceleration matching the
acceleration of the previous move profile at the point of transition. When the initial
acceleration is high enough, there may only be time to perform an acceleration dwell and
decelerate to the new target. When this occurs, parameter 10/11:1939 [VRef Move Seg]
= ‘DwellDecel’.

Figure 36 - Velocity Moves with Initial Acceleration

2000
[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.
Figure 37 - Velocity Moves that Decelerate Only

2000
[RPM]
Vel
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]

Initial accelerations can increase so much with respect to the approaching target velocity,
that there may only be time to decelerate past the new target, then reverse velocity back to
it. When this occurs, parameter 10/11:1939 [VRef Move Seg] = ‘Reversing’.
Figure 38 - Velocity Move that Reverses

5000
Reversing
[RPM]
Vel
0
0 1 2 3 4 5 6 7 8 9 10
30
[rev/sec ]
2
20
Accel 10
0
-10
0 1 2 3 4 5 6 7 8 9 10
[rev/sec ]
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]

Chapter 10
Droop Control for Parallel Operation of

PowerFlex 755TM AFE Bus Supplies
Droop control of the DC bus voltage reference level is an internal process for
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 the motoring direction, droop control increases the DC bus voltage reference
as the active current reference decreases in magnitude. As the active current
reference increases towards full load, droop control decreases the DC bus
reference towards the minimum DC bus voltage. The DC bus voltage reference is
greater when near zero load than it is when near full load. In this way, the AFE
bus supply tends to increase its share near zero load, and is less likely to increase its
share near full load.
In the regenerating direction, droop control increases the DC bus voltage

reference as the active current reference increases in magnitude (becomes more
negative). As the magnitude increases toward full negative load, droop control
increases the DC bus reference. The DC bus voltage reference is lower when near
zero load than it is when near full negative load. In this way, the AFE bus supply
tends to increase its share near zero load, and is less likely to increase its share near
full negative load.

Chapter 10 Droop Control for Parallel Operation of PowerFlex 755TM AFE Bus Supplies
Figure 39 - Shared Bus Supply
AC Mains
AFE Bus Supply AFE Bus Supply

#1 #2
Shared DC Bus
In this simple example, 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.

Droop Control for Parallel Operation of PowerFlex 755TM AFE Bus Supplies Chapter 10
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).
Figure 40 - Linear Mode

DC Bus
Voltage
Reference
Minimum DC
Bus Voltage
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load Motoring
Regenerating Current Current Current Current
Minimum DC bus voltage reference is the same as the automatic (optimized)

DC bus voltage reference. This is 2% above the peak of the naturally rectified
voltage level. For example, if the incoming voltage is 480 Vrms, then minimum
DC Bus voltage reference is 692.4V DC (VDC = VRMS x SQRT(2) x 1.02).
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).
Figure 41 - Full Load Regions

Slope of Droop
Function
0%
13:352 [NoLd DroopGain]
13:351 [FullLd DroopGain]
Active 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].
Figure 42 - Nonlinear Mode

Slope of Droop
Function
0%
0.3 x 13:352 [NoLd DroopGain]
1.2 x 13:351 [FullLd DroopGain]

Active Current

Droop Control for Parallel Operation of PowerFlex 755TM AFE Bus Supplies Chapter 10
This results in a smooth and progressive curve for the DC bus voltage reference.
Figure 43 - DC Bus Voltage Reference

DC Bus Voltage
Reference
Minimum DC Bus Voltage
Active Current
Derating for Voltage Boost In standalone operation (not parallel), PowerFlex® 755TM bus supplies are
designed to operate with the DC bus voltage reference equal to the optimized or
minimum DC bus level. This optimization maximizes energy efficiency. Because
the Droop function raises the DC bus voltage reference, you must account for
this when sizing the bus supplies.
Consider the DC bus voltage reference at full load in the regenerating direction
with default values. The reference at that operating point is:
Minimum DC Bus Voltage + (No Load Droop Gain/100) x Minimum DC Bus

Voltage + (Full Load Droop Gain/100) x Minimum DC Bus Voltage
Or
Minimum DC Bus Voltage x [1 + (No Load Droop Gain/100) + (Full Load
Droop Gain/100)]
Consider a 480Vrms example with default values in the gain parameters.

• Minimum DC Bus Voltage = 480 x SQRT(2) x 1.02 = 692.4V DC
• No Load Droop Gain = 1%
• Full Load Droop Gain = 5%
• Trans Droop Cur = 50%
• DC bus voltage reference = 692.4 x (1 + 0.01 + 0.05) = 733.9V DC
This is a considerable boost to the DC bus voltage. For information about

derating for this, see PowerFlex 750-Series Products with TotalFORCE® Control,
publication 750-TD100.

Notes:

Chapter 11
Application References
PowerFlex 755T Lifting/ TorqProve™ is a PowerFlex® 755T drive feature that is intended for applications
that require proper coordination between motor control and a mechanical brake.
Torque Proving 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.
ATTENTION: Loss of control in suspended-load applications can cause personal

injury and/or equipment damage. The drive or a mechanical brake must always
control the loads. Parameters 9:60 [Brk Release Time]…78 [DI FloatMicroPsn]
are designed for lifting/torque prove applications. It is the responsibility of the
engineer and/or end user to configure drive parameters, test any lifting
functionality and meet safety requirements in accordance with all applicable
codes and standards.
Overview
TorqProve can be operated encoderless or with an encoder. See the PowerFlex
Drives with TotalFORCE® Control Programming Manual, publication 750-
PM100 for detailed information.
TorqProve functionality with an encoder includes:

• Torque Proving (includes flux up and last torque measurement)
• Brake Proving
• Brake Slip (feature slowly lowers load if brake slips/fails)
• Float Capability (ability to hold full torque at zero speed)
• Micro positioning
• Fast Stop
• Speed Deviation Fault, Output Phase Loss Fault, Encoder Loss Fault.
Encoderless TorqProve functionality includes:

• Torque Proving (includes flux up and last torque measurement)
• Micro positioning
• Fast Stop
• Speed Deviation Fault, Output Phase Loss Fault

Chapter 11 Application References
IMPORTANT Brake Slip detection and Float capability (ability to hold load at zero speed) are
no available in encoderless TorqProve.
Figure 44 - Torque Proving Flow Diagram

Operator Run Run
Commands Command Command Released
Run can be initiated any time

Time
Drive Running
9:60 [Brk Release Time] 9: 72 [ZeroSpdFloatTime] 9:61 [Brk Set Time]
Drive Torque Brake Float Brake (1) Brake

Actions Prove Initiated Released Initiated Set Slip Test
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 Relay
nn:10 [RO0 Sel] to 9:52 [Trq Prove Status] Bit 4 ‘Brake Set’ and set nn:6 R0NO
[Dig Out Invert] Bit 0 ‘Relay Out 0’ = 1. R0C
Control
Voltage
Brake Slip Test I/O Module TB2
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 Limit Slew
Rate] 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.

Application References Chapter 11
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 is 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 104.
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 Connected Components Workbench

software, follow these steps.
1. Connect to the PowerFlex 755T drive through Connected Components

Workbench software
2. Once connected, click ‘Device Definition’ on the Overview page.
3. Click ‘Dynamics Features’.
4. Under ‘Application Sel’ select Torque Prove. This adds Port 9 –
Application Torque Prove to the PowerFlex 755T drive.
5. To accept the changes, click Ok.
6. Power cycle the drive.
To configure the PowerFlex 755T drive via the HIM, follow these steps.
1. Navigate to 0:70 [Application Mode].

2. Click the ‘edit’ soft key and change 0:70 [Application Mode] = 2 ‘Torque
Prove’
3. To accept changes, click the ‘enter’ soft key.
4. Power cycle the drive.

Bus Regulation
When you use a PowerFlex 755T drive in a lifting application, a PowerFlex

755TR drive is used to allow full line regeneration capabilities. You do not need
to use a dynamic braking resistor in this configuration. The PowerFlex 755TL
drive is not recommended for lifting applications. Typical bus regulation
parameter settings that are associated with regeneration are:
• 10/11:229 [Regen Power Lmt] = -200%
• 10/11:116 [Bus Reg Mode A] = Disabled
Brake Proving Configuration
By default, the drive is testing for brake slip only during Brake Slip Test Step 7
(see Brake Slip Test on page 102). 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 is no brake slip test.
After stopping, the drive engages the brake when the motor speed falls below the
setting in 9:70 [Float Tolerance].
Tuning the Motor for Torque Prove Applications
It is important that you enter all motor data correctly. When using PowerFlex
755T Autotune features, it is recommended to disconnect the motor from the
hoist/crane equipment during the tests. It is 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, so that the brake releases when the motor starts to run.
ATTENTION: To guard against personal injury and/or equipment damage due

to an unexpected brake release, verify that the digital output that is used for
brake connections and/or programming. The PowerFlex 755T drive does not
control the mechanical brake until TorqProve is enabled. If the brake is
connected to a digital output, it could be released. If necessary, disconnect the
digital output until wiring/programming can be completed and
verified.
Torque Proving is only supported on induction motors. PowerFlex 755T motor

control modes Induction Sensorless Vector (SV) and Induction Flux Vector (FV)
are supported.

Crane Setup—with Encoder Feedback
ATTENTION: Loss of control in suspended load applications can cause personal

control the loads. Parameters 9:50…78 are designed for lifting/torque prove
applications. It is the responsibility of the engineer and/or end user to configure
drive parameters, test any lifting functionality, and meet safety requirements in
accordance with all applicable codes and standards.
These setup instructions assume the following.

• The drive is a 755TR regenerative and low harmonic drive.
• Drive and motor size have been carefully selected.
• The drive is at factory defaults.
If not, unplug the output relay terminal block and issue a reset to factory
defaults for the HOST and all PORTS. Plug terminal block back in.
• Programming is done via Connected Components Workbench software.
• Crane control is done via Run Forward/Run Reverse inputs.
• The drive is equipped with an I/O card, such as a 20-750-2262C-2R, in
port (slot) 4. Mechanical brake control is wired to Output Relay 0 on that
card.
• The drive is equipped with an incremental (20-750-ENC-1) or dual
incremental encoder board (20-750-DENC-1) in port (slot) 5. You can
use a Universal Feedback Board (20-750-UFB-1). However, that
configuration is not covered in these instructions.
• The encoder is mounted on the back of the motor (not behind the
gearbox).
• Recommended encoder specification: Quadrature differential (A, A-, B,
B-), Line driver output, Minimum 1000PPR 5V, or 12V signals (12V
preferred).

Configure the Modular Control Profiles
1. Power up the drive and establish a connection with Connected

Components Workbench software.
2. Navigate to the Overview page for the drive. Then click Device
Definition.
3. Then click Dynamic Features.
4. Select Induction FV under Primary Motor Control Mode.

5. To accept the change to the motor control selection, click OK.
6. Select Torque Prove under Application Select.
7. Click OK.
The software commits the changes.

8. To navigate to the parameter display, click Parameters in the left pane.
9. Navigate to port 0, which is the Main Product Port.

10. Find parameter 0:33 [VoltageClass Cfg] and enter the configuration for
either Low Voltage or High Voltage.

11. Find parameter 0:35 [Duty Rating Cfg] and enter the configuration.
Heavy Duty is recommended, but not required.
12. Navigate to parameter 0:46 [Velocity Units] and enter the configuration
for Hz or RPM. This is only needed when you are using RPM.
Cycle Power and Verify the Modular Control Profile Configurations
1. Cycle power or reset the drive (Reset Device) to load the control profiles.
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]
Configure the Line Side Converter
1. Navigate to port 13, which is the port for Line Side Converter Control.
2. Navigate to the following parameters and enter the data for the incoming
power conditions.
13:30 [Nom Line Freq] 13:32 [AC Line kVA A] 13:34 [AC Line Imped% A]
3. Navigate to parameter 13:104 [Regen Power Lim] and enter a value

of -200%.
Enter the Motor Nameplate Data
1. Navigate to port 10, which is the port for Motor Side Inverter Control.
2. Navigate to the following parameters and enter the data from the motor
nameplate.
10/11:400 [Motor NP Volts] 10/11:403 [Motor NP RPM] 10/11:406 [Motor NP Power]
10/11:401 [Motor NP Amps] 10/11:407 [Motor Poles] 10/11:402 [Motor NP Hertz]
10/11:900 [Motor Inertia] (1)
(1) If the data is not available on the motor nameplate or data sheet, use the following equation to estimate motor
inertia: Motor Inertia = Motor Hp/250 x (Motor Hp /500 + 1)

Configure the Motor Side Inverter
1. Stay at port 10, which is the port for Motor Side Inverter Control.
2. Navigate to parameter 10/11:110 [Mtr Stop Mode A] and enter a value
of 'Ramp' (1).
3. Navigate to parameter 10/11:229 [Regen Power Lim] and enter a value
of -200%.
4. Navigate to parameter 10/11:204 [Mtr OL Hertz] and enter a value that
reflects the cooling capacity of the motor. See parameter 10/11:204 [Mtr
OL Hertz].
5. Navigate to parameter 10/11:220 [Drive OL Mode] and enter a value of
‘Reduce PWM’ (2).
6. Navigate to parameter 10/11:222 [Current Limit 1] and enter a value
equal to 200% of motor nameplate amps.
7. Navigate to parameter 10/11:256 [OutPhaseLossActn] and enter a value
of ‘FltCoastStop’ (3).
8. Navigate to parameter 10/11:116 [Bus Reg Mode A] and enter a value of
0 ‘Disabled’.
9. Navigate to parameter 10/11:913 [Autotune Trq Lim] and enter a value
of 100%.
Configure the Motor Encoder Feedback
2. Navigate to parameter 10/11:1000 [Pri Vel Fb Sel]. Select the encoder
feedback on the feedback card in port 5.
If you are following the guidelines at the beginning of this procedure (with
a 20-750-ENC-1 in slot 5), the resulting value is 50004 ‘Port 5: Enc 0 FB’.
Then enter the two-digit port number for feedback option card, and the
four-digit parameter number for the parameter that displays the feedback.
3. Navigate to parameter 10/11:1013 [PReg Fb Sel]. Then enter the same
value that you used for 10/11:1000 [Pri Vel Fb Sel].
4. Navigate to the port that contains the feedback option card. That would
be port 5 when using a 20-750-ENC-1 in slot 5.
5. Configure the parameters on the feedback option card to match the
encoder you are using.
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 LossCfg] is 3 ‘FltCoastStop’.

Autotune the Motor Side Inverter
Follow these Autotune steps to configure the motor side inverter.
Perform Direction Test
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.
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. For example, the value
would be 50004 ‘Port 5: Enc 0 FB’ when you use a 20-750-ENC-1 in
slot 5.
• View the result in parameter 10/11:1834 [Enc VRef ].
6. Stop the drive, using 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 the next step.
• If the direction is reverse, power down and physically reverse the motor
leads.
8. Address the polarity of the feedback signal.
• If the polarity is forward, proceed to the next step.
• If the polarity is reverse, power down and physically reverse the encoder
leads.
Perform the Rotate Motor ID Test
During the Rotate Motor ID Test, the motor rotates for approximately 15
seconds in the commanded direction. It runs at speeds up to 75% of motor
nameplate speed. You can execute this test with a motor that is disconnected
from the crane or with a lightly loaded condition. Lightly loaded conditions
include a motor that is connected to gearbox, cable drum, or cable and hook.

When the motor is connected to a load, verify that there is 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 cannot 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.
‘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 the Static Motor ID Test
Perform this test if you cannot 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.
Confirm Flux-up Time
1. Navigate to parameter 10/11:432 [c FluxUpTime].

2. If the value is less than 0.05 seconds, change the value of parameter 10/
11:431 [FluxUpTm C/U Sel] to 1 ‘User’. Then set parameter 10/11:433 [u
FluxUpTime] to 0.05 seconds.

Configure the Digital Output for Brake Control
1. Determine whether logic of the brake control circuit is ‘Active High’ or

‘Active Low’.
‘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 example, navigate to port 4 when using a 20-750-2262C-2R in slot 4.

3. Configure the digital output selector to receive control from the correct
bit in the Torque Prove status word.
For example, when using Relay Output 0 on the 20-750-2262C-2R in slot

4 to control the brake, go to parameter 4:10 [RO0 Sel]:
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’.
Configure the Torque Prove Function
1. Navigate to port 9, which is the port for Application Control.

2. Navigate to parameter 9:50 [Trq Prove Cfg]. Set bit 0 ‘TP Enable’.
3. Then set bit 6 ‘BrkSlipStart’.
4. 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 the crane up and down without load.
3. Run the 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
cause this fault.
• Verify that the current limit is not 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.
Troubleshooting information can be found in Knowledgebase Article

1061994, PowerFlex 755T in Lifting Applications.
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 is not a concern. Encoders offer additional protection and must be used
where personal safety is a concern. Encoderless TorqProve cannot 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 Options Cfg] 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.
These setup instructions assume the following.

• The drive is a 755TR regenerative and low harmonic drive.
• Drive and motor size have been carefully selected.
• The drive is at factory defaults.
If not, unplug the output relay terminal block and issue a reset to factory
defaults for the HOST and all PORTS. Plug terminal block back in.
• Programming is done via Connected Components Workbench software.
• Crane control is done via Run forward/Run Reverse inputs.

• The drive is equipped with an I/O card, such as a 20-750-2262C-2R, in

port (slot) 4. Mechanical brake control is wired to Output Relay 0 on that
card.
ATTENTION: Loss of control in suspended load applications can cause personal

control the loads. Parameters 9:60 [Brk Release Time]…78 [DI FloatMicroPsn]
are designed for lifting/torque prove applications. It is the responsibility of the
engineer and/or end user to configure drive parameters, test any lifting
functionality and meet safety requirements in accordance with all applicable
codes and standards.
Configure the Modular Control Profiles
1. Power up the drive and establish a connection with Connected

Components Workbench software.
2. Navigate to the Overview page for the drive. Then click Device
Definition.
3. Then click Dynamic Features.

4. Select Induction FV under Primary Motor Control Mode.
5. To accept the change to the motor control selection, click OK.
6. Select Torque Prove under Application Select.
7. Click OK.
The software commits the changes.

8. Navigate to the parameter display by clicking Parameters in the left-hand

pane.
9. Navigate to port 0, which is the Main Product Port.

10. Find parameter 0:33 [VoltageClass Cfg] and enter the configuration for
Low Voltage or High Voltage.
11. Find parameter 0:35 [Duty Rating Cfg] and enter the configuration.
Heavy Duty is recommended, but not required.
12. Navigate to parameter 0:46 [Velocity Units] and enter the configuration
for Hz or RPM. This is only needed when you are using RPM.
Cycle Power and Verify the Modular Control Profile Configurations
1. Cycle power or reset the drive (Reset Device) to load the control profiles.
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]
Configure the Line Side Converter
1. Navigate to port 13, which is the port for Line Side Converter Control.
2. Navigate to the following parameters and enter the data for the incoming
power conditions.
13:30 [Nom Line Freq] 13:32 [AC Line kVA A] 13:34 [AC Line Imped% A]
3. Navigate to parameter 13:104 [Regen Power Lim] and enter a value

of -200%.

Enter the Motor Nameplate Data
1. Navigate to port 10, which is the port for Motor Side Inverter Control.
2. Navigate to the following parameters and enter the data from the motor
nameplate.
10/11:400 [Motor NP Volts] 10/11:403 [Motor NP RPM] 10/11:406 [Motor NP Power]
10/11:401 [Motor NP Amps] 10/11:407 [Motor Poles] 10/11:402 [Motor NP Hertz]
10/11:900 [Motor Inertia] (1)
(1) If the data is not available on the motor nameplate or data sheet, use the following equation to estimate motor
inertia: Motor Inertia = Motor Hp/250 x (Motor Hp /500 + 1)
Configure the Motor Side Inverter

2. Navigate to parameter 10/11:110 [Mtr Stop Mode A] and enter a value
of 1 'Ramp'.
3. Navigate to parameter 10/11:229 [Regen Power Lim] and enter a value
of -200%.
4. Navigate to parameter 10/11:204 [Mtr OL Hertz] and enter a value that
reflects the cooling capacity of the motor. See parameter 10/11:204
[Mtr OL Hertz] on page 199.
5. Navigate to parameter 10/11:220 [Drive OL Mode] and enter a value of
2 ‘Reduce PWM’.
6. Navigate to parameter 10/11:222 [Current Limit 1] and enter a value
equal to 200% of motor nameplate amps.
7. Navigate to parameter 10/11:256 [OutPhaseLossActn] and enter a value
of 3 ‘FltCoastStop’.
8. Navigate to parameter 10/11:116 [Bus Reg Mode A] and enter a value of
0 ‘Disabled’.
9. Navigate to parameter 10/11:913 [Autotune Trq Lim] and enter a value
of 100%.

Autotune the Motor Side Inverter
Follow these Autotune steps to configure the motor side inverter.
Perform the Direction Test
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.
‘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.
Perform the Rotate Motor ID Test
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.
If the motor is connected to a load, determine whether there is enough travel

distance for the Rotate Motor ID Test sequence to complete. If necessary, run the
crane hook to top or bottom for more travel distance in the opposite direction.
It is preferable to run the Rotate Motor ID Test. If you cannot 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.
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 the Static Motor ID Test
Perform this test if you cannot perform the Rotate Motor ID test. If you can
perform the Rotate Motor ID 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.
Confirm Flux-up Time
1. Navigate to parameter 10/11:432 [c FluxUpTime].

2. If the value is less than 0.05 seconds, change the value of parameter 10/
11:431 [FluxUpTm C/U Sel] to 1 ‘User’. Then set parameter 10/11:433 [u
FluxUpTime] to 0.05 seconds.
Configure the Digital Output for Brake Control
1. Determine whether logic of the brake control circuit is ‘Active High’ or

‘Active Low’.
‘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 example, navigate to port 4 when using a 20-750-2262C-2R in slot 4.

3. Configure the digital output selector to receive control from the correct
bit in the Torque Prove status word.
For example, when using Relay Output 0 on the 20-750-2262C-2R in slot

4 to control the brake, go to parameter 4:10 [RO0 Sel]:
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’.
Configure the Torque Prove Function
1. Navigate to port 9, which is the port for Application Control.

2. Navigate to parameter 9:50 [Trq Prove Cfg].
a. Set bit 0 ‘TP Enable’
b. Set bit 1 ‘Encoderless’
c. Set bit 5 ‘BrkSlipEncls’
IMPORTANT An alarm indicates that the drive is in the state described on page 113.
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 is not 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.
Troubleshooting information can be found in Knowledgebase Article

1061994, PowerFlex 755T in Lifting Applications.
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 is not
excited as a result of a horizontal move. Note that the pendulum can still be
excited from external disturbances such as wind or from non zero initial
conditions like picking up a load off center.
Calculating the Sway Frequency
In crane/hoist applications, the sway frequency is only a function of cable length

L. The sway frequency (Reference Notch Filter Frequency) can be calculated
from the cable length or derived from experiment.
• The frequency calculation in [Hz] is a function of cable length L in
[inches] and the acceleration of gravity g = 386 [inches/sec2].
1
f =  ------  --g- Equation 1
 2  L
Where g = acceleration due to gravity

9.80665 m/sec2
32.17417 ft/sec2
386.09 in/sec2
Where L = length in meters, feet, or inches. Gravity and length must have
the same distance units.

• The experimental method involves displacing of the load to an initial

angle, letting it oscillate for a time period of T seconds while counting the
number of swings n. With this knowledge, frequency is derived as:
n
f = --- Equation 2
T
Knowing the accurate cable length is important as it affects the center frequency
of the notch filter. 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 45.
Figure 45 - Sway Magnitude (Degrees) vs. Cable Length Error (Percent)

8
7
6
Sway Magnitude (Degrees)
5
4
3
2
1
0
-60% -40% -20% 0% 20% 40% 60%
Cable Length Implied by Notch Filter / True Cable Length
Cable Length Variation

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.
See Figure 46. The range of such length change can determine the system
configuration.
A larger variation of cable length can result in a larger variation in frequency.
Figure 46 - Simple Diagram for Anti-Sway Application

Z- axis Hoist
Lmin X- axis
Trolley
Y- axis Lmax
Load
Gantry
Sway magnitude
(degrees)
Load

Notch Filters Configuration
Different applications have different variations of cable length. Based on these

variations, there are three configurations: Fixed Frequency One Filter, Fixed
Frequency Two Filters, or Variable Frequency.
Fixed Frequency One Filter
In this configuration, only one reference notch filter is set in the trolley and/or
gantry drives.
The notch frequency is calculated based on the average length using the
following equation. This can be an acceptable approach when cable length
variation is not large.
1 g
f = ------ -----------------------------------------
- Equation 3
2  L min + L max   2
Figure 47 - Average Length for Fixed Frequency One Filter Configuration
Lmin
Load
(Lmin + Lmax)/2
Lmax
Load
Fixed Frequency Two Filters
In this configuration, both reference notch filters are set in the gantry and/or
trolley drives. One is set at the average length and one at the maximum length.
This has better performance compared to one filter configuration, and can be
good for greater length variations but can increase move times.
1 g
f 1 = ------ ------------------------------------------ Equation 4
2  L min + L max   2
1 g -
f 2 = ------ ----------- Equation 5
2 L max

Variable Frequency
In this configuration, one reference notch filter is set dynamically as the length of
the cable changes. This approach requires hardware interconnection. The
encoder feedback from the Z (hoist) drive is connected to a Logix controller.
This feedback is used to calculate instantaneous cable length, then the length is
used to calculate the instantaneous filter frequency. The trolley and/or gantry
drives are also connected to the controller via datalinks. The instantaneous filter
frequency is then sent to the reference notch filter in these drives.
Figure 48 - Variable Frequency Configuration
Lmin
Load
(Lmin + Lmax)/2
Lmax
Load
To calculate the cable length from hoist drive encoder feedback, we can assume a
linear relationship between the cable length (L) and the encoder counts (x), as:
Current Encoder Counts - Offset Encoder Counts
L= Equation 6
Conversion Constant
To find the Conversion Constant (Equation 6), two given points are required:
L1and L2 which can be obtained by measuring the cable length at two arbitrary
points and capturing the corresponding hoist encoder counts, as shown in
Figure 49. The Offset encoder counts are determined via a homing routine or an
absolute encoder feedback position. Therefore:
L1 - L2
Conversion Constant = Equation 7
Delta Length Change
Figure 49 - Relationship Between Hoist Encoder Counts and Cable Length
Load
Corresponding to x1 counts, L1
Corresponding to x2 counts, L2
Load

Operating Modes Configuration
Manual Mode: Manually controls the crane position trolley or gantry with a
joystick or a pendant controller and simultaneously stabilizes the sway load. The
drive is typically configured in Velocity loop to send velocity commands.
Automatic Mode: Automatically controls the crane trolley or gantry to specified

target position and simultaneously stabilizes the load with programmable target
positions.

Notes:

.
Rockwell Automation Support

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User Forums, and Product Notification Updates.
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code to route your call directly to a technical support
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Literature Library Installation Instructions, Manuals, Brochures, and http://www.rockwellautomation.com/global/literature-library/
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Reference Manual

PowerFlex 750-Series Products with TotalFORCE Control

Labels may also be on or inside the equipment to provide specific precautions.

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 3

4 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

The purpose of this manual is to provide detailed information about configuring

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 5

You can view or download publications at

6 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

A brief overview of Load Observer, Adaptive Tuning, and Autotune is provided

When load observer is enabled with autotuned control loop gains:

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 7

Autotune The Autotune function is used to measure motor characteristics. It is composed

8 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Figure 1 - Regulator Schemes

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 9

Bus Observer Limitations

Figure 2 and Figure 3 show the Bus Observer function.

Figure 2 - Voltage Control (VoltCtrl) Block Diagram

Port 0,DC Bus Volts

Volt Reg Damping 56

Internal Bus Capacitance Total Sys Cap

Ext Bus Cap 52

10 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Figure 3 - DC Bus Observer Block Diagram

Cur Lmt Command

c BusObs Kp 321 323 cBus Obs Ki

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 11

Figure 4 - Feed Forward Power Block Diagram

Conv Options Cfg

FF Power Gain 13:44

Table 1 - Feed Forward Power Parameters

12 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Figure 5 - Position Reference 2 (PRef2) Block Diagram

942 Ref NF1 Freq 948 Ref NF2 Freq

943 Ref NF1 Width 949 Ref NF2 Width

944 Ref NF1 Depth 950 Ref NF2 Depth

945 Ref NF1 Gain 951 Ref NF2 Gain

Figure 6 - Velocity Reference – Flux Vector (VRef Vect)

Cubic 1018 1046

Figure 7 - Process PID (Proc1) Block Diagram Block Diagram

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 13

Table 2 - Notch Filter Parameters

Notch Filters Examples

14 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Figure 8 - Velocity Command – Before Reference Notch Filter

Figure 9 - Velocity Command – After Reference Notch Filter

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 15

16 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 17

IMPORTANT Do not overstate the external bus capacitance.

18 Rockwell Automation Publication 750-RM100A-EN-P - August 2019

Voltage and Current Regulator Tuning

A good indication that the converter needs to be de-tuned is the presence of

Rockwell Automation Publication 750-RM100A-EN-P - August 2019 19

Table 4 - Capacitor Resonance Fault Thresholds—400/480V Products

Table 5 - Capacitor Resonance Fault Thresholds—600/690V Products

20 Rockwell Automation Publication 750-RM100A-EN-P - August 2019