750 Rm100 - en P (Predictive Maintenance)
750 Rm100 - en P (Predictive Maintenance)
750 Rm100 - en P (Predictive Maintenance)
Original Instructions
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
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
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
Overview
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
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
Adaptive Control
Load Observer The load observer feature is a control loop inside the drive that estimates the
mechanical load on the motor and compensates for it while the drive is running.
This feature allows high performance and control loop tuning simplicity similar
to that of a mechanically disconnected motor. Its primary function is to:
• Automatically compensate for unknown inertia, compliance, and low
frequency resonance
• Automatically compensate for disturbances and changes in inertia
• Force consistent dynamic behavior, which makes the drive easier to tune
Benefits
You can use load observer with out-of-box control loop gains, where the load is
unknown or compliant and thus 10/11:901 [Load Ratio] = 0. You can also use
load observer with autotuned control loop gains where 10/11:901 [Load
Ratio] > 0. This value can be a known positive value or one that is calculated by
performing an autotune procedure.
When load observer is enabled with the recommended out-of-box control loop
gains:
• A tuning expert is not needed
• Commissioning time is reduced, especially for high drive count
• Relatively high performance control is provided without tuning
• Changes in inertia, compliance, and low frequency resonances are
compensated for automatically
• Periodic retuning to account for machine wear over time is not needed
Adaptive Tuning 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
Autotuning is often unnecessary when you apply Load Observer with the
recommended default settings.
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.
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.
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
u Volt Reg Kp 57 1
LscCtrlCfg [C5]
IqRefVbusReg
IqRefDcBusObs
+ X
- Limit
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
-
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.
PFC [A2,E2,A4,E4]
VoltCtrl [H2]
Converter Mode Select
X
Output Power 10:4
DC Bus Obs[H2]
IqRefDcBusObs
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.
PRef NF Out
15
Ref NF 1 Ref NF 2 ¦ 1731 Position Command
PRef NF Out
PReg [C3]
Motor Side Sts 1 (Running) Velocity Ramp and Move Profiles (VRef Move)
354 16 Vel Ctrl Options
Motor Side Sts 1 OR (Delayed Ref)
(Stopping)
355 9 VRef Ramp In 1950 8
354 18 Motor Side Sts 2 1923 VRef Ramped
1
0 (Autotuning) 1 Proc 2 [C2] 0
Not Stopping
and Active
Virtual Encoder
0
0
1 VRef Delayed
0 One 1
Stopping LinScurve 1924
or Not Active Scan
SineSquared Delay PRef 1 [C5]
Virtual Enc EPR Virtual Enc Psn
Poly5 (Edges Per Rev)
931 One
1017
Ref NF2 Freq 948 Ref Move Type Scan
Ref NF2 Width 949 Delay Virtual EncDelay
Virtual Encoder
950 PRef 1 [C5]
Ref NF2 Depth
Ref NF2 Gain 951
VRef Filter
VRef NF In
1925
36
Ref NF2 Ref NF1
Accel FF Output
Velocity Comp
2070
Vel Comp Sel
These graphs show a velocity command before and after the reference notch
filter. The command going into the filter is a ramp to 50 rpm in 0.5 seconds and
the first notch filter is set to a frequency of 0.5 Hz.
0.03
10/11:381 [Testpoint REAL 1]
0.025
0.02
0.015
0.01
0.005
0.0
-1 999 1999 2999 3999
Milliseconds
60
10/11:1925 [VRef Filtered]
40
RPM
20
0
-1 999 1999 2999 3999
Milliseconds
0.02
0.015
0.01
0.005
0.0
-1 999 1999 2999 3999
Milliseconds
60
10/11:1925 [VRef Filtered]
40
RPM
20
0
-1 999 1999 2999 3999
Milliseconds
Notes:
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.
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.
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.
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.
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)
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
u Volt Reg Kp 57 1
Active Current
7
Cur Reg C/U Sel 74 CurRegKiIq
Metering [I1]
VqSyncRef
PFC [G3]
c Cur Reg Ki 80 CurRegKpIq
Cur Reg BW 75 0
P
Cur Reg Damping 76 W
u Cur Reg Ki 79 1
Auto Gain M
Calculation CurRegKpId
u Cur Reg Kp 77 1
IdSyncErr CurRegdOut
AC Line Source 31
Reactv Cur Cmd 73
CurPwrLmt [G4]
PI Regulator
AC Line kVA A 32
Reactive Current
AC Line Imped% A 34
Source
8
Impedance
AC Line kVA B 33 Processing Metering [I2]
PFC [G4]
AC Line Imped% B 35
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.
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.
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.
Precharge Sequence
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.
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.
The active motor control profile is defined in 0:74 [Motor Ctrl Sel]. There are
two methods you can use to change between the primary and secondary motor
control profiles.
Logix Configuration
The motor control profile that is actively being used can be changed by writing to
0:74 [Motor Ctrl Sel] either through a datalink or with an explicit message
instruction. You can verify that the active motor control profile has changed as
expected by doing a readback from the PowerFlex 755T drive by using 0:75 [Mtr
Ctrl Sel Act].
You can wire a digital input to an I/O option module installed in the PowerFlex
755T drive. The digital input is configured to 0:169 [DI Mtr Ctrl Sel] to switch
between the primary and secondary motor control profiles. If the input is open or
de-energized, the drive selects the Primary Motor Control profile.
If both methods to control the active motor control profile are being used, the
digital input that is configured in 0:169 [DI Mtr Ctrl Sel] takes priority.
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.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
100 Hp 150 Hp
Power Structure
100 Hp 150 Hp
You can use secondary motor control when one PowerFlex 755T drive is used to
switch from two different motor control types. For this example, the PowerFlex
755T drive is configured to switch between controlling an induction motor and
an SPM permanent magnet motor. Induction Flux Vector is configured in the
Primary Motor Control profile, and SPM Motor Flux Vector is configured in the
Secondary Motor Control profile.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
Power Structure
Induction SPM
You can use secondary motor control when one PowerFlex 755T drive is used to
switch from controlling one motor to controlling a multi-motor system. For this
example, the PowerFlex 755T drive is configured to switch between controlling
one motor in induction flux vector mode and controlling a multi-motor system
in induction VHz mode. Induction Flux Vector is configured in the Primary
Motor Control profile, and Induction VHz is configured in the Secondary
Motor Control profile.
The drive is configured to switch between the primary and secondary motor
control profiles that are based on which contactor is closed and electrically
connected to the specified motor.
Port 10 Port 11
Pri Mtr Ctrl Sec Mtr Ctrl
Notes:
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.
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.
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.
AC precharge successful.
Owned State
After powerup and when AC precharge is complete, the function moves to the
Owned state. The Owned state is the traditional operating state. The line side
converter is energized and can modulate. The motor side inverter is energized
and can modulate.
In the Owned state, the function waits for an Energy Pause command. If it
receives one, it moves to the Paused state. An Energy Pause command is ignored
if the line side converter and the motor side inverter are 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.
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
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:
Predictive Maintenance
Overview The overall goal of the predictive maintenance function is to enable regular
maintenance of drives, motors, and machines.
The predictive maintenance function allows you to set the event action and event
levels. The event level changes how much of the total life of a component is
consumed before the predictive maintenance function notifies you to replace the
component.
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.
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.
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 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.
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]
IGBTs in power module L1 14:240 [L1IGBT RemainLif]
… …
IGBTs in power module L9 14:1040 [L9IGBT 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]
IGBTs in power module L1 14:239 [L1IGBT ElpsdLife]
… …
IGBTs in power module L9 14:1039 [L9IGBT 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]
IGBTs in power module M1 12:239 [M1IGBT ElpsdLife]
… …
IGBTs in power module M9 12:1039 [M9IGBT ElpsdLife]
Fan or Blower
The following fans have the proposed fan life model implemented:
• Heatsink fan (Power module and LCL filter module blower)
• Control pod fan
• Power bay roof fan: IP54 only (frame 8…12)
• Input bay roof fan: Input bay (frame 8…9) and Control bay (frame 8…12)
• Door fan: Input bay (frame 10…12), Entry wire bay (frame 8…12), and
Exit wire bay (frame 8…12)
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
°C Temperature 0:25 [Ctrl Pod Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp] 0:503 [Meas Amb Temp]
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
Hours Remaining 0:513 0:533 0:523 0:553 0:543
Life [PodFan RemainLif] [PwrRfFanRem Life] [In FanRemainLif] [CtrlFanRem Life] [WrgFanRem Life]
Units Definition Motor Side Power Module Fans Line Side Power Module Fans LCL Filter Module Fans
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]
Units Definition Control Pod Power Bay Roof Input Bay Fan Control Bay Roof Wiring Bay Fans
Hours Elapsed Life 0:512 [PodFan ElpsdLife] 0:532 [PwrRfFanElpsdLif] 0:522 [In FanElpsdLife] 0:552 [CtrlFanElpsdLif] 0:542 [WrgFanElpsdLif]
DC Bus Capacitors
Airflow Health
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
Circuit Breakers
Circuit breakers generally have a fixed number of cycles available. This number
varies based on whether the breaker disconnect operation occurs under electrical
load..
Table 19 - Event Level and Event Action Parameters
Units Definition AC Precharge Main Circuit Breaker AC Precharge Contactor DC Precharge Molded Case Switch
% Event Level 0:578 [MCB LifeEvntLvl] 0:582 [PCC LifeEvntLvl] 0:574 [MCS Event Level]
1 or 0 Event Action 0:579 [MCB LifeEvntActn] 0:583 [PCC LifeEvntActn] 0:575 [MCS Event Action]
LCL Capacitors
The calculation of line capacitor life is simplified. The only operating parameter
is ambient temperature.
Table 21 - Input Parameters
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]
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.
Follow these steps to reset the Elapsed Life and Remaining Life parameters for
the heatsink fan in the M0 power module in the motor side inverter.
1. Go to port 0 and open parameter 0:504 [PredMain Rst En]. Set bit 10
‘M0’.
2. Go to the Predictive Main group in the M0 Power Module file in port 12.
3. Find parameter 12:130 [M0PredMaintReset]. Then select 1 ‘M HSFan
Life’ in the drop-down menu.
Follow these steps to reset the Elapsed Life and Remaining Life parameters for
the pods on the control pod.
1. Go to port 0 and open parameter 0:504 [PredMain Rst En]. Set bit 0 ‘Port
0’.
2. Stay in port 0, and go to parameter 0:505 [Pred Maint Reset]. Then select
1 ‘PodFan Life’.
Parameter 0:505 [Pred Maint Reset] returns to 0 ‘Ready’ after the reset is
performed.
3. Return to parameter 0:504 [PredMain Rst En] in port 0. Then clear bit 0
‘Port 0’.
Configuration Examples This section provides instructions for configuring the Predictive Maintenance
Event Level and Event Action.
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.
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
Now all IGBT events occur when 60% of the IGBT life is consumed. The IGBT
events affect IGBTs in the M0 Motor Side Inverter power module and the L0
Line Side Converter power module.
Go to parameter 0:567 [IGBT Event Actn]. The value is set to ‘Alarm’ with an
internal value of 1.
When set to alarm, an IGBT event results in a numbered alarm with text to
indicate which power module is affected.
Now the control pod fan event occurs when 70% of the fan life is consumed.
When set to alarm, a Control Pod Fan event results in a numbered alarm with
text.
Monitoring Examples This section provides instructions for monitoring the Elapsed Life and
Remaining Life.
Follow these steps to view the Elapsed Life and Remaining Life parameters for
the heatsink fan in the M0 power module in the motor side inverter.
This group lists all of the parameters that are related to predictive
maintenance on the M0 power module.
3. Double-click parameters 12:135 [M0HSFanElpsdLife] and 12:136
[M0HSFanRemainLif ].
The value for the parameter you selected appears.
Follow these steps to view the Elapsed Life and Remaining Life parameters for
the bus capacitors in the L0 power module in the line side converter.
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.
DeviceLogix
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.
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.
2. Add the Application DLX Only option module in the Peripherals list.
7. Click the blocks or instructions and drag and drop elements on the sheet
to add code.
8. Click one connection pin and move the cursor to another pin and then
release to interconnect items. Notice that the editor makes a connection
line.
Double-click the inputs and outputs to define the tags to use, or double-
click the function blocks to see the parameters.
DeviceLogix Tag Database Use the Tag Editor to add the tags to be used in the code.
1. Select the Show Tag Database option from the Tools menu.
The Tag Database window opens.
For example, to select digital input 0 from an I/O module in port 4, select
4:1 [Dig In Sts] bit 0 ‘Input 0’ and click Add.
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.
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.
IMPORTANT The emergency override of protections and faults can reduce the life of the
product (drive or bus supply). Their purpose is to help protect the product
from conditions that can damage the product.
The person or company that configures the override assumes responsibility
for the damage to the product from the conditions that would otherwise
have triggered the protections.
Configuration There are two modes for the function: Only Override and Purge Frequency.
Go to parameter 0:454 [Emerg OVRD Mode] and select the desired mode.
Only Override
In Only Override mode, the product overrides faults to continue running. The
product uses its normal methods for starting and stopping. The product follows
its regular position/velocity/torque mode.
Purge Frequency
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.
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.
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.
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.
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.
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.
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.
3 SpdFFRef En
0 = Rate
1406 PTP Vel Max
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).
[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]
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.
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).
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]
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’.
You can completely decouple acceleration and deceleration parts of a move, making it
easier to generate asymmetric move profiles.
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]
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.
[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.
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]
The following example shows what happens when velocity limits are lowered below what
is required by an unconstrained move with adjusted acceleration and deceleration times.
Not Limitied
Vel Lim = 40
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec 2 ]
2
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
[rev/sec ]
20
3
Jerk
0
-20
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
0.5
3
[rev /sec ]
Energy
2
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Typical trajectories moving from rest to rest accelerate to a peak velocity and then
decelerate back to zero. When this occurs, parameter 10/11:1411 [PTP Move Seg] =
‘AccelDecel’. However, when a move profile is initiated while another is in motion, the
new move will start at an initial velocity matching the velocity of the previous move
profile at the point of transition. When the initial velocity is high enough, there may only
be time to perform a velocity dwell and decelerate to the new target. When this occurs,
parameter 10/11:1411 [PTP Move Seg] = ‘DwellDecel’.
[counts]
Pos
AccelDecel
DwellDecel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
50
[RPM]
Vel
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
2
[rev/sec 2 ]
Accel
0
-2
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
10
3
[rev/sec ]
Jerk
-10
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Time [sec]
Initial velocities increase as the target distance becomes closer. In this case, there may
only be time to decelerate to the new target or decelerate to the new target while hitting
the deceleration limit. When this occurs, parameter 10/11:1411 [PTP Move Seg] =
‘Decel’ or ‘DecelLimited’, respectively.
Decel
DecelLimited
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
500
[RPM]
Vel
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
0
[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’.
[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
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.
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
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.
When 10/11:933 [Ref Time Base] = ‘Rate’, acceleration and deceleration times are
calculated as a function of target velocity and parameters in the following table. This is
standard functionality in 750 series drives.
Figure 30 shows different target velocities for a LinScurve velocity move with a 10 second
acceleration time.
When 10/11:933 [Ref Time Base] = ‘Time’, you can enter acceleration and deceleration
times directly using parameters in the following table. However, this only affects
commands that are generated when 10/11:931 [Ref Move Type] = ‘SineSquared’, ‘Poly5’,
or ‘Cubic’. Rate based calculations are always applied when 10/11:931 [Ref Move Type]
= ‘LinScurve’.
Individual acceleration and deceleration times allow you more control over decoupling
acceleration and deceleration moves. The following example shows various moves with 5
second acceleration times and 10 second deceleration times.
Limits are typically set high to protect drive systems from dynamics they cannot handle.
Slower moves are unaffected by limits, however move dynamics approach limits and then
become limited as move times are decreased or move distance is increased.
You can also apply limits proactively by intentionally lowering them to balance dynamics
and energy. When limited, a dwell is added to ensure the correct area under the curve and
therefore the correct trajectory. The final move time is automatically increased for best
performance when inputs generate constrained circumstances. Moves will smoothly
transition in and out of acceleration and jerk limits when 10/11:931 [Ref Move Type] =
‘SineSquared’, ‘Poly5’, or ‘Cubic’.
The following example shows what happens when minimum and maximum jerk limits
are lowered below what is required by an unconstrained 10 second move.
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.
The following example shows what happens when acceleration limits are lowered below
what is required by an unconstrained move with adjusted acceleration time.
[RPM]
Vel
1000
AccelDecel
DwellDecel
0
0 1 2 3 4 5 6 7 8 9 10
[rev/sec 2 ]
Accel
0
0 1 2 3 4 5 6 7 8 9 10
[rev/sec 3 ]
Jerk
0
-2
0 1 2 3 4 5 6 7 8 9 10
2
[rev/sec 4 ]
Snap
-2
0 1 2 3 4 5 6 7 8 9 10
Time [sec]
Initial accelerations increase as the target velocity becomes closer. In this case, there may
only be time to decelerate to the new target or decelerate to the new target while hitting
the jerk limit. When this occurs, parameter 10/11:1939 [VRef Move Seg] = ‘Decel’ or
‘DecelLimited’, respectively.
1000
Decel
DecelLimited
0
0 0.5 1 1.5 2 2.5 3 3.5 4
50
[rev/sec 2 ]
Accel
0
0 0.5 1 1.5 2 2.5 3 3.5 4
0
[rev/sec 3 ]
Jerk
-50
-100
0 0.5 1 1.5 2 2.5 3 3.5 4
500
[rev/sec 4 ]
Snap
-500
0 0.5 1 1.5 2 2.5 3 3.5 4
Time [sec]
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’.
[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]
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.
AC Mains
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.
Modes of Operation There are two modes of operation: Linear and Nonlinear. The default mode of
operation is Linear. To change the mode of operation in the PowerFlex 755T,
adjust parameter 13:350 [DroopCtrlModeSel].
Linear Mode
The Linear Mode uses a piecewise linear function to determine the DC bus
voltage reference. In this function, the active current reference is the input (X-
axis). The DC bus voltage reference is the output (Y-axis).
Minimum DC
Bus Voltage
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load Motoring
Regenerating Current Current Current Current
There are four regions of operation. The Motoring Full Load region is between
positive ‘Trans Droop Current’ and positive full load current. The Motoring No
Load region is between zero current and positive ‘Trans Droop Current’. The
Regen No Load region is between zero current and negative ‘Trans Droop
Current’. The Regen Full Load region is between negative ‘Trans Droop Current’
and negative full load current. The value in parameter 13:353 [Trans Droop Cur]
defines the positive and negative ‘Trans Droop Current’ points on the X-axis.
You determine the horizontal boundaries of the regions by entering the value of
parameter 13:353 [Trans Droop Cur]. This value determines the locations of the
inflection points on DC bus voltage droop curve.
In the Motoring Full Load and Regen Full Load regions, the value in parameter
13:351 [FullLd DroopGain] determines the slope of the curve. Set the value of
this parameter as percent increase in DC bus voltage reference (percent of
minimum DC bus voltage) over the positive current range (zero load to full
load).
In the Motoring No Load and Regen No Load regions, the value in parameter
13:352 [NoLd DroopGain] determines the slope of the curve. Set the value of
this parameter as percent increase in DC bus voltage reference (percent of
minimum DC bus voltage) over the positive current range (zero load to full
load).
0%
13:352 [NoLd DroopGain]
13:351 [FullLd DroopGain]
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load Motoring
Regenerating Current Current Current Current
Nonlinear Mode
The Nonlinear Mode uses a continuous curve to determine the DC bus voltage
reference. The function builds a slope curve using two of the parameters from the
Linear Mode. These are 13:351 [FullLd DroopGain] and 13:352 [NoLd
DroopGain]. It builds the slope curve with a slope at full load equal to 1.2 x
13:351 [FullLd DroopGain] and the slope at the no load point equal to 0.3 x
13:352 [NoLd DroopGain].
0%
0.3 x 13:352 [NoLd DroopGain]
This results in a smooth and progressive curve for the DC bus voltage reference.
Active Current
-Full Load -Trans Droop Zero Current +Trans Droop +Full Load Motoring
Regenerating Current Current Current 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:
Notes:
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.
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.
IMPORTANT Brake Slip detection and Float capability (ability to hold load at zero speed) are
no available in encoderless TorqProve.
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
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.
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 the HIM, follow these steps.
Bus Regulation
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].
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.
7. Click OK.
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.
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.
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]
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)
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%.
1. Stay at port 10, which is the port for Motor Side Inverter Control.
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’.
IMPORTANT During this test, the drive uses an internal reference that is positive (forward).
During operation and other tests, the drive uses an external reference that you
select. An external reference can include the HIM, analog input, or
communicated reference. The direction of rotation depends on the polarity
(direction) of that external reference. Make sure the external reference moves
the motor in the intended direction.
1. Stay at port 10, which is the port for Motor Side Inverter Control.
2. Navigate to parameter 10/11:910 [Autotune] and enter a value of 1
‘Direction Test’.
3. Start the drive. You can use the control bar feature in Connected
Components Workbench software, the start key on the HIM, or the
normal start signal.
4. Verify that the motor direction is forward.
5. Verify the polarity of the encoder feedback.
• Navigate to parameter 10/11:1832 [Enc VRef Sel] and select the
encoder feedback on the feedback card in port 5. 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.
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.
Perform this test if you cannot perform the Rotate Motor ID Test. If you can
perform that test, skip to Confirm Flux-up Time.
‘Active High’ control sets or engages the brake when the signal is energized.
‘Active Low’ control sets or engages the brake when the signal is de-
energized.
2. Navigate to the port that contains the IO option card.
For ‘Active High’ control, set the value to 9:52 [Trq Prove Status] bit 4
‘Brake Set’
or
For ‘Active Low’ control, set the value to 9:52 [Trq Prove Status] bit 8
‘BrakeRelease’.
Confirm Configuration
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.
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.
7. Click OK.
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.
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]
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)
IMPORTANT During this test, the drive uses an internal reference that is positive
(forward). During operation and other tests, the drive uses an external
reference that you select. An external reference can include the HIM, analog
input, or communicated reference. The direction of rotation depends on the
polarity (direction) of that external reference. Make sure the external
reference moves the motor in the intended direction.
1. Stay at port 10, which is the port for Motor Side Inverter Control.
2. Navigate to parameter 10/11:910 [Autotune] and enter a value of 1
‘Direction Test’.
3. Start the drive. You can use the control bar feature in Connected
Components Workbench software, the start key on the HIM or the
normal start signal.
4. Verify that the motor direction is forward.
5. Verify the polarity of the encoder feedback.
• Navigate to parameter 10/11:1832 [Enc VRef Sel] and select the
encoder feedback on the feedback card in port 5. The value would be
50004 ‘Port 5: Enc 0 FB’ when using a 20-750-ENC-1 in slot 5.
• View the result in parameter 10/11:1834 [Enc VRef ].
6. Stop the drive from the control bar feature in Connected Components
Workbench software, the stop key on the HIM, or the normal stop signal.
7. Address the direction.
• If the direction is forward, proceed to next step.
• If the direction is reverse, power down and physically reverse the motor
leads.
During the Rotate Motor ID Test, the motor rotates for around 15 seconds in the
commanded direction. It runs at speeds up to 75% of motor nameplate speed.
You can execute this test with the motor that is disconnected from the crane or
with a lightly loaded condition. Lightly loaded conditions include motor that is
connected to gearbox, cable drum, or cable and hook.
It 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.
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.
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’.
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
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.
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.
1
f = ------ --g- Equation 1
2 L
Where L = length in meters, feet, or inches. Gravity and length must have
the same distance units.
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.
5
4
3
2
1
0
-60% -40% -20% 0% 20% 40% 60%
Cable Length Implied by Notch Filter / True Cable Length
Lmin X- axis
Trolley
Y- axis Lmax
Load
Gantry
Sway magnitude
(degrees)
Load
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
Lmin
Load
(Lmin + Lmax)/2
Lmax
Load
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.
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
Load
Corresponding to x1 counts, L1
Corresponding to x2 counts, L2
Load
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.
Notes:
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