Rockwell Automation Allen-Bradley PowerFlex 23PFC Betriebsanleitung

PowerFlex DC Field Controller

Catalog Number 23PFC

Programming Manual

Original Instructions

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are

required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may

be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from

the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

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

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).

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 3

Table of Contents

Preface

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Firmware Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

Startup Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tools Required for Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Start up a PowerFlex DC Field Controller. . . . . . . . . . . . . . . . . . . . . . . 10

Startup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Before You Apply Power to the Controller or Drive . . . . . . . . . . 10

Apply Power to the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 2

Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Change the HIM Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Change the Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . 21

Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Parameter Cross Reference – by Number. . . . . . . . . . . . . . . . . . . . . . . . 84

Chapter 3

Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Field Controller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

HIM Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Manually Clear Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Clear an Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Common Field Controller Symptoms and Corrective Actions . . . 100

Field controller does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Field controller activates but there is no output current . . . . . 100

The field controller is unable to generate commanded

current or voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Appendix A

Control Block Diagrams Parameter Type Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017

Table of Contents

Appendix B

HIM Overview External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Using the S.M.A.R.T. List Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

View a Parameter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Edit a Parameter Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Remove/Install the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Appendix C

Application Notes Alpha Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Alpha Test Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Example 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Example 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Analog-input Signal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Logic Command/Status Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Reference Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

“Auto” Voltage Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

“Manual” Voltage Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Voltage Source Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Scale Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Link Parameters Via the Scale Block Parameters. . . . . . . . . . . . . 142

SCR Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Open SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Shorted SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

S-curve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

S-curve Acceleration Ramp Example:. . . . . . . . . . . . . . . . . . . . . . . 146

Voltage Regulation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Adaptive Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Voltage Threshold Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Voltage Zero Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Voltage Draw Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Voltage / Current Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Zero Current Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Voltage Regulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Current Regulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Digital Current Regulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Start at Powerup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Fine Tune the Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Using the Test Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 5

Table of Contents

Manually Adjust the Current Regulator Tune Settings. . . . . . . 153

Manually Adjust the Voltage Regulator. . . . . . . . . . . . . . . . . . . . . 155

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

6Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017

Table of Contents

Notes:

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 7

Preface

This manual provides information on how to startup, program, and

troubleshoot the PowerFlex® DC Field Controller. Startup procedures are

provided for a PowerFlex DC Field Controller that is used in standalone mode

and when a field controller is used with a PowerFlex DC drive or PowerFlex

DC Standalone Regulator. This manual excludes instructions for installation

and use of the PowerFlex DC Fiber-optic Interface option module (cat. no.

20P-S5H781), used for communication between the field controller and a

PowerFlex DC drive or PowerFlex DC Standalone Regulator. See the list of

Additional Resources on page 8for more information on related publications.

This manual is intended for qualified personnel. You must be able to program

and operate DC drives, DC field controllers, and associated equipment. In

addition, you must have an understanding of the parameter settings and

functions that are detailed in this manual.

Firmware Revision The contents of this manual pertain to PowerFlex DC Field Controller

firmware revision 1.001.

You can view the current firmware revision of the field controller on the HIM

(if installed) in parameter 331 [Software Version]. See the HIM Overview on

page 123, for details on how to use the HIM. If a HIM is not installed, the

firmware revision of the field controller is included on the data nameplate label.

See the PowerFlex DC Field Controller Installation Instructions, publication

23PFC-IN001, for details.

Product Downloads Download firmware, associated files (such as Add-on Profile, DTM, and EDS),

and access product release notes from the Product Compatibility and

Download Center at http://www.rockwellautomation.com/

rockwellautomation/support/pcdc.page.

8Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017

Preface

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

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

To order paper copies of technical documentation, contact your local

Allen-Bradley distributor or Rockwell Automation sales representative.

Resource Description

PowerFlex Digital DC Drive and Field Controller Technical Data, publication 20P-TD001 Provides detailed information on:

• Basic product selection

• Field controller specifications

• Option specifications

• Circuit protection

PowerFlex DC Field Controller Installation Instructions, publication 23PFC-IN001 Provides installation instructions for the PowerFlex DC Field Controller.

PowerFlex DC Fiber-optic Interface Option Module Installation Instructions, publication

20P-IN078

Provides installation instructions for the PowerFlex DC fiber-optic interface module.

PowerFlex Digital DC Drive - Frame A Hardware Service Manual, publication 20P-TG001 Provides hardware test procedures and spare parts replacement instructions for

Frame A PowerFlex DC drives and field controllers.

PowerFlex Digital DC Drive - Frame B Hardware Service Manual, publication 20P-TG002 Provides hardware test procedures and spare parts replacement instructions for

Frame B PowerFlex DC drives and field controllers.

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, http://www.rockwellautomation.com/global/certification/

overview.page

Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017 9

Chapter 1

Startup

This chapter provides basic startup procedures for the PowerFlex® DC Field

Controller.

Qualified Personnel The procedures in this section are intended for qualified personnel.

• You must understand the hazards that are associated with

electromechanical equipment installations.

• You must understand and follow all applicable local, national, and/or

international electrical codes.

• You must be able to program and operate DC drives, field controllers,

and associated devices.

• You must have an understanding of the parameter settings and functions

for both DC drives and DC field controllers.

Tools Required for Startup You must use one of these tools to configure and start up the PowerFlex DC

Field Controller:

• LCD human interface module (HIM). If you use the HIM to

commission the field controller, read the HIM Overview on page 123

before performing the procedures in this chapter. If an operator interface

is not available, use a remote device to start up the field controller.

• DriveExecutive™ software - You must use DriveTools™ SP version 4.01 or

later, with the PowerFlex DC drive specific software patch installed. The

latest version of DriveTools SP software can be downloaded from the

Product Compatibility and Download Center at:

https://compatibility.rockwellautomation.com/Pages/home.aspx.

• Connected Components Workbench® software, version 10 or later.

ATTENTION: Power must be applied to the field controller to perform the

following startup procedures. Some of the voltages present are at incoming

line potential. To avoid electric shock hazard or damage to equipment, allow

only qualified service personnel to perform the following procedure.

Thoroughly read and understand the procedure before beginning. If an event

does not occur while performing this procedure, Do Not Proceed. Remove

Power including user-supplied control voltages. Correct the malfunction

before continuing.

10 Rockwell Automation Publication 23PFC-PM001A-EN-P - December 2017

Chapter 1 Startup

Start up a PowerFlex DC Field

Controller

Complete this startup procedure for a PowerFlex DC Field Controller that is

used in standalone mode or with a PowerFlex DC drive.

To complete the steps in these startup procedures, see the supporting

information in these publications:

• PowerFlex DC Field Controller Installation Instructions, publication

23PFC-IN001.

• PowerFlex DC Fiber-optic Interface Option Module Installation

Instructions, publication 20P-IN078

• PowerFlex Digital DC Drive User Manual, publication 20P-UM001.

Startup Sequence

This list contains the main procedures that are required to commission the

field controller.

Before You Apply Power to the Controller or Drive

Complete these procedures before you apply power to the field controller or

drive (if used).

Verify the Analog Input Configuration Settings

1. Remove the covers from the field controller and drive (if used).

2. Verify all switch settings for the analog inputs (S9, S10, and S11) on the

main control circuit board.

Description Page

Before You Apply Power to the Controller or Drive

Verify the Analog Input Configuration Settings 10

Verify the Power Wiring 11

Verify the Control and I/O Wiring 11

Apply Power to the Device

Apply Voltage to the Control Circuits 11

Verify the Control Voltages 12

Load the Default Settings 12

Configure the Most Commonly Used Parameters 12

Verify Field Controller Operation 15

Tune the Current Regulator 17

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