Rockwell Automation PowerFlex 7000 Gebrauchsanweisung

PowerFlex® 7000

Medium Voltage AC Drive

TECHNICAL DATA

Firmware Version 7.xxx

Table of Contents

7000-TD002A-EN-P – September 2007

Chapter 1 Introduction ..............................................................................1-1

Description of Operation .........................................................1-2

Speed Command ......................................................................1-3

Speed Reference ......................................................................1-4

Speed Control ..........................................................................1-6

Flux Control .............................................................................1-8

Flux Control for Synchronous Motor ....................................1-10

Current Control ......................................................................1-12

Line Converter Feedback .......................................................1-14

Machine Converter Feedback ................................................1-15

Motor Model ..........................................................................1-16

Drive/Motor Protection ..........................................................1-17

Power Semiconductor Diagnostics ........................................1-19

Off-line Detection of Failed SCRs/SGCTs .....................1-20

Line Converter ..........................................................1-20

Machine Converter ...................................................1-22

On-line Detection of Failed SCRs/SGCTs ......................1-23

Test Modes .............................................................................1-24

Flying Start (Induction Motor) .............................................1-26

Flying Start (Synch Motor) ....................................................1-27

Tachometer/Encoder Option ..................................................1-28

Synchronous Transfer ............................................................1-29

Transfer to Bypass ...........................................................1-31

Transfer to Drive .............................................................1-34

PID Process Control ..............................................................1-35

Power Factor Compensation ..................................................1-38

Analog Outputs ......................................................................1-38

Analog Inputs .........................................................................1-39

Chapter 2 Parameters Parameter Descriptions ............................................................2-1

Parameters Listed by Group ................................................2-199

Parameters Listed by Linear Number ..................................2-217

Alphabetical Index ...............................................................2-229

Linear Number Index ...........................................................2-237

Chapter 3 Troubleshooting Documenting Shutdowns .........................................................3-1

Acronyms and Abbreviations Used in this Manual .................3-2

Drive Fault Messages ..............................................................3-3

Drive Warning Messages .......................................................3-32

Appendix A Logic Command Word – Database 7.xxx................................A-1

Product Specific Logic Command – Firmware 7.xxx ............A-2

Functional

Description

Drive Lo

ic Command

and Status

ii Table of Contents

7000-TD002A-EN-P – September 2007

Chapter 1

7000-TD002A-EN-P – September 2007

PowerFlex 7000 Functional Description

Introduction The PowerFlex 7000 is an adjustable speed ac drive in which motor

speed control is achieved through control of the motor torque. The

motor speed is estimated or measured and the torque is adjusted as

required to make the speed equal to the speed command. The motor

and load determine the stator frequency and the drive synchronizes

itself to the motor. This is in contrast to the volts/hertz ac drive in

which the drive determines the stator frequency and does not attempt

to synchronize its output to the motor.

The method of control used in PF7000 is known as direct rotor flux

oriented vector control. The term rotor flux vector control indicates

that the position of the stator current vector is controlled relative to

the motor flux vector. Direct vector control means that the motor

flux is measured, in contrast to the indirect vector control in which

the motor flux is predicted. In both control methods, the stator

current (Is) is split into flux producing component (Isd) and an

orthogonal torque producing component (Isq) which are controlled

independently. The aim of vector control is to allow a complex ac

motor to be controlled as if it were a simple dc motor with

independent, decoupled field and armature currents. This allows the

motor torque to be changed quickly without affecting the flux. For

typical Medium Voltage motors the rotor time constant is in the

range of seconds and therefore the flux cannot be changed quickly.

The PowerFlex 7000 drive can be used with either induction

(asynchronous) or synchronous motors. Synchronous motor drives

are identical to induction motor drives except for the addition of a

current regulated field supply to the synchronous drive. The features

that are unique to a synchronous motor drive are confined to the flux

control function and the encoder option.

1-2 Functional Description

7000-TD002A-EN-P – September 2007

Description of Operation A complete block diagram of the PF7000 control circuit is shown in

Figure 1.1. The major blocks are described in the following sections.

Line

Protection

Rectifier DCLink

inductor

Line filter

cap

Inverter Motor filter

cap Motor

Voltage

Motor

Current Speed

Command

Speed

Reference

Machine side

feedbackand

gating

Alpha

Inverter

Alpha

Rectifier

Line side feedback

and gating

LineVoltage

ACLine

Reactor

Line

Current

Faults

InvTorque

CurCmd

Inv Flux

CurCmd

FluxRange

Machine

Protection

Sync

Transfer

Speed

Control

Stator freq

Slipfreq

FluxFeedback

Speed Feedback

Flux

Control

Faults

Tach

Feedback

Source

Motor

Current

Control Motor

Model

IdcFeedback

Figure 1.1 – Functional Block Diagram of PF 7000 control system

Functional Description 1-3

7000-TD002A-EN-P – September 2007

Speed Command The function of Speed Command block is to select one of the 10

possible speed command inputs. Parameter Speed Ref Select (7) in

conjunction with Local/Remote selector switch is used to define the

speed command input Speed Command In (276). When the selector

switch is in Local position, the default speed command is the Analog

Speed Potentiometer typically mounted on the LV panel. When the

selector switch is in Remote position, the parameter Speed Ref Select

defines the source of speed command. The options available are:

Local ( Speed Potentiometer)

3 DPI commands ( DPIAdapter1, DPIAdapter2, DPIAdapter5)

2 Analog Inputs configured either for 0-10V or 4-20mA (Analog

Inp1, Analog Inp2)

3 Preset speeds (Preset Spd 1, Preset Spd 2, Preset Spd 3)

1 Preset Jog

In addition, the speed command can come from a built in PID

controller. 

The above speed commands are used when the drive is in Normal

mode of operation. However PF7000 has many special modes of

operation e.g. test modes or auto-tuning for which different speed

commands are selected. Table 1.A summarizes the speed command

during these special modes.

Table 1.A – Speed Commands for special operating modes of PF7000

Special operating modes of PF7000 Speed Command In(276)

DC test mode Rated line frequency

Open Circuit Rated Line Freq (17)

Open Loop 0.1 x Rated Line Freq (17)

Rs autotune 2Hz

Ls autotune Rated Line Freq (17)

Flux Reg autotune Autotune Spd Cmd (213)

Speed Reg autotune Autotune Spd Cmd (213)

Sync transfer requested Bypass Frequency (159)

The selected Speed Command In is clamped to a minimum and a

maximum level by parameter Speed Cmd Max (290) and Speed Cmd

Min (293) to give Speed Command (277). The maximum value of

Speed Command cannot be greater than 125% of Base Speed (98).

Note: Contact the factory for applications that require output

frequencies greater than 125% of the motor base speed.

Contact factory for the availability of this feature.

1-4 Functional Description

7000-TD002A-EN-P – September 2007

Speed Command (cont.) Three skip speeds Skip Speed 1(49), Skip Speed 2 (50), Skip Speed 3

(51) are provided to prevent the drive from continuously operating at

a certain speed. This feature is sometimes needed to avoid mechanical

vibrations occurring in a drive system at certain speeds. The skip

speed zone around each Skip Speed is specified by the parameter

Skip Speed Band1 (53), Skip Speed Band2 (54), Skip Speed Band3

(55) If the desired Speed Command lies in a given skip speed zone,

the Speed Command is clamped to the lowest value in the zone.

Example

If Skip Speed 1 is 45 Hz with Skip Speed Band1 as 1 Hz, then the

skip speed range extends from 44.5 Hz to 45.5 Hz. If the desired

speed command is set to 45 Hz, then the drive will avoid this speed

and run at 44.5 Hz.

The final stage in processing the command is the whether the drive

has been requested to run forward or reverse. The sign is changed if

reverse rotation is selected. The Speed Command is set to zero if the

drive is stopped.

Speed Reference The function of the Speed Reference block is to determine the Speed

Reference (278) from the desired Speed Command (277). PF7000

provides two options:

•S-curve

•Linear Ramp

To select, S curve a non-zero value of S curve Percent (475) is

selected. Using parameter S curve Acc1 (481), the drive

automatically calculates the linear and the non-linear portions of the

S curve as shown in Figure 1.2. Following example shows how to

use S curve parameters:

Example

If S curve Accel 1 is set for 20 sec with 20% in S curve Percent, then

the total acceleration time is increased by 0.2 x 20 = 4 seconds. The

total acceleration time will now be 24 seconds with 4 seconds in the

non-linear portion of the S curve. Since the curve is symmetrical,

each of the segments will be of 2 seconds duration.

The parameters for deceleration are calculated using parameter S curve

Decel 1 (479) and S curve Percent (475) and shown in Figure 1.2.

Linear Ramp is enabled if the S curve Percent is set to zero.

Independent four section ramps are provided for acceleration and

deceleration. The ramp is specified by 4 Ramp Speeds, 4 Accel and

Decel times and is shown in Figure 1.3.

Functional Description 1-5

7000-TD002A-EN-P – September 2007

Linear Portion Non-Linear

Portion

Non-Linear

Portion

S Curve Acc1

(481)

0.005*

S Curve Acc1

*S Curve

Percent S Curve Dec1

(479)

Linear Portion

Non-Linear

Portion Non-Linear

Portion

0.005*

S Curve Acc1

*S Curve

Percent

0.005*

S Curve Dec1

*S Curve

Percent

0.005*

S Curve Dec1

*S Curve

Percent

Linear Portion Non-Linear

Portion

Non-Linear

Portion

S Curve Acc1

(481)

0.005*

S Curve Acc1

*S Curve

Percent S Curve Dec1

(479)

Linear Portion

Non-Linear

Portion Non-Linear

Portion

0.005*

S Curve Acc1

*S Curve

Percent

0.005*

S Curve Dec1

*S Curve

Percent

0.005*

S Curve Dec1

*S Curve

Percent

Figure 1.2 – Speed Reference: S-curve

Ramp Speed1

(73)

Ramp Speed4

(76)

Ramp Speed3

(75)

Ramp Speed2

(74)

Accel

Time1

(65)

Accel

Time4

(68)

Accel

Time3

(67)

Accel

Time2

(66)

Decel

Time1

(69)

Decel

Time2

(70)

Decel

Time3

(71)

Decel

Time4

(72)

Ramp Speed1

(73)

Ramp Speed4

(76)

Ramp Speed3

(75)

Ramp Speed2

(74)

Accel

Time1

(65)

Accel

Time4

(68)

Accel

Time3

(67)

Accel

Time2

(66)

Decel

Time1

(69)

Decel

Time2

(70)

Decel

Time3

(71)

Decel

Time4

(72)

Figure 1.3 – Speed Reference: Linear Ramp

1-6 Functional Description

7000-TD002A-EN-P – September 2007

Speed Control The function of the speed control block is to determine the torque-

producing component (Isq) of the stator current (Is). The inputs to the

block are the Speed Reference (278) from the speed ramp and the

Stator Frequency (448) and Slip Frequency (343) from the motor

model. If drive is installed with an optional tachometer, then the

motor speed is determined by counting the tach pulses.

In Sensorless operation, the Slip Frequency is subtracted from the

Stator Frequency and filtered to determine the Speed Feedback

(289). In Pulse Tach mode, the speed is determined directly by using

Tach Feedback (349). The Speed Feedback is subtracted from the

Speed Reference to determine the Speed Error (472) which is

processed by the speed PI regulator. The gains of the regulator are

based on the Total Inertia (82) of the system and the desired Spdreg

Bandwidth (81). The output of the speed regulator is the Torque

Reference (291) whose rate of change is limited by Trq Rate Limit

(83). The calculated Torque Reference is divided by the Flux

Reference (305) and motor constant to determine the torque

component of the stator current MtrTorque CurCmd (292). To

calculate the torque producing current supplied by the inverter

InvTorque CurCmd (294), the current supplied by the motor filter

capacitor in torque production (orthogonal to motor flux) is

calculated and subtracted from MtrTorque CurCmd.

In Sensorless mode, the drive uses TrqCmd0 Sensrlss (86) and

TrqCmd1 Sensrlss (87) for an open loop start up. At frequencies

greater than 3Hz, the drive enables the speed loop and disables the

open loop start mode. In Pulse Tach mode, the drive is always in

closed loop. The maximum torque a drive can deliver in motoring

mode is determined by Trq Lmt Motoring (84). In regenerative mode

the torque is limited to Trq Lmt Braking (85). It should be noted that

at speeds above the Base Speed (98), the motor torque capability is

de-rated and varies in inverse proportion to the speed (constant

power range).

Depending open the application, a drive can be configured in

different torque control modes by setting the parameter Trq Control

Mode (90). E.g. in stand-alone drives the parameter is set as Speed

Reg allowing the drive to be in speed control mode and regulating

the torque in the motor. In torque follower applications like

conveyors, one of the drives (Master) is set in Speed Reg mode

which enables the speed regulator while the other drives (torque

followers) are set in Trq Cmd External mode. The torque reference

produced by the Master drive is then passed on to the torque follower

drives by Trq Cmd External (91). Figure 1.4 shows other various

modes of operation.

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