Rockwell Automation Allen-Bradley PowerFlex 750 Series Bedienungsanleitung

PowerFlex 750-Series Products with TotalFORCE Control

Catalog Numbers 20G, 20J

Reference 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 750-RM100A-EN-P - August 2019 3

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

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

Table of Contents

Chapter 6

Predictive Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Setting the Event Levels and Event Actions. . . . . . . . . . . . . . . . . . . . . . 40

Monitor Elapsed Life and Remaining Life . . . . . . . . . . . . . . . . . . . . . . . 41

Predictive Maintenance Function Details . . . . . . . . . . . . . . . . . . . . . . . 42

Resetting the Meters After Component Replacement . . . . . . . . . . . . 47

Reset Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Configuration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Monitoring Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chapter 7

DeviceLogix Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DeviceLogix Configuration Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

DeviceLogix Tag Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Download and Enable the Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 8

Emergency Override Function Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Activate the Emergency Override Feature . . . . . . . . . . . . . . . . . . . . . . . 65

Decide Which Protections to Override. . . . . . . . . . . . . . . . . . . . . . . . . . 66

Chapter 9

Reference Motion Planners New Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Position Reference Motion Planner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Velocity Reference Motion Planner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Chapter 10

Droop Control for Parallel

Operation of PowerFlex 755TM

AFE Bus Supplies

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Derating for Voltage Boost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Chapter 11

Application References PowerFlex 755T Lifting/Torque Proving . . . . . . . . . . . . . . . . . . . . . . 101

Anti-Sway Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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

Preface

Overview

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

PowerFlex® 750-Series products with TotalFORCE® control for common

applications.

Who Should Use This

Manual

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

and operate Adjustable Frequency AC Drive devices. In addition, you must have

an understanding of the parameter settings and functions.

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

Technical Data, publication 750-TD100

Provides detailed information about:

• Drive and bus supply specifications

• Option specifications

• Fuse and circuit breaker ratings

PowerFlex 755TM IP00 Open Type Kits Technical Data,

publication 750-TD101

Provides detailed information about:

• Kit selection

• Kit ratings and specifications

• Option specifications

PowerFlex 755TM IP00 Open Type Kits Installation

Instructions, publication 750-IN101

Provides instructions to install IP00 Open Type kits in

user-supplied enclosures.

PowerFlex 750-Series I/O, Feedback, and Power Option

Modules Installation, publication 750-IN111

Provides instructions to install and wire 750-Series

option modules.

PowerFlex Drives with TotalFORCE Control Programming

Manual, publication 750-PM100

Provides detailed information about:

• I/O, control, and feedback options

• Parameters and programming

• Faults, alarms, and troubleshooting

Drives in Common Bus Configurations with PowerFlex

755TM Bus Supplies Application Techniques, publication

DRIVES-AT005

Provides basic information to wire and ground the

following products in common bus applications:

• PowerFlex 755TM drive system for common bus

solutions

• PowerFlex 750-Series AC and DC input drive

• Kinetix® 5700 servo drives

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

Preface

You can view or download publications at

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

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

EtherNet/IP Adapter User Manual, publication 750COM-

UM009

Provides information about how to install, configure,

and troubleshoot applications for the PowerFlex

drives with the built-in EtherNet/IP™ adapter.

PowerFlex 750-Series Products with TotalFORCE Control

Hardware Service Manual, publication 750-TG100

Provides detailed information about:

• Preventive maintenance

•Component testing

• Hardware replacement procedures

PowerFlex 750-Series Safe Speed Monitor Option Module

Safety Reference Manual, publication 750-RM001

These publications provide detailed information

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

Module) User Manual, 20HIM-UM001

Provides detailed information about HIM

components, operation, and features.

PowerFlex 755TM AC Precharge Modules Unpacking and

Lifting Instructions, publication 750-IN102

These publications provide detailed information

about:

• Component weights

• Precautions and recommendations

• Hardware attachment points

• Lifting the component out of the packaging

PowerFlex 755TM DC Precharge Modules Unpacking and

Lifting Instructions, publication 750-IN103

PowerFlex 755TM Power and Filter Modules Unpacking

and Lifting Instructions, publication 750-IN104

PowerFlex 750-Series Service Cart Instructions, publication

750-IN105

Provides detailed setup and operating instructions for

the module service cart and DC precharge module lift.

PowerFlex 755TM Power and Filter Module Storage

Hardware Instructions, publication 750-IN106

Provides detailed installation and usage instructions

for this hardware accessory.

PowerFlex 755T Module Service Ramp Instructions,

publication 750-IN108

Provides detailed usage instructions for the module

service ramp.

Industry Installation Guidelines for Pulse Width Modulated

(PWM) AC Drives, publication DRIVES-AT003

Provides basic information about enclosure systems,

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

Modulated (PWM) AC Drives, publication DRIVES-IN001

Provides basic information to properly wire and

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

Resource Description

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

Chapter 1

Adaptive Control

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

in this section. For detailed information about how to use each of these features,

see the PowerFlex® 755T Flux Vector Tuning Application Technique, publication

750-AT006.

Load Observer The load observer feature is a control loop inside the drive that estimates the

mechanical load on the motor and compensates for it while the drive is running.

This feature allows high performance and control loop tuning simplicity similar

to that of a mechanically disconnected motor. Its primary function is to:

• Automatically compensate for unknown inertia, compliance, and low

frequency resonance

• Automatically compensate for disturbances and changes in inertia

• Force consistent dynamic behavior, which makes the drive easier to tune

Benefits

You can use load observer with out-of-box control loop gains, where the load is

unknown or compliant and thus 10/11:901 [Load Ratio] = 0. You can also use

load observer with autotuned control loop gains where 10/11:901 [Load

Ratio] > 0. This value can be a known positive value or one that is calculated by

performing an autotune procedure.

When load observer is enabled with the recommended out-of-box control loop

gains:

• A tuning expert is not needed

• Commissioning time is reduced, especially for high drive count

• Relatively high performance control is provided without tuning

• Changes in inertia, compliance, and low frequency resonances are

compensated for automatically

• Periodic retuning to account for machine wear over time is not needed

When load observer is enabled with autotuned control loop gains:

• Load disturbances are compensated for automatically

• Tracking errors, machine vibration, and power consumption are

minimized

• Bandwidth and line speeds can be increased

• Tighter control of moving parts reduces wear and saves material costs

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

Chapter 1 Adaptive Control

Adaptive Tuning The adaptive tuning feature is an algorithm that continuously monitors and, if

necessary, adjusts filter parameters and control loop gains to compensate for

unknown and changing load conditions. Adaptive tuning performs the following

functions:

• Monitors motor-side resonances

• Automatically adjusts torque loop notch and low pass filter parameters to

suppress resonances

• Automatically tunes control loop gains to avoid instability

Benefits

When you enable adaptive tuning with the recommended out-of-box control

loop settings, you do not need a tuning expert. You also gain the following

benefits:

• Reduced commissioning time, especially for high drive count

• Automatically suppressed continuously changing resonances

• Periodic identification of resonances and retuning is not needed

• Periodic retuning of filters is not needed

• Minimized tracking errors, machine vibration, and power consumption

• Increased bandwidth and line speeds

• Tighter control of moving parts reduces wear and saves material costs

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

of several individual tests, each of which is intended to adjust one or more motor

parameters. These tests require you to enter motor nameplate information into

the drive parameters. Although you can change some of the parameter values

manually, measured values can provide improved performance.

Autotuning is often unnecessary when you apply Load Observer with the

recommended default settings.

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

Adaptive Control Chapter 1

Position and Velocity

Regulators

The PowerFlex 755T utilizes a series form of a Proportional-Integral (PI)

controller for the Position Regulator (PReg) and the Velocity Regulator (VReg).

The proportional and integral gains are expressed in units of Hz. The

proportional gains have been normalized by removing inertia and represent

bandwidth which is a readily understood and measureable value. Relating the

proportional gains to bandwidth makes the tuning experience more intuitive.

Figure 1 - Regulator Schemes

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.

[Hz]

s2K

2K

[Hz]

s2K

2K

Position Regulator Velocity Regulator

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

Chapter 1 Adaptive Control

Example: The bandwidth = 400 Hz with bus observer disabled. However, the

bandwidth = 150 Hz with bus observer enabled for equivalent DC bus voltage

regulation with lower inductor temperatures.

Bus Observer Limitations

• If the external capacitance is greater than three times the supply, DC bus

regulation can become unstable.

• Do not enter an external capacitance value greater than what is connected

or stability can be affected. It is recommended to use the lowest estimated

value. Bus observer can compensate for increased line capacitance, but it

cannot reduce line capacitance.

• Cannot be enabled or disabled while the converter is active (running).

Figure 2 and Figure 3 show the Bus Observer function.

Figure 2 - Voltage Control (VoltCtrl) Block Diagram

Auto Gain

Calculation

PI Regulator

Volt Reg BW

Volt Reg Damping

Volt Reg C/U Sel

u Volt Reg Ki

u Volt Reg Kp

c Volt Reg Ki 60

c Volt Reg Kp 58

DC Bus Command

VoltRefGen [G3]

Internal Bus Cap

acitance

Metering [D5]

DC Bus Ob

A[2]

Ext Bus Cap

VbusErr

VbusRegKi

VbusRegKp

IqRefVbusReg

Volt Reg C/U Sel Selector:

0- Calculated

1- User Entered

Total Sys Cap

DcBusObs [C1]

BusRegIntegTerm

BusRegPropTerm

BusObsMode

BusObsMode (320):

0- BusObs Only

1- BusObsVltEst 320

Port 0,DC Bus Volts

DC Bus Obs

[H5]

BusObs Volt Est

0,2

BusDistRejMode(300):

0- Disabled

1-BusObserver.

2- FF Power.

300

BusCompMode

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