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OEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well Drive Installation Instr

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Installation InstructionsOriginal InstructionsOEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well DriveCatalog Numbers 26-R1-MCB1-PF755-PMMDW, 26-R1-MCB1-F8-PMMDWThe PowerFlex® 755 Permanent Magnet Motor (PMM) Deep Well function is an enhancement to the basic pump application. In this application, long motor cables require a sine-wave filter to remove the pulse width modulation (PWM) from the drive output. A step-up transformer is used to meet the required voltage TopicPageAdditional Resources2What the Kit Contains3Custom Firmware Overview3Hardware4Main Control Board Replacement6PMM Deep Well Set-Up Procedure12About Parameters25Standard Firmware (Port 0) Parameters27Custom Firmware Parameters89Inverter (Port 10) Common Parameters96Inverter 1 (Port 10) Parameters98Converter (Port 11) Common Parameters100Converter 1 (Port 11) Parameters103ATTENTION: The custom firmware is designed for a specific application and load condition. It differs from the standard PowerFlex 755 product and must be installed and run only under this custom application. Run this custom firmware under any other type of application and unpredictable and/or hazardous conditions can result.ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.2Rockwell Automation Publication 750-IN035B-EN-P - September 2015OEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well Driveon the motor and compensate for the voltage drop in the sine wave filter and motor cable.Additional ResourcesThis custom firmware differs from the PowerFlex 755 standard control firmware. This publication is a supplement to the standard PowerFlex 750-Series drive publications.This table lists publications that provide general drive-related information that includes basic installation guidelines, power and motor connections, and basic troubleshooting.StandardPowerFlex 755InverterPowerStructureSine-waveFilterStep UpTransformerVoltageSenseModulePMMMotor CableMotor Voltage FeedbackI/OI/OI/ORSTUVWU1V1W1U2V2W2PRI1PRI2PRI3SEC1SEC2SEC3UVWUVWResourceDescriptionPowerFlex 750-Series AC Drives Programming Manual, publication 750-PM001Provides detailed information on:•I/O, control, and feedback options•Parameters and programming•Faults, alarms, and troubleshootingPowerFlex 750-Series AC Drives Technical Data, publication 750-TD001Provides detailed information on:•Drive specifications•Option specifications•Fuse and circuit breaker ratingsPowerFlex 20-HIM-A6 / -C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001Provides detailed information on HIM components, operation, features.PowerFlex 750-Series AC Drives Hardware Service Manual - Frame 8 and Larger, publication 750-TG001Provides detailed information on:•Preventive maintenance•Component tests•Hardware replacement proceduresPowerFlex 755 Drive Embedded EtherNet/IP Adapter User Manual, publication 750COM-UM001These publications provide detailed information on to configure, use, and troubleshoot PowerFlex 750-Series communication option modules and adapters.PowerFlex 750-Series Drive DeviceNet Option Module User Manual, publication 750COM-UM002Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001Provides basic information to properly wire and ground PWM AC drives.PowerFlex AC Drives in Common Bus Configurations, publication DRIVES-AT002Provides basic information to properly wire and ground PWM AC drives with a common bus.Safety Guidelines for the Application, Installation, and Maintenance of Solid-State Control, publication SGI-1.1Provides general guidelines for the application, installation, and maintenance of solid-state control.Guarding Against Electrostatic Damage, publication 8000-4.5.2Provides practices for guarding against Electrostatic damage (ESD)Product Certifications website, http://www.ab.comProvides declarations of conformity, certificates, and other certification details.Rockwell Automation Publication 750-IN035B-EN-P - September 20153OEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well DriveWhat the Kit ContainsThis kit contains the following:•One Main Control Board with custom firmware.•One Field Installed Option label. See page7.•One Custom Firmware Notice label. See page8.Additional hardware requirements are listed under Hardware on page4.Custom Firmware OverviewThis custom firmware, which is based on the PowerFlex 755, supports the Deep Well, Electrical Submersible Pump (ESP) application with permanent magnet (PM) motors. The motors can be either surface mount magnets or interior mount magnets.Parameters have been added to the standard PowerFlex 755 firmware. These parameters define the characteristics of the motor, sine-wave filter, transformer, and cable and a speed profile for starting and for reversing through zero speed.Some features of the standard PowerFlex 755 firmware have been removed. The only Motor Control Mode supported by this firmware is PMM Deep Well. No other control mode can be selected. The only language that is supported in the product is English.This custom firmware and the 26-R1-MCB1-PF755-PMMDW and 26-R1-MCB1-F8-PMMDW board kits have not been evaluated with the Safe Speed Monitor (20-750-S) and Safe Torque Off (20-750-S1) functions. This combination of firmware, main control boards, and safety option modules cannot be used to claim Functional Safety.The new control algorithm addresses the challenges of sine-wave filter, transformer, and long cable that is presented at the drive outputs. When the drive is put into run, it begins in low speed mode where motor current is regulated with a defined speed ramp profile to provide high starting torque capability. It then transitions to advanced close-loop vector control for optimized performance in the high-speed range.If debris is lodged in the pump and the rotor is locked, the normal starting process results in positive and negative torque pulses as the inverter output vector passes over the poles of the permanent magnets. If this process does not clear the debris, the drive can be started with a negative speed reference, and then started with a positive speed reference to attempt to clear the debris.The control supports flying start to catch the motor while spinning and then accelerate up to the selected speed reference. If the motor is caught spinning in the reverse direction, the transition from reverse to forward speed follows a defined speed profile.An open loop operation mode is selectable through parameter 2087 [PMM OL Select] to test the tap setting on the step-up transformer. In this test, the motor is disconnected from the transformer secondary side, and the drive operates in open loop mode to ramp up voltage with frequency. Use this test to check the integrity of drive and output network connections before connecting the system to the motor.4Rockwell Automation Publication 750-IN035B-EN-P - September 2015OEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well DriveHardwareThe following hardware is used in the PMM Deep Well application.Variable Frequency Drive•PowerFlex 755 AC drive•480V AC input•Frame 2…7 wall mount drives•Frame 8 floor mount drivesThe PMM Deep Well Application drive requires the PMW carrier frequency to be set to 4 kHz so the sine-wave filter can operate at the required fundamental frequency of 150 Hz. Operating at 4 kHz, the drive derating is the same as the standard product and is shown in the following table. The complete definition of the PF750 derating is found in the PowerFlex 750-Series AC Drives Technical Data, publication 750-TD001. Other derating can be required as a function of ambient and altitude but the following currents are available based on operating at 4 kHz.FrameCat. No.Derating NotesNormal Duty 4 kHz Continuous Amps220x…D014No derating at 4 kHz1420x…D022No derating at 4 kHz22320x…D027No derating at 4 kHz2720x…D034No derating at 4 kHz3420x…D040No derating at 4 kHz40420x…D052No derating at 4 kHz5220x…D065No derating at 4 kHz65520x…D077No derating at 4 kHz7720x…D096No derating at 4 kHz96620x…D125No derating at 4 kHz12520x…D156No derating at 4 kHz15620x…D186No derating at 4 kHz18620x…D24880% Load at 4 kHz198720x…D30290% Load at 4 kHz27120x…D36170% Load at 4 kHz25220x…D41580% Load at 4 kHz332820x…D430No derating at 4 kHz43020x…D48590% Load at 4 kHz43620x…D54580% Load at 4 kHz43620x…D61780% Load at 4 kHz49320x…D71070% Load at 4 kHz49720x…D74070% Load at 4 kHz518Rockwell Automation Publication 750-IN035B-EN-P - September 20155OEM PowerFlex 755 Main Control Board Kit - Permanent Magnet Motor Deep-Well DriveMain Control BoardThe PMM Deep Well application requires custom firmware that is programmed into the main control board at the factory. There are two different control boards for low-power and high-power drives. Frames 2…7 use the low-power main control board. Frame 8 uses the high-power main control board. The main control boards are programmed at the factory and can be reprogrammed in the field with another revision of the PMM Deep Well firmware. Standard main control boards cannot be converted to the PMM Deep Well firmware. Main control boards that are programmed with the PMM Deep Well firmware cannot be converted to the standard firmware.Analog Input BoardsThree 22-Series I/O Modules are used to monitor motor voltage.Sine-wave FilterA custom sine-wave filter is required to attenuate the PWM switching. Filters are specified per drive frame size to match the rated power.Voltage Sense ModuleCatalog number 26-750-VFB, the Voltage Feedback Kit, contains the voltage sense module that is used to scale the motor voltage to a level that is compatible with the analog inputs on the 22-Series I/O module.Step-up TransformerThe step-up transformer is required to boost the inverter voltage to compensate for the voltage drop in the long cable down the well.Motor CableThe motor cable connects the transformer to the motor at the bottom of the well.PM MotorThe permanent magnet motor can be surface mount magnets or interior mount magnets. Enter the motor design data from the motor manufacturer into drive parameters as explained in PMM Deep Well Set-Up Procedure on page12.ATTENTION: In this application, a short to ground in the motor cable, or in the motor, does not cause a Fault 13 [Ground Fault] or Fault Code 14 [Ground Warning]. The step-up transformer is installed between the sine-wave filter and the motor. The Wye terminals of the transformer are connected to the motor and the Xo of the Wye is connected to ground. Therefore, if there is a short to ground in the motor cable, or in the motor, the ground current flows through the Xo and inverter does not see this event. To help prevent damage, additional ground fault protection equipment, external to the inverter, is required for the motor cable and the motor.

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