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PowerFlex Drives with TotalFORCE Control Programming

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PowerFlex Drives with TotalFORCE Control Programming ManualProgramming ManualOriginal InstructionsImportant User InformationRead 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 prohibitedThroughout 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.IMPORTANTIdentifies 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-PM100A-EN-P - June 20173Table of ContentsPrefaceOverviewWho Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7What Is Not In This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Chapter 1Start UpWho Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Supported Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Step 1: Gather Required Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Step 2: Validate the Drive Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 15Step 3: Power Up, Configure the Modular Control Profiles. . . . . . . 16Step 4: Configure the Line Side Converter . . . . . . . . . . . . . . . . . . . . . . 19Step 5: Enter Motor Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Step 6: Enter Motor Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Step 7: Configure Motor Encoder Feedback . . . . . . . . . . . . . . . . . . . . . 21Step 8: Autotune the Motor Side Inverter Control. . . . . . . . . . . . . . . 21Step 9: Set Up Velocity Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Step 10: Set Up Start/Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Step 11: Special Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Step 12: Verify Drive Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Establishing A Connection With EtherNet/IP . . . . . . . . . . . . . . . . . . 26Apply and Remove Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Chapter 2Parameter OrganizationAbout Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Parameter References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37How Drive Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . 37Chapter 3Port 0 PowerFlex 755T ParametersPort 0 Parameter Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93Chapter 4Port 9 Application ParametersPort 9 Parameter Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Chapter 5Port 10 Primary Motor Side Control ParametersPrimary Motor Side Control (Port 10) Parameters. . . . . . . . . . . . . . 1544Rockwell Automation Publication 750-PM100A-EN-P - June 2017Table of ContentsChapter 6Port 12 Motor Side Power ParametersMotor Side Power (Port 12) Parameters. . . . . . . . . . . . . . . . . . . . . . . . 252Chapter 7Port 13 and 14 Line Side Control ParametersLine Side Control (Port 13) Parameters. . . . . . . . . . . . . . . . . . . . . . . . 266Line Side Power (Port 14) Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . 297Chapter 8Option Module ParametersCommunication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32011-Series I/O Module Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32222-Series I/O Module Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Single Incremental Encoder Module Parameters . . . . . . . . . . . . . . . . 346Dual Incremental Encoder Module Parameters . . . . . . . . . . . . . . . . . 349Universal Feedback Module Parameters. . . . . . . . . . . . . . . . . . . . . . . . 356Safe Speed Monitor Module Parameters. . . . . . . . . . . . . . . . . . . . . . . . 374Integrated Safety - Safe Torque Off Module . . . . . . . . . . . . . . . . . . . . 386Chapter 9TroubleshootingFaults, Alarms, Events, and Configurable Conditions . . . . . . . . . . . 387Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389HIM Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Power Layer Interface (PLI) Board 7-Segment Display . . . . . . . . . . 391AC Precharge and DC Precharge Board Indications. . . . . . . . . . . . . 392Setting Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Hardware Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Fault and Alarm Display Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Fault and Alarm (Port 0) Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 396Motor Side Inverter Control (Port 10) Faults and Alarms . . . . . . . 415Motor Side Inverter Power (Port 12) Faults and Alarms . . . . . . . . . 422Torque Accuracy Module (Port 12) Faults and Alarms . . . . . . . . . . 429DC Precharge Module (Port 12) Faults and Alarms . . . . . . . . . . . . . 431Line Side Converter Control (Port 13) Faults and Alarms . . . . . . . 434Line Side Converter Power (Port 14) Fault and Alarms. . . . . . . . . . 439AC Precharge Module (Port 14) Faults and Alarms . . . . . . . . . . . . . 446Current Sense Board (Port 14) Faults and Alarms. . . . . . . . . . . . . . . 449Safe Torque Off Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Safe Speed Monitor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Integrated Safety - Safe Torque Off Faults. . . . . . . . . . . . . . . . . . . . . . 453ATEX Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453Single Incremental Encoder Faults and Alarms. . . . . . . . . . . . . . . . . . 454Dual Incremental Encoder Faults and Alarms. . . . . . . . . . . . . . . . . . . 454Universal Feedback Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 455Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . 463Technical Support Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Rockwell Automation Publication 750-PM100A-EN-P - June 20175Table of ContentsAppendix APowerFlex 755T Control Block DiagramsDiagram Conventions and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . 468Line Side Converter Control Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 469Motor Side Inverter Control Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 482Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511

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