Professional Documents
Culture Documents
1.1. PowerFlex
PowerFlex 700S
700S Phase
Phase IIII Overview
Overview
2.2. Load
Load Sharing
Sharing
3.3. Installation
Installation
4.4. Q&A
Q&A
PowerFlex 700S
1.1. PowerFlex
PowerFlex 700S
700S Phase
Phase IIII Overview
Overview
2.2. DriveLogix
DriveLogix
3.3. SynchLink
SynchLink
4.4. Safe-Off
Safe-Off
PowerFlex Drives
PowerFlex ???
= Powerful Performance + Flexible Control
PowerFlex Drives
PowerFlex Family of Drives Offering
Sustainable solutions
• Improve motor control performance
• Reduce energy consumption
• Global standards & voltage ratings
• Safe-Torque off (SIL3/Cat 3)
• Safe Speed Control (SIL3/Cat 4)
5
PowerFlex Family of Drives
• Power ratings from 0.2kW (0.25 Hp) single phase to 25MW (34,000 Hp) at medium voltage
• Seamless control system integration – maximize uptime
• Decrease development time by as much as 70% with Premier Integration —RSLogix 5000 Software with
PowerFlex drives add-on-profiles
• Power ratings from 0.2kW (0.25 Hp) single phase to 25MW (34,000 Hp) at medium voltage
• Seamless control system integration – maximize uptime
• Decrease development time by as much as 70% with Premier Integration —RSLogix 5000 Software with
PowerFlex drives add-on-profiles
• Increase productivity and flexibility with
integrated safe speed control technology
and safe torque off options
• Flexible control – simplifies operation,
reduces training & costs
– Common operator interface &
integration capabilities
– Consistent programming structure
– Consistent software tools
– Variety of packaging designs
Yaskaw a
ABB
Schneider
Siemens
Danf oss
Mitsubishi
TB Woods
Emerson/Control Techniques
• Rockwell Automation markets electric motor
Lenze/AC Technology
drives under two brands
Toshiba • Allen-Bradley
Saf tronics • Reliance Electric
Baldor
• RA is the clear drive leader in North America
Eaton-Cutler Hammer
GE-Fuji
• Number 2 or 3 in the world
General Electric
Source: ARC 2001 Global High Horsepower Markets for AC Drives
Vacon ARC 2001 Global Low Horsepower Markets for AC Drives
Marketing Data from RA Drives Mktg Team
ASI Robicon
市场 : 低压变频器的市场份额
Control Magazine 2008 Readers’ Choice
Awards
Top Honors
Software, Alarm Management Software, Human-Machine Interface Software, Loop Tuning
1. Rockwell Automation -- 24%* 1. Rockwell Automation -- 31%* 1. Rockwell Automation -- 27%*
2. Emerson Process Management -- 18% 2. Invensys Wonderware – 25% 2. Emerson Process
3. Siemens – 8% 3. GE Fanuc – 16% Management – 22%
TiPs – 8% 4. Emerson Process 3. Expertune – 17%
GE Fanuc – 7% Management – 8% 4. ControlSoft – 8%
Invensys Wonderware -- 7% FactoryTalk View Software from 5. Honeywell – 5%
7. Honeywell – 5% Rockwell Automation* RSLogix 5000 Programming Software
Iconics – 5% from Rockwell Automation*
Matrikon -- 5%
FactoryTalk Alarms and Events from
Rockwell Automation*
PowerFlex 700
Widest
WidestPower
PowerRange:
Range:
PowerFlex 70
1.1
1.1AAtoto1500A!
1500A! PowerFlex
0.5
0.5hp
hptoto1600
1600hp!
hp! 700H
5 10 20 50 200 2000
Power Rating (HP @ 460V)
700S
Performance
• Selectable Motor Control Algorithms
– Vector Control with Force Technology™ – with or without an
encoder
• Voltage Adaption
– Permanent Magnet Motor
– V/Hz control
• Speed, Torque or Position Control
• Point to Point, Direct or Interpolated (Course to Fine)
positioning, Logix based motion with DriveLogix
• Inertia Adaption - Can increase speed regulator BW x4
• Feedback Options
PowerFlex 700S
Overview – Specifications and Features
• Drive Ratings (normal duty) • Features
– Motor Overload Retention
– 200-240V, 0.75…66 kW • 1…100 Hp • 4.2…260 A – DriveGuard® Safe-off
– 400-480V, 0.75…800 kW • 1…1250 Hp • 2.1…1250 A – Assisted Start-up Routine
– 500-600V, 75…1500 kW • 1…1600 Hp • 1.7…1500 A – Advanced Diagnostics
– Analog Loss Detection
– 690V, 75…1500 kW • 1…1600 Hp • 1.7…1500 A – Feedback Loss Switchover (in speed mode)
• Motor Control – Stegmann Interface
– Vector Control with FORCE™ Technology – Heidenhain™ Interface
– Slip Compensation – Resolver Interface
– Stahltronic and Temposonics® SSI Interface
– Encoder Speed Control – Integral Position Loop
– Encoderless Speed Control – SynchLink™ (high speed data link)
– Torque Regulation – DriveLogix™ Option
– V/Hz Motor Control – Inertia Adaptation
– Permanent Magnet Motor Control – User Function Blocks
• – Common Bus Capability
Ambient Temperature Limit for Enclosures
– Adv. Drive Overload Protection
– IP20, NEMA/UL Type Open: 0 to 50°C (32 to 122°F) – Bus Regulation
– IP21, NEMA/UL Type 1: 0 to 40°C (32 to 104°F)
• Enclosure Styles (Wall mount)
– IP21 / NEMA/UL Type 1 – Frame 9
• Enclosure Styles (Floorstanding)
– Rittal Style “A’ – Frames 10-14
• IP21 / NEMA/UL Type 1
– MCC Style “B” – Frames 10-12 (400,480, and 600V)
• IP21 / NEMA/UL Type 1
PowerFlex 700S
Overview – Packaging
• IP20 Wall Mount – Frame 1-9
• Rittal Cabinet IP21 – NEMA 1
• Motor Control Center (MCC)
IP21 – NEMA 1
• IP00 – NEMA Open
PowerFlex 700S
Ratings and Dimensions
Ratings Ratings
Ratings
400V: 200-250 kW, (385-500A) 400V: 315-400 kW, (590-730A)
400V: 132-160 kW, (261-300A)
480V: 350-450Hp, (385-500A) 480V: 500-600Hp, (590-730A)
480V: 200-250Hp, (261-300A)
600V: 250-450Hp, (250-450A) 600V: 450-600Hp, (460-590A)
600V: 150-200Hp, (170-208A)
690V: 250-400 kW, (250-450A) 690V: 450-560 kW, (460-590A)
690V: 160-200 kW, (170-208A)
After completing this lesson you will be able to identify the PowerFlex 700S Phase II drive and its
and associated components by completing the following tasks:
• Describe the Purpose and features of the PowerFlex 700S Phase II drive
• Identify the PowerFlex 700S Phase II drive and its components
• List the power connections to the drive
• Describe the network and control connections to the drive
• From a list match the operation of the drive power section to its function
Before You Begin
The drive package is very powerful for precise multiple position control and
indexing applications.
The PowerFlex 700S Phase II drive consists of the following major components:
• Drive cover
• Communications adapter
• HIM (Human Interface Module)
• Drive main control board
• Encoder feedback board (Optional High resolution )
• DriveLogix embedded Logix engine (Optional)
• I/O and status LEDs
Drive Cover
The PowerFlex 700S Phase II drive cover by using a screwdriver to lift the red locking tab:
Drive Cover
The PowerFlex communication adapters allows the drive to communicate with its controlling
systems via :
• DeviceNet
• Remote I/O
• ControlNet
• EtherNet/IP
• Profibus-DP
• Modus TCP/IP
• Modus RTU
Communications Adapters
The HIM is located on the front cover of the drive and can be removed by pressing on the tab on
top of the drive and lifting the HIM out of its cradle.
HIM Options
SynchLink
Connector
Encoder 1
Connector
• Feedback option
• Second encoder connection Compact Flash
• Compact Flash
NetLinx Daughter
Card
Feedback Option
The following table shows the Main Control Board connector layout for TB1.
Main Control Board Connectors (TB2)
The following tables show the Main Control Board connector layout for TB2.
Main Control Board I/O Configuration
Settings
Topologies
• Star - updates up to 256 slave drives at maximum data rate
• Daisy Chain - passes data peer to peer at maximum data rate, multi-drive
configurations (up to 10 drives) receive data at multiples of the maximum
data rate
• Ring - a variation of the Daisy Chain, closing the “ring” from the last node
back to the master
PowerFlex 700S Phase II Power
Connections
BR1
BR2
DC+
DC–
PE
U (T1 )
V (T 2 )
W (T 3 )
R (L 1 )
S (L 2 )
T (L 3 )
PowerFlex 700S Phase II
Power Connection Recommendations
The following illustration shows the recommended power and ground connections
PowerFlex Power Structure
PowerFlex Power Structure-Converter
The DC bus components filter, remove noise and smooth the rectified 3 phase AC
• Filter capacitors
• High frequency noise capacitors
• DB bus chokes
PowerFlex Power Structure – DC Bus
PowerFlex Power Structure - Inverter
Converts the DC bus plus and minus into a sine coded pulse width modulated
waveform (PWM) that the motor sees as AC.
The inverter section consists of insulated gate bi-polar transistors (IGBT) that
perform as high speed low loss switches.
PowerFlex Power Structure - Inverter
Power Structure – Current Sensing
1.1. Performance
Performance and
and Power
Power Range
Range
2.2. DriveLogix
DriveLogix
3.3. SynchLink
SynchLink
4.4. Safe-Off
Safe-Off
PowerFlex 700S
DriveLogix
• The DriveLogix option is a real Logix
controller embedded on the main control
board of a PowerFlex 700S
• You program it with RSLogix 5000
(just like other Logix controllers)
• It can reside on a network
(just like other Logix controllers)
• It can scan local I/O
(just like other Logix controllers)
• It has a RUN/REM/PROG switch
(just like other Logix controllers)
• It supports Logix Motion Commands
(just like other Logix controllers)
• It has a high-speed connection to its host
drive via a “virtual backplane”
(better than other Logix controllers)
• Saves space and money with no extra power
supply or chassis (better than other Logix
controllers)`
DriveLogix5730 – Integrated Motion
Maximum Average
SLC™ 5/04 or 5/05 25ms 19ms
FlexLogix 8.9ms 5.0ms
DriveLogix 5730 CompactLogix L35E 5.4ms 3.1ms
ControlLogix® L55 5.4ms 3.7ms
ControlLogix L63 3.3ms 2.1ms
*Lower times are better
PowerFlex 700S
1.1. Performance
Performance and
and Power
Power Range
Range
2.2. DriveLogix
DriveLogix
3.3. SynchLink
SynchLink
4.4. Safe-Off
Safe-Off
PowerFlex 700S
SynchLink
• SynchLink is a high-speed (data transferred every 50 microseconds) , synchronous,
drive-to-drive data link for transmitting synchronized drive and application data
• SynchLink uses fiber-optic cable (so it is immune to electromagnetic interference)
• SynchLink is ideal for transferring:
– Torque command (in a load sharing application)
– Position command (in an electronic line shaft or positioning application)
• Useful for: Electronic Line Shaft, Electronic Gear Ratio, Load Sharing
PowerFlex 700S
SynchLink Example - Electronic Line Shaft
PowerFlex 700S
1.1. Performance
Performance and
and Power
Power Range
Range
2.2. DriveLogix
DriveLogix
3.3. SynchLink
SynchLink
4.4. Safe-Off
Safe-Off
PowerFlex 700S
Safe-Off
• Will not send energy to motor when Safe-Off input is low.
• Operator Safety
• Machine and Factory Productivity
• EN-954-1 Category 3
• TUV Functional Safety Report
• Duality (Redundancy), Diversity, Diagnostics
PowerFlex 700S
Control Hardware Loc.
PowerFlex 700S
Options Overview
Options available in the Slim or Expanded cassette
– SynchLink
– DriveLogix 5730
• Embedded EtherNet/IP
Options that require the Expanded cassette
– Feedback options
• 2nd Encoder, Stegmann, Heidenhain, Resolver, MDI
• Heidenhain EnDat through Global Drive Systems
– Logix Expansion board
• NetLinx daughter cards communications
(1788-xxxx)
• CompactFlash
• Compact I/O
Use the Expanded so you can add options later
PowerFlex 700S
Target Applications and Industries
• Applications that Require High Performance
– Low speed torque
– Tight torque or speed or position control
• Applications that Require Esoteric Feedback Capability
– Stegmann or Heidenhain or linear or Resolver
– Feedback loss switch over
• Applications that Require Permanent Magnet Motor Control
• Applications that Require High Speed Synchronization
• Applications that Require Logix or Motion Commands
• Applications that Require Safe-Off
PowerFlex 700S
Target Applications and Industries
• Metals, Paper, Converting…
– Web handling
– Winding/un-winding
– Extruders
– Flying Shear
• Automotive
– Test Stands
– Transfer Systems
– Feeders (Press, cut-off…)
• Printing
– Electronic Gearing
– Cut to Length
– Unwind
PowerFlex 700S related manual
1.1. PowerFlex
PowerFlex 700S
700S introduction
introduction
2.2. Load
Load Sharing
Sharing
3.3. Installation
Installation
4.4. Q&A
Q&A
Load Sharing with AC Drives
– Is NOT multiple motors controlled by one drive powering the same process
– Is NOT having each drive/motor combination operate entirely independent of
each other.
Load Sharing
• Using
– Droop Follower
– Torque Follower (master / slave)
– Speed Trim Follower (Cascade)
Droop Follower
• Uneven load of material can cause one motor to pull harder than the
others.
• Droop on each drive will allow load sharing with some change in speed.
• Leaving one drive without droop will provide better speed regulation but
worse load sharing.
Droop Follower Applications
Advantages Disadvantages
• Simple. • Poor speed regulation.
• No extra wiring. • Limited speed range difference.
• High Performance drives not • Sharing of load is not precise.
required.
• Does not result in runaway
condition when load is
uncoupled.
Load Sharing
• Using
– Droop Follower
– Torque Follower (master / slave)
– Speed Trim Follower (Cascade)
Torque Follower
Advantages Disadvantages
• Precise load sharing to act as one • Available only on FVC drives –
drive. PF700S-PF700VC – PF70EC
• No speed range limit. -1336 Impact.
• Do not have to give up speed • Requires interconnected signal
regulation. wiring.
• Min/Max torque reference • Load loss can cause torque
compare feature eliminates run follower drives to run away.
away
Load Sharing
• Using
– Droop Follower
– Torque Follower (master / slave)
– Speed Trim Follower (Cascade)
Speed Trim Follower
• Chain Conveyor
– Large speed range may exist.
– Overall Speed regulation is critical.
– Proper load share prevents excess equipment wear.
– Mechanical coupling between motors is pull only
Speed Trim Follower Applications
Advantages Disadvantages
• Continuous automatic load sharing • Available only on higher
compensation. performance drives
• No manual compensation for “initial
loading” or “strip out” functions. • Requires interconnected signal
• No speed range limit. wiring.
• Do not have to give up speed
regulation.
• Trim feature built into the drive.
Summary
1.1. PowerFlex
PowerFlex 700S
700S introduction
introduction
2.2. Load
Load Sharing
Sharing
3.3. Installation
Installation
4.4. Q&A
Q&A
AC Drive and Motor Installation Practices
Line Transients
A little protection
and good
technique
ACME INCORPORATED go a long way to
insure a good
drive installation
Common Mode
&
Capacitive Coupling
?
Tell me again
why I’m using Harmonics
drives?
Reflected Wave
Grounding
&
Bonding
Recommended System Grounding Scheme
• Reflective Wave
• Common Mode Noise
• Capacitve Coupling
• Grounding and Panel Layout
• Power Quality
IGBT Advantages
7.5HP MOTOR
LINE B
Per Phase Motor
1
- Zo = L/C v=
L*C
Possible 2x To 4x
PROBLEM: Bus Voltage Ring Up
* Motor Insulation Capability Now The Voltage Across The First Few Turns
Of The Coil Group Can Be > 1350 Volts, Rather
Than The Typical AcrossTheLine Voltage Of
1030 Volts
* Cable Insulation Capability Need Higher Rating Voltage Long Life
* Increased Motor dv/dt Noise Current Oscillating In The 1 3MHz Range
Typical PWM VLL Output Pulse at the Motor
Terminal
+2
+1
-1
What will the amplitude be?
PLUS
1.8
100 ns IGBT
200 ns
1.6
400 ns
1.4 600 ns
BJT
1 us
1.2
2 us
1
4 us GTO
1 10 100 1000 10000
Cable Distance [ft]
Insulation breakdown
1600 1600 Volts
Corona Susceptible Areas
1400
1200
1000 1000 Volts
800
600
400
200
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Time ( s)
500
T1 ORN
T3 ORN 400
T5 ORN Line End Coil V
o 300
T7 ORN
l
T9 ORN t 200
T11 ORN a
g 100
T13 ORN
e
T1 BLU 0
T3 BLU
100
T5 BLU
T7 BLU 200
T9 BLU Second Coil 0 0.5 1 1.5 2 2.5 3 3.5 4
T11 BLU Time (uS)
T13 BLU
Coils 312
T0
12 coils
• Peak Inter-turn Voltage is a Function of the Transmission
12 coils Line affect of the motor and the number of Turns of the
T2 T3 coil group
Effect of Corona
• White Residue
• Phase to Phase W/O Separator
• Turn to Turn
• Drive Typically OL Trip
Where is the highest risk?
AC Drive
Allen-Bradley
AC
Motor
AC Drive
1204-RWR2
Reactor
Non Inverter Duty Motor
KLC filter or
@drive
AC
Motor
Terminator
1204-TFA1
1204-TFB2
@Motor
Results
Plot 2
Before and after the addition of a 1204-RWR2 & 3.0mhy output reactor
1305 3HP 460V 60HZ No-load
300ft shielded cable
After addition of
1321 output reactor
1140Vpk @ Motor
14s/rise time Before addition of
1204-RWR2
1180Vpk @ Motor
660Vpk @ Inverter
After addition of
1204-RWR2
720Vpk @ Motor
660Vpk @ Inverter
Cable Issues Require Attention
• Capacitive Coupling
C MOD PHASE A
C MOD
ISG1 CSG MOTOR
CHASSIS GND
GROUND
ALL CURRENTS IG MUST ISG WIRE
RETURN HERE OR HERE
I SG2
I G RETURN
* I GND Can Find Its Way Into CNC, PLC, And Computer Grounds
70 ns
Inverter V
LL
output
voltage
Common
Mode
dv
Current
6 MHz
I C
dt
I PEAK
Philosophy Of Common Mode Noise
Abatement
• 1. Grounding practices
• Eliminate ground loops (Single Point Grounding)
• Panel Layout
• 2. Attenuate noise source (drive)
• Add Common mode chokes to drives output
• Add common mode chokes to Blue Hose
• 3. Shield noise away from sensitive equipment
• Use 4 conductor shielded cable (required for CE)
• Use 4 conductor in conduit
• 4. Capture and return noise to source (drive)
• EMI/RFI filter (required for CE)
• Add common mode caps
Single Point Grounding/ Panel Layout
Neutral
For PLC grounding
Equipment recommendation
Ground PLC
refer to Publication
1770-4.1
TE-ZERO VOLT
POTENTIAL BUS (Isolated from panel)
1336 Plus
1305
Motor
Logic
Logic
PE PE
PE GROUND BUS Motor
Usually bonded
to nearest
Building ground
Figure 1: Grounding requirements vary depending on the type of drive implemented, drives with true earth
(TE) terminals must have a zero volt potential bus, separate from potential earth (PE) ground bus. users
now have two choices. They can either tie the buses together at one point in the control cabinet or bring
them back separately to the building ground grid (tied within 10ft of each other).
Single Point Grounding/ Panel Layout
Neutral
For PLC grounding
Equipment recommendation
Ground refer to Publication
PLC 1770-4.1
TE-ZERO VOLT
POTENTIAL BUS (Isolated from panel)
1336 Impact 1336 Plus
Motor
Logic Logic
PE TE PE
PE GROUND BUS Motor
Usually bonded
to nearest
Building ground
Figure 1: Grounding requirements vary depending on the type of drive implemented, drives with true earth
(TE) terminals must have a zero volt potential bus, separate from potential earth (PE) ground bus. users now
have two choices. They can either tie the buses together at one point in the control cabinet or bring them back
separately to the building ground grid (tied within 10ft of each other).
System Grounding Scheme
1336 Plus 1336 Plus 1336 Impact 1336 Force
1305 1305
Logic Logic
Logic Logic
PE PE PE
PE Logic Logic
PE TE PE TE
TE Bus
Common Mode Voltage V 12
Common Mode Current I I ao
ao
Ground Potential #1 Ground Potential #2
Improper Cabinet Grounding w/Drives & Susceptible
Equipment
Conduit or Conduit or
Output Conduit / Armor Output Conduit / Armor
Armor Bond M1, M2, M3, PE
Armor Bond L1, L2, L3
U VW PE R S T
Noise Current Drive 1 Drive 2
Return Path
Cabinet Back Plane
PLC PE PE
Drive 3 Drive 4
PE PE
PE Copper Bus
To System Ground
Proper Cabinet Grounding w/Drives & Susceptible
Equipment
Common Mode
Current on Armor
PE PE All Drives
Output Conduit orArmor
Input Conduit / Armor
Bond to Cabinet
L1, L2, L3, GND
U V W R S T
Drive 1 Drive 2
PLC PE PE
Cabinet Back Plane
Drive 3 Drive 4
Common Mode
Current on Green Wire
PE PE
PE Copper Bus
Optional PE to Structure
Steel if Required
X = Io RETURN
X X
X X
X X
SHIELD X
X
a b X
X
. = Io SOURCE
X X
X X COAXIAL LOW INDUCTANCE STRUCTURE
X X
X FOR ZERO SEQUENCE CURRENT
Shield Noise X
X c g X
X X
X X SHIELD PREDOMINATES 95% Io
Iao
<<
AC MOTOR
DRIVE Ibo
<<
C STATOR /GROUND
SLOT
CAPACITANCE
Ico
<<
Io RETURN FRAME
60 Hz SAFETY GROUND 5%
A B C A B C
TRAY TRAY
ARMOR
ARMOR PVC
PVC PVC
STRANDED
A A A A NEUTRAL
B C B C B C B C
+
MOTOR
+ LEM
LLINK
GND
CHASSIS
Technical Solutions
MOTOR
CONDUIT / RFI FILTER FRAME
4 WIRE CABLE COMMON OUTPUT
1336 PLUS MODE REACTOR SHIELDED
DRIVE CORE CABLE
L1
A
B MOTOR
WINDINGS
L2 C
PE / GND GROUND
PE SHIELD
L3 + DC
PE GROUND
DC PER LOCAL
NEC CODE
RIO / DH+
+/ COMMON
MODE CAPS
COMMON PE
MODE
CORE
ROD TO COMPUTER
GROUND AT TE GROUND
Capacitive Coupling
• Simple solutions
– Limit motor lead length for small drives
– Reduce drive carrier (PWM) frequency
What is Capactive Coupling?
• Every time the drives’ DC bus voltage switches at the carrier (or
PWM) frequency it causes current to conduct through this
capacitance.
• These capacitive current spikes then get reflected back to the drive
and measured by it’s current feedback circuitry.
• 460 volt drives will exhibit this phenomenon to a greater degree then will
230 volt drives.
• One of the ways to mitigate this effect is by reducing the carrier (or PWM)
frequency to 2 KHz.
• Thank you.
• Questions?