VFD Application Techniques Presented to you by AE’s - Keith Schultz & Mark Michalak K endall C onnection L ive! 1 March 7 & 8, 2018
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
VFD Application Techniques
Presented to you by AE’s - Keith Schultz & Mark Michalak
K endall
C onnection
L ive!
1March 7 & 8, 2018
2
Drive Selection
DC
AC
Loose or Configured
MCC
Medium voltage
March 7 & 8, 2018
3
Starting Method
Characteristic Across the Line Star Delta Soft StartAC Variable
Speed Drive
Speed/Torque
ControlNone None Start/Stop Only Full Control
Shock/Jolt
ReductionNone Low High High
Reduce Start
Inrush CurrentNo Yes Yes Yes
Control Motor
StopNo No Yes Yes
Purchase Cost Low Low/Medium Medium High
Potential for
Energy SavingsLow Low Low High
When it comes to choosing the best method of control for your motor systems,
it is imperative to account for the characteristics of your application,
desired performance and energy usage/savings considerations.
Drive Selection
March 7 & 8, 2018
4
Drive Selection
Typical reasons for considering VFDs include:
• Energy savings
• Controlled starting current
• Adjustable operating speed
• Torque
• Controlled stopping
• Reverse operation
• Replace Starters Improve operation.• VFDs cut energy consumption, especially with centrifugal fan and pump loads.
Halving fan speed with a VFD lowers the required horsepower by a factor of eight,
as fan power is proportional to the cube of fan speed
March 7 & 8, 2018
5
Drive Selection
Applications…………..????
Can you think of any?
Fan VFD Mode V/Hz
Conveyor SVC/ FVC
Platen FVC
Pump V/Hz/SVC
Positioning FVC
Extruder FVC
Presses SVC/FVC
SLAT Speed & torque control FVC
March 7 & 8, 2018
FVC - Flux Vector control
6
Drive Selection
Do we have any options to select the correct drive for the application?
March 7 & 8, 2018
7
Drive Selection DC Drives
March 7 & 8, 2018
8
Drive Selection DC Drives
March 7 & 8, 2018
9
Drive Selection DC Drives
March 7 & 8, 2018
10
Drive Selection DC Drives
March 7 & 8, 2018
11
Drive Selection DC Drives -
March 7 & 8, 2018
12
PowerFlex 523, 525
PowerFlex 527
PowerFlex 4M, 400
PowerFlex 40. 40P Consider PF 523, 525
PowerFlex 4 Consider PF 523
1305 AC DrivesConsider PF 523,
525
Bulletin 160Consider PF 4M,
523, or 525
PowerFlex® COMPACT DrivesLife Cycle Status
March 7 & 8, 2018
13
PowerFlex® DrivesLife Cycle Status
March 7 & 8, 2018
14
Drive Selection
Does it matter what Control Mode the VFD operates in?
March 7 & 8, 2018
15
VFD control mode choice greatly depends on the application.
The three VFD control modes are volts-per-Hertz (V/Hz),
sensorless vector (sometimes called open-loop vector), and closed-loop.
V/Hz-type VFDs use the ratio between voltage and frequency to develop
the operating flux to supply operating torque to the motor.
Sensorless-vector VFDs have accurate torque control over a wide speed range
without having to use encoder feedback.
Closed-loop VFDs use encoder feedback to obtain motor speed and slip information.
V/Hz control is adequate for many applications such as fans and pumps.
However, for applications that require greater degrees of speed regulation,
sensorless vector or closed-loop control types may be necessary.
Applications such as paper mills, web printing presses, or material converting
require the added speed regulation that closed-loop control provides.
Drive Selection
March 7 & 8, 2018
16
Drive Selection
• Consider both torque and peak currents.
• Obtain the highest peak current under the worst operating conditions.
• Check the motor FLA, which is located on the motor’s nameplate.
Note that if a motor has been rewound, its FLA may be higher than
what’s indicated on the nameplate.
How old is the motor… Is it Inverter rated?
Speed Range… Need to be a zero speed – full torque?
Existing Motor….Why should I consider the current of the motor/application?
March 7 & 8, 2018
17
Size the VFD to the motor based on the maximum current requirements under
peak torque demands.
Do not size the VFD based on horsepower ratings. Many applications have
failed because of this.
Remember, the maximum demands placed on the motor by the load must also
be met by the VFD.
Drive Selection
March 7 & 8, 2018
18
Drive Selection
Nema B
Motor –
Speed/Torque
Curve
March 7 & 8, 2018
19
Drive Selection
Shift of torque-versus-speed curve as drive reduces frequency
Provides max torque..
March 7 & 8, 2018
20
Drive - Motor- Selection
BlackMax
BlackMax
Explosion Area
Rated
BlueMax w/encoder
RPM AC
Medium Voltage 4000VAC
Permanent Magnet
March 7 & 8, 2018
21
Drive Selection
What does the motor nameplate tell me?
March 7 & 8, 2018
22
Drive Selection
What does the motor nameplate tell me?
March 7 & 8, 2018
23
Drive Selection - Communications
Migrating from RIO
DeviceNet
ControlNet.
To: Ethernet
16 bit to 32 bit data
Look at the
Rockwell Automation
Knowledgebase site..
March 7 & 8, 2018
24
Drive Selection
March 7 & 8, 2018
25
Drive SelectionWe have options……………
March 7 & 8, 2018
26
Drive Selection
Power Structures - Standalone Drive
AC supply sourceInput fusing and circuit breakers
AC drive PowerFlex
AC Motor
CablesPower and Feedback
Input line Reactor or Transformer “Isolation”
Drive Installation
Guidelines
DRIVES-IN001
March 7 & 8, 2018
27
VFD’s…. likely faults…
**Decel Inhibit fault….750 family Fault 24
Dec Inhibit Actn par 409
Deceleration Inhibit Action
Configures the response to a Decel Inhibit condition, which occurs when the drive is not
decelerating. One possible cause could be bus voltage regulation.
“Ignore” (0) – No action is taken.
“Alarm” (1) – Type 1 alarm indicated.
“Flt Minor” (2) – Minor fault indicated. If running, drive continues to run.
Enable with P950 [Minor Flt Cfg]. If not enabled, acts like a major fault.
“FltCoastStop” (3) – Major fault indicated. Coast to Stop.
Decel Inhibit is a fault that is generated when the drive cannot slow down due to a
rising DC bus voltage. It will typically happen after a ramp to stop has been asserted
but can occur anytime the DC bus rises due to regenerative energy.
The Decel Inhibit fault is generated if the drive-stops decelerating altogether.
March 7 & 8, 2018
28
VFD’s…. likely faults…
**Safety Fault – 525 F59
March 7 & 8, 2018
29
VFD’s…. likely faults…
Typical symptoms for this issue are:
•Drive will not command speed higher than low speeds and motor draws
high current
•While accelerating, the motor is having stability issues (speed oscillations)
•While decelerating, the motor won't follow the decelerate ramp (decel
inhibit or speed oscillations)
•Drive will not stop but only run to a low speed.
•The Bus Regulator is too active and not able to stabilize.
•Drive will operate above current limit
•DC Bus voltage fluctuation that may result in an input phase loss F17
PowerFlex 750 Series Drive – Motor Speed Oscillating -Slip Compensation On
To disable the slip compensation set Parameter 621[Slip RPM at FLA] to 0.
This cannot be done unless Parameter 70[Autotune] is set to 0 [Ready].
March 7 & 8, 2018
30
VFD’s…. likely faults…Networked Drive.
Configuration issues.. Latest AOP & Database
Logix does not allow configuration or cannot see drive product.
RSLinx has big ? Obtain or upload EDS file.
PCDC - Product Compatibility & download Center
March 7 & 8, 2018
31
VFD’s…. Configuring…Braking Options
…. PowerFlex 520
March 7 & 8, 2018
32
• Parameter 370 [Stop Mode A] - 1= "Ramp"
• Parameter 372 [Bus Reg Mode A] - This should be set to: 2 = "Dyn Brake", 3 =
"Both DB 1st", or 4 = "Both Frq 1st".
• Parameter 374 [BusReg Lvl Cfg] - Usually left at default.
• Parameter 375 [Bus Reg Level] - Usually left at default. This configures the drive
regarding when to turn on the bus regulator and the dynamic brake.
• Parameter 382 [DB Resistor Type] - Set to a value of 1 = "External".
• Parameter 383 [DB Ext Ohms] - Enter in the value of the brake resistor in ohms.
• Parameter 384 [DB Ext Watts] - Enter in the value of the brake resistor in watts.
Parameter 385 [DB Ext Pulse Watts] - The value of this parameter is a characteristic of
the dynamic brake resistor. Pulse watts is a quantification of the amount of watts the
resistor can withstand in one second (joules).
Braking Options
…. PowerFlex 750 ….
VFD’s…. Configuring…
March 7 & 8, 2018
33
VFD’s…. likely faults…
When the drive appears to be non-functional! Now What?
March 7 & 8, 2018
34
VFD’s…. likely faults…The power structure of an AC drive consists of diodes or SCRs on the input and IGBTs on the
output. Diodes will go into conduction between 0.3 V - 0.7 V when forward biased and read
OL (open circuit) when reverse biased. IGBTs can be tested by measuring the flyback diode
that is reverse biased across the IGBT. Therefore all readings described below are done with
a digital multi meter in diode test mode.
SCRs will read OL in forward or reverse bias. Generally drives under 50 hp will have diode
inputs. Larger drives may have SCR inputs or an input comprised of 3 diodes and 3 SCRs
which results in 3 OLs and 3 diode drops.
March 7 & 8, 2018
35
VFD’s…. likely faults…
March 7 & 8, 2018
36
VFD’s…. likely faults…
If any of these tests show a short (0.0V) Try to find the cause of the short or replace the drive
March 7 & 8, 2018
37
VFD’s….Software…
Configure
Program
Visualize
March 7 & 8, 2018
38
Setting up the 527 on Ethernet…
679035 - PowerFlex 527 Supported Controllers and Ethernet/IP Communication Modules
680057 - PowerFlex 527 and Integrated Safety on Ethernet/IP
679882 - PowerFlex 527 drive Add-On Profile download
747295 - PowerFlex 527 drive Network Safety
679031 - PowerFlex 527 Coarse Update Rate
680076 - PowerFlex 527 Drives Encoder Feedback Option 25-ENC-2
753381 - PowerFlex 525/523/527 Drive HP and Current Ratings by Frame Sizes, Weights, Dimensions
679893 - PowerFlex 527 supported Motor Types
727869 - PowerFlex 527 drive: AOI sample for mechanical brake control
679885 - PowerFlex 527 Drive IP Address Configuration
731516 - PowerFlex 527 does not have Hand Off Auto Functionality
725534 - PowerFlex 527 drive: Meaning of Velocity filter taps
732095 - Powerflex 527 or Kinetix axis cip drive: Connection Request Error 16#0106
707492 - PowerFlex 527 Drive Stuck in Connecting on Power Up
732026 - Powerflex 527 Drive Motion Database Cannot be Found
456849 - PowerFlex 755/527 CIP Motion Drive - Selecting Dynamic Brake Resistor
726411 - PowerFlex 527: Preventing the motor turning at zero speed reference
679045 - PowerFlex 527 Component Class Motion Drive
679881 - PowerFlex 527 as a Stand Alone Product
821670 - Powerflex 527 digital input to assign to motion function as enable, home, registration or overtravel
728762 - PowerFlex 527 C1, C2 terminal
680345 - PowerFlex 527 Out-of-Box Safety State / Configuration
725832 - PowerFlex 527 with Integrated Safe Torque Off
766032 - Axis Configuration Examples for the PowerFlex 527 Drive
768604 - Evaluation of Cip Axis State for axis cip drive (such as Powerflex 527)
819673 - Ramp acceleration/deceleration set on a PowerFlex 527 drive MDS in frequency mode
839321 - PowerFlex 527: change speed on the fly
1005566 - External Dynamic Brake Kit Values for AK-R2 Resistors when used in CIP Motion Axis Drives
March 7 & 8, 2018
39
Setting up the 527 on Ethernet…
ControlLogix 1756-L7x, 1756-L7xS or 1756-L8x with
1756-EN2T (Firmware version 3.1 and up), -EN2XT,
-EN2TR, -EN2TRXT, -EN3T, -EN3TR Ethernet/IP
communications module.
The 1756-L61 ControlLogix Processor will not work
with the PowerFlex 527, You need a minimum of
Version 24 in the processor and the L61 only goes
up to 20.019.
March 7 & 8, 2018
40
Setting up the 527 on Ethernet…
March 7 & 8, 2018
41
Setting up the 527 on Ethernet…
Safety Function: Actuator Subsystems – Category 0 orCategory 1 Stop via a PowerFlex 527
Drive with IntegratedSafe Torque-off Application Techniques, Publication Safety-AT141.
Sample Code Website 527 AOI
March 7 & 8, 2018
42
Setting up the 527 on Ethernet…
Demo - utilizing the AOI with the 527
March 7 & 8, 2018
43
Good Job everyone!
March 7 & 8, 2018
Related Documents
