Rockwell Automation PowerFlex 7000 Instruction manual

PowerFlex® 7000
Medium Voltage AC Drive
TECHNICAL DATA
Firmware Version 7.xxx

Table of Contents
7000-TD002A-EN-P – September 2007
Chapter 1 Introduction ..............................................................................1-1
Description of Operation .........................................................1-2
Speed Command ......................................................................1-3
Speed Reference ......................................................................1-4
Speed Control ..........................................................................1-6
Flux Control .............................................................................1-8
Flux Control for Synchronous Motor ....................................1-10
Current Control ......................................................................1-12
Line Converter Feedback .......................................................1-14
Machine Converter Feedback ................................................1-15
Motor Model ..........................................................................1-16
Drive/Motor Protection ..........................................................1-17
Power Semiconductor Diagnostics ........................................1-19
Off-line Detection of Failed SCRs/SGCTs .....................1-20
Line Converter ..........................................................1-20
Machine Converter ...................................................1-22
On-line Detection of Failed SCRs/SGCTs ......................1-23
Test Modes .............................................................................1-24
Flying Start (Induction Motor) .............................................1-26
Flying Start (Synch Motor) ....................................................1-27
Tachometer/Encoder Option ..................................................1-28
Synchronous Transfer ............................................................1-29
Transfer to Bypass ...........................................................1-31
Transfer to Drive .............................................................1-34
PID Process Control ..............................................................1-35
Power Factor Compensation ..................................................1-38
Analog Outputs ......................................................................1-38
Analog Inputs .........................................................................1-39
Chapter 2 Parameters Parameter Descriptions ............................................................2-1
Parameters Listed by Group ................................................2-199
Parameters Listed by Linear Number ..................................2-217
Alphabetical Index ...............................................................2-229
Linear Number Index ...........................................................2-237
Chapter 3 Troubleshooting Documenting Shutdowns .........................................................3-1
Acronyms and Abbreviations Used in this Manual .................3-2
Drive Fault Messages ..............................................................3-3
Drive Warning Messages .......................................................3-32
Appendix A Logic Command Word – Database 7.xxx................................A-1
Product Specific Logic Command – Firmware 7.xxx ............A-2
Functional
Description
Drive Lo
g
ic Command
and Status

ii Table of Contents
7000-TD002A-EN-P – September 2007

Chapter 1
7000-TD002A-EN-P – September 2007
PowerFlex 7000 Functional Description
Introduction The PowerFlex 7000 is an adjustable speed ac drive in which motor
speed control is achieved through control of the motor torque. The
motor speed is estimated or measured and the torque is adjusted as
required to make the speed equal to the speed command. The motor
and load determine the stator frequency and the drive synchronizes
itself to the motor. This is in contrast to the volts/hertz ac drive in
which the drive determines the stator frequency and does not attempt
to synchronize its output to the motor.
The method of control used in PF7000 is known as direct rotor flux
oriented vector control. The term rotor flux vector control indicates
that the position of the stator current vector is controlled relative to
the motor flux vector. Direct vector control means that the motor
flux is measured, in contrast to the indirect vector control in which
the motor flux is predicted. In both control methods, the stator
current (Is) is split into flux producing component (Isd) and an
orthogonal torque producing component (Isq) which are controlled
independently. The aim of vector control is to allow a complex ac
motor to be controlled as if it were a simple dc motor with
independent, decoupled field and armature currents. This allows the
motor torque to be changed quickly without affecting the flux. For
typical Medium Voltage motors the rotor time constant is in the
range of seconds and therefore the flux cannot be changed quickly.
The PowerFlex 7000 drive can be used with either induction
(asynchronous) or synchronous motors. Synchronous motor drives
are identical to induction motor drives except for the addition of a
current regulated field supply to the synchronous drive. The features
that are unique to a synchronous motor drive are confined to the flux
control function and the encoder option.

1-2 Functional Description
7000-TD002A-EN-P – September 2007
Description of Operation A complete block diagram of the PF7000 control circuit is shown in
Figure 1.1. The major blocks are described in the following sections.
Line
Protection
Rectifier DCLink
inductor
Line filter
cap
Inverter Motor filter
cap Motor
Voltage
Motor Current Speed
Command
Speed
Reference
Machine side
feedbackand
gating
Alpha
Inverter
Alpha
Rectifier
Line side feedback
and gating
LineVoltage
ACLine
Reactor
Line
Current
Faults
InvTorque
CurCmd
Inv Flux
CurCmd
FluxRange
Machine
Protection
Sync
Transfer
Speed
Control
Stator freq
Slipfreq
FluxFeedback
Speed Feedback
Flux
Control
Faults
Tach
Feedback
Source
Motor
Current
Control Motor
Model
IdcFeedback
Figure 1.1 – Functional Block Diagram of PF 7000 control system

Functional Description 1-3
7000-TD002A-EN-P – September 2007
Speed Command The function of Speed Command block is to select one of the 10
possible speed command inputs. Parameter Speed Ref Select (7) in
conjunction with Local/Remote selector switch is used to define the
speed command input Speed Command In (276). When the selector
switch is in Local position, the default speed command is the Analog
Speed Potentiometer typically mounted on the LV panel. When the
selector switch is in Remote position, the parameter Speed Ref Select
defines the source of speed command. The options available are:
Local ( Speed Potentiometer)
3 DPI commands ( DPIAdapter1, DPIAdapter2, DPIAdapter5)
2 Analog Inputs configured either for 0-10V or 4-20mA (Analog
Inp1, Analog Inp2)
3 Preset speeds (Preset Spd 1, Preset Spd 2, Preset Spd 3)
1 Preset Jog
In addition, the speed command can come from a built in PID
controller. 
The above speed commands are used when the drive is in Normal
mode of operation. However PF7000 has many special modes of
operation e.g. test modes or auto-tuning for which different speed
commands are selected. Table 1.A summarizes the speed command
during these special modes.
Table 1.A – Speed Commands for special operating modes of PF7000
Special operating modes of PF7000 Speed Command In(276)
DC test mode Rated line frequency
Open Circuit Rated Line Freq (17)
Open Loop 0.1 x Rated Line Freq (17)
Rs autotune 2Hz
Ls autotune Rated Line Freq (17)
Flux Reg autotune Autotune Spd Cmd (213)
Speed Reg autotune Autotune Spd Cmd (213)
Sync transfer requested Bypass Frequency (159)
The selected Speed Command In is clamped to a minimum and a
maximum level by parameter Speed Cmd Max (290) and Speed Cmd
Min (293) to give Speed Command (277). The maximum value of
Speed Command cannot be greater than 125% of Base Speed (98).
Note: Contact the factory for applications that require output
frequencies greater than 125% of the motor base speed.
Contact factory for the availability of this feature.

1-4 Functional Description
7000-TD002A-EN-P – September 2007
Speed Command (cont.) Three skip speeds Skip Speed 1(49), Skip Speed 2 (50), Skip Speed 3
(51) are provided to prevent the drive from continuously operating at
a certain speed. This feature is sometimes needed to avoid mechanical
vibrations occurring in a drive system at certain speeds. The skip
speed zone around each Skip Speed is specified by the parameter
Skip Speed Band1 (53), Skip Speed Band2 (54), Skip Speed Band3
(55) If the desired Speed Command lies in a given skip speed zone,
the Speed Command is clamped to the lowest value in the zone.
Example
If Skip Speed 1 is 45 Hz with Skip Speed Band1 as 1 Hz, then the
skip speed range extends from 44.5 Hz to 45.5 Hz. If the desired
speed command is set to 45 Hz, then the drive will avoid this speed
and run at 44.5 Hz.
The final stage in processing the command is the whether the drive
has been requested to run forward or reverse. The sign is changed if
reverse rotation is selected. The Speed Command is set to zero if the
drive is stopped.
Speed Reference The function of the Speed Reference block is to determine the Speed
Reference (278) from the desired Speed Command (277). PF7000
provides two options:
•S-curve
•Linear Ramp
To select, S curve a non-zero value of S curve Percent (475) is
selected. Using parameter S curve Acc1 (481), the drive
automatically calculates the linear and the non-linear portions of the
S curve as shown in Figure 1.2. Following example shows how to
use S curve parameters:
Example
If S curve Accel 1 is set for 20 sec with 20% in S curve Percent, then
the total acceleration time is increased by 0.2 x 20 = 4 seconds. The
total acceleration time will now be 24 seconds with 4 seconds in the
non-linear portion of the S curve. Since the curve is symmetrical,
each of the segments will be of 2 seconds duration.
The parameters for deceleration are calculated using parameter S curve
Decel 1 (479) and S curve Percent (475) and shown in Figure 1.2.
Linear Ramp is enabled if the S curve Percent is set to zero.
Independent four section ramps are provided for acceleration and
deceleration. The ramp is specified by 4 Ramp Speeds, 4 Accel and
Decel times and is shown in Figure 1.3.

Functional Description 1-5
7000-TD002A-EN-P – September 2007
Linear Portion Non-Linear
Portion
Non-Linear
Portion
S Curve Acc1
(481)
0.005*
S Curve Acc1
*S Curve
Percent S Curve Dec1
(479)
Linear Portion
Non-Linear
Portion Non-Linear Portion
0.005*
S Curve Acc1
*S Curve
Percent
0.005*
S Curve Dec1
*S Curve
Percent
0.005*
S Curve Dec1
*S Curve
Percent
Linear Portion Non-Linear
Portion
Non-Linear
Portion
S Curve Acc1
(481)
0.005*
S Curve Acc1
*S Curve
Percent S Curve Dec1
(479)
Linear Portion
Non-Linear
Portion Non-Linear Portion
0.005*
S Curve Acc1
*S Curve
Percent
0.005*
S Curve Dec1
*S Curve
Percent
0.005*
S Curve Dec1
*S Curve
Percent
Figure 1.2 – Speed Reference: S-curve
Ramp Speed1
(73)
Ramp Speed4
(76)
Ramp Speed3
(75)
Ramp Speed2
(74)
Accel
Time1
(65)
Accel
Time4
(68)
Accel
Time3
(67)
Accel
Time2
(66)
Decel
Time1
(69)
Decel
Time2
(70)
Decel
Time3
(71)
Decel
Time4
(72)
Ramp Speed1
(73)
Ramp Speed4
(76)
Ramp Speed3
(75)
Ramp Speed2
(74)
Accel
Time1
(65)
Accel
Time4
(68)
Accel
Time3
(67)
Accel
Time2
(66)
Decel
Time1
(69)
Decel
Time2
(70)
Decel
Time3
(71)
Decel
Time4
(72)
Figure 1.3 – Speed Reference: Linear Ramp

1-6 Functional Description
7000-TD002A-EN-P – September 2007
Speed Control The function of the speed control block is to determine the torque-
producing component (Isq) of the stator current (Is). The inputs to the
block are the Speed Reference (278) from the speed ramp and the
Stator Frequency (448) and Slip Frequency (343) from the motor
model. If drive is installed with an optional tachometer, then the
motor speed is determined by counting the tach pulses.
In Sensorless operation, the Slip Frequency is subtracted from the
Stator Frequency and filtered to determine the Speed Feedback
(289). In Pulse Tach mode, the speed is determined directly by using
Tach Feedback (349). The Speed Feedback is subtracted from the
Speed Reference to determine the Speed Error (472) which is
processed by the speed PI regulator. The gains of the regulator are
based on the Total Inertia (82) of the system and the desired Spdreg
Bandwidth (81). The output of the speed regulator is the Torque
Reference (291) whose rate of change is limited by Trq Rate Limit
(83). The calculated Torque Reference is divided by the Flux
Reference (305) and motor constant to determine the torque
component of the stator current MtrTorque CurCmd (292). To
calculate the torque producing current supplied by the inverter
InvTorque CurCmd (294), the current supplied by the motor filter
capacitor in torque production (orthogonal to motor flux) is
calculated and subtracted from MtrTorque CurCmd.
In Sensorless mode, the drive uses TrqCmd0 Sensrlss (86) and
TrqCmd1 Sensrlss (87) for an open loop start up. At frequencies
greater than 3Hz, the drive enables the speed loop and disables the
open loop start mode. In Pulse Tach mode, the drive is always in
closed loop. The maximum torque a drive can deliver in motoring
mode is determined by Trq Lmt Motoring (84). In regenerative mode
the torque is limited to Trq Lmt Braking (85). It should be noted that
at speeds above the Base Speed (98), the motor torque capability is
de-rated and varies in inverse proportion to the speed (constant
power range).
Depending open the application, a drive can be configured in
different torque control modes by setting the parameter Trq Control
Mode (90). E.g. in stand-alone drives the parameter is set as Speed
Reg allowing the drive to be in speed control mode and regulating
the torque in the motor. In torque follower applications like
conveyors, one of the drives (Master) is set in Speed Reg mode
which enables the speed regulator while the other drives (torque
followers) are set in Trq Cmd External mode. The torque reference
produced by the Master drive is then passed on to the torque follower
drives by Trq Cmd External (91). Figure 1.4 shows other various
modes of operation.