PowerFlex 700 with Vector Control Option Custom Firmware, “BA
Contents
1. 0 Disabled Used to enable Pump Off control Options 0 Disabled 1 Baseline Set 2 Fixed Setpt Disabled 0 Pump Off control is not active Baseline Set 1 The control uses a torque baseline created after any start of the drive first ten cycles IMPORTANT It is critical that this data is gathered from a full well Fixed Setpt 2 The control uses the value in Torque Setpoint Use the value in Drop Torque as a guideline in Automatic or Position mode In Cycle mode use Cycle Torque as a guideline Rockwell Automation Publication 20B IN020C EN P January 2014 6 PowerFlex 700 with Vector Control Option Custom Firmware Custom Firmware Parameters cont Parameter Name and Description Values 3 2 E See User Manual for symbol descriptions E 683 Pump Off Config Default 0 Automatic Sets the torque data to use for Pump Off control Options 0 Automatic 1 Position 2 Cyde 684 Oil Well Pump Automatic 0 The downstroke torque is used if the torque waveform synchronizes with previously saved waveform If the position was not found after 6 cycles the cycle torque is used Bit 3 in Pump Off Status indicates if cycle torque is used Position 1 The downstroke torque is used to determine the pump off condition The torque waveform needs to be able to re synchronize with the previously s2. 2508 1846 Publication 20B INO20C EN P January 2014 Supersedes Publication 20B INO20B EN P July 2009 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
3. Pump OffSetup Bit 1 Pos Filter Sets the level of filtering on torque for position calculation 0 light default e 1 heavy the effect on the filter can be seen at testpoint 680 Bit 2 Pos Offset Adjusts correction factor for motor slip in position calculator e 0 400 default e 1 50 to see the effect of this check the timing between the position and torque testpoint 635 and 636 Rockwell Automation Publication 20B INO20C EN P January 2014 4 PowerFlex 700 with Vector Control Option Custom Firmware Pump Stroke Position Initialization Steps cont Step 4 Parameter 682 Pump Off Control Description Disabled pump off control is not active Baseline Set Uses a torque baseline created when the drive is first run first ten cycles IMPORTANT It is critical that this data is gathered from a full well Fixed Setpt Uses the value in parameter 685 Torque Setpoint 683 Pump Off Config e Automatic The downstroke torque is used if the position is found If the position is not found after 6 cycles the cycle torque is used Position The downstroke torque is used to determine the pump off condition e Cycle The cycle torque is used to determine the pump off condition The gear ratio and output speed are used to determine the cycle If the average torque is unstable compare testpoint 717 to the torque waveform Testpoint 717 is the calculated position used
4. 686 Torque Setpoint Default 0 0 Sets the torque level for Pump Off when Pump Off Control is Min Max 0 0 100 0 set to Fixed Setpoint Units 0 1 Pump Off Level Default 5 0 Sets the percent change in torque from the baseline or Min Max 0 0 100 0 setpoint that indicates the well is in a pump off condition Units 0 1 When the pump is started it creates a baseline torque level assuming the well is full For example if the baseline torque is 50 and the Pump Off Level is set to 10 the drive goes into pump off when the torque drops to 45 Rockwell Automation Publication 20B INO20C EN P January 2014 PowerFlex 700 with Vector Control Option Custom Firmware 7 Custom Firmware Parameters cont Parameter Name and Description Values 3 E S See User Manual for symbol descriptions 3 687 Pump Off Speed Default 20 0 Sets the percent drop in speed from the commanded speed Min Max 0 0 100 0 during a pump off condition Units 0 1 688 Pump Off Time Default 600 0 Secs Sets the time the drive continues to run at the reduced Min Max 120 0 60000 0 Secs pump off speed before returning to commanded full Units 0 1 Secs speed and checking if the pump off condition still exists 689 Pump Off Setup Controls additional Pump Off features Lo fs CRE XS SKE SS ANYS 3 x x
5. to determine a full stroke If the position moves compared to the torque the gear ratio can be adjusted to account for the motor slip 684 Pump Off Action Change Spd The speed is lowered when a pump off condition occurs the drive does not stop See Pump Off Speed Always Stop This stops the drive during a pump off condition Stop After 1 The drive first slows down according to the setting in parameter 687 If torque continues to drop the drive stops Stop After 2 The drive slows down according to the setting in parameter 687 twice before stopping 685 Torque Setpoint This sets the level for a pump off condition when Pump Off Control is set to Fixed Setpt 686 Pump Off Level Sets the percentage drop in torque that indicates the well is in a pump off condition The pump off level based on the baseline torque can be seen at testpoint 645 687 Pump Off Speed Sets the speed reduction in percent from the commanded speed that occurs during a pump off condition when parameter 684 is set to Change Spd Stop After 1 or Stop After 2 688 Pump Off Time Sets the time delay before speed recovers from a pump off condition unless torque continues to drop 178 Sleep Wake Mode Direct Uses the time in parameter 688 as the time to remain in pump off condition A digital input also needs to be set for Stop Rockwell Auto
6. 29 The start time for a 24 hour cycle used to determine day 730 Pointer to arrays of data 731 0 13 Number of pump off counts in the past 24 hours that the drive was powered This changes during the current day Number of pump off counts in the previous 13 days The count is pushed down at the end of each day Number 1 is the previous day and 13 is 13 days ago 732 0 13 Stroke count for the current 24 hour period Full stroke count for previous days 733 0 23 Stroke count per hour updated once per hour 0 is the most current 734 0 23 Downstroke or cycle torque updated once per hour 0 is the most current Allen Bradley Rockwell Software PowerFlex and Rockwell Automation are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Rockwell Otomasyon Ticaret A Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Klectlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852
7. Installation Instructions Allen Bradley PowerFlex 700 with Vector Control Option Custom Firmware BA Option Pump Off Function Series B Topic Page Custom Firmware Overview 2 Pump Off Setup 3 Initializing the Pump Stroke Position 3 Custom Firmware Parameters 5 New Selection for Existing Parameters 9 Test Points 9 ATTENTION The custom firmware is designed for a specific application and load condition It differs from the standard PowerFlex 700 Vector Control product offering and must be installed and run only under this custom application Attempting to run this custom firmware under any other type of application can result in unpredictable and or hazardous conditions ATTENTION The drive contains parts and assemblies that are sensitive to electrostatic discharge ESD Static control precautions are required when installing testing servicing or repairing parts and assemblies Component damage can result if ESD control procedures are not followed If you are not familiar with static control procedures refer to Guarding Against Electrostatic Damage Data Sheet publication 8000 4 5 2 or other applicable ESD protection handbook The PowerFlex 700 sensorless pump off function is an enhancement to the basic pumpjack oil well application The pump off function detects when the fluid level in a well drops Programming then determines if the drive slows down or stops pumping The low level detection is accomplished by a
8. alue 656 Parameter 682 Pump Off Control 657 Pump off control state 659 Down average calc 660 Up average calc 661 Output frequency 662 Maximum speed detected during cycle 665 Position with top of stroke offset 666 Peak 1 torque 667 Peak 1 position 668 Peak 2 torque 669 Peak 2 position 670 Valley 1 torque 671 Valley 1 rising position 672 Valley 1 min position 673 Valley 2 torque 674 Valley 2 rising position 675 Valley 2 min position Rockwell Automation Publication 20B INO20C EN P January 2014 PowerFlex 700 with Vector Control Option Custom Firmware 11 Test Points cont Test Point Description 676 Counter for position reconnect 677 Pump status bit 13 Pump off disable input active bit 12 0 Position 1 Cycle torque used bit 11 1 Top of stroke bit 10 Position initialization active bit 9 Sleep mode enabled bit 8 Sleep is active drive is stopped bit 7 Position initialization storing values bit 6 Detected upstroke bit 5 Detected downstroke bit 4 Pump off control active and external disable input off bit 3 Not used bit 2 Drive is at commanded speed bit 1 Upstroke bit 0 Downstroke 678 State of position detector 1 6 and reconnect 7 14 679 Torque used to slope detection 680 Heavily filtered torque used for position detection 682 Filter level for above can be changed 683 Stored values of position 1 for reconnect 684 Stor
9. aseline Disable Function When Pump Off Control is enabled a torque baseline is created each time the drive is started The control uses this baseline when parameter 682 Pump Off Control is set to option 1 Baseline Set The Baseline Disable function disables the calculation of a new torque baseline each time the drive is started When one of the Baseline Disable selections is enabled the drive uses the torque baseline that was previously calculated and saved Ifa Baseline Disable selection is enabled and there is no existing torque baseline torque values in the baseline are zero the drive calculates a torque baseline when it is started and a stable running condition is reached The saved torque baseline is erased when all Baseline Dis selections are off and the drive is running or when Pump Cycle Store is selected Downstroke Torque Function The downstroke torque can change position on some wells If this happens the variance of the torque waveform can change enough that the position synchronization does not work properly This can be seen on the position test point the position continues to reset early To function properly on these pumps the torque waveform is averaged over one cycle Rockwell Automation Publication 20B INO20C EN P January 2014 PowerFlex 700 with Vector Control Option Custom Firmware 3 Pump Off Setup Follow these steps to set up the pump off function eS hae Set pa
10. aved waveform Cycle 2 The full pump cycle torque is used to determine the pump off condition Pump Off Action Default Change Spd 0 Selects if the drive changes speed or stops during a pump Options 0 Change Spd off condition 1 Always Stop 2 Stop After 1 3 Stop After 2 Change Speed 0 When a pump off condition is detected speed is reduced by a selected percentage and runs for the time in parameter 688 If condition continues speed is reduced a second time The pump remains at this speed until the pump off condition no longer exists Always Stop 1 Stops pump when a pump off condition is detected The pump remains stopped for the time entered in Sleep Time parameter 183 Stop After 1 2 When a pump off condition is detected speed is reduced by a selected percentage and runs for the time in parameter 688 The pump stops if torque continues to change at the reduced speed The pump remain stopped for the time entered in parameter 183 Stop After 2 3 When a pump off condition is detected speed is reduced by a selected percentage and runs for the time in Pump Off Time parameter 688 If torque change continues speed is reduced a second time by the selected percentage The pump stops if torque change continues at this reduced speed The pump remains stopped for the time entered in Sleep Time parameter 183 685
11. ed values of position 2 for reconnect 685 Stored values of position 3 for reconnect 686 Stored values of position 4 for reconnect 687 Stored values of position 5 for reconnect 688 Top of stroke position 689 TRUE if pump off stop enable and PO occurred 690 Used to detect stop while sleeping 691 Parameter 684 Pump Off Action 692 2ms counter used in Pump Off timing 693 Pump Off time in drive units 694 TRUE if initializing position 695 Amount of dither for position correction 699 Bus Limit Ki 700 Bus Limit Kp 704 Bus Limit Enable 705 Bus Limit reference 706 Time in msec for a stroke based on gear ratio Rockwell Automation Publication 20B INO20C EN P January 2014 Test Points cont Test Point Description 707 Simulator torque no filtering 708 Position 1 detected during reconnect 709 Position 2 detected during reconnect 710 Position 3 detected during reconnect 711 Position 4 detected during reconnect 712 Position 5 detected during reconnect 713 Full stroke average torque 714 Pump off trip level 1 x100 715 Pump off trip level 2 716 Pump off trip level 3 717 Position used when in full stroke average mode 720 Holds speed reference during startup 721 This shows the sleep time used for pump off it is parameter 183 722 Counts number of times position reconnect restarted 723 Counts number of sleep states same as parameter 690 728 Elapsed time in current day 0 0001 hours 7
12. igital InX Sel added a new selection 61 Baseline Dis Test Points The following test points are provided for pump diagnostics Refer to the PowerFlex 700 AC Drives Frames 0 10 User Manual Vector Control Firmware 4 001 and Up publication 20B UM002 for instructions to access the test points Test Points Test Point Description 635 Calculated pump position 636 Filtered torque 637 Filtered strokes per minute 638 Pump Off Level 639 Average drop torque 640 Count of torque above below pump off setpoint 641 Torque level alarm 642 Torque alarm state 643 Torque alarm timer Rockwell Automation Publication 20B INO20C EN P January 2014 10 PowerFlex 700 with Vector Control Option Custom Firmware Test Points cont Test Point Description 644 Baseline torque calculated on first run or when commanded speed is changed 645 Pump off trip level x100 646 Pump off detector current value x100 647 Speed used during pump off 648 Baseline torque after 1st spd change 649 Pump off trip level 1st change 650 Commanded speed 651 Pump jack state 0 Initialize baseline torque levels 1 Running 2 Delay before returning to run after pump off 3 Pump off 1 baseline 4 Pump off 1 run wait 5 Pump off 2 baseline 6 Pump off 2 run wait 7 Pump off sleeping stopped 652 Counter for torque averaging 655 Storage for average torque v
13. mation Publication 20B INO20C EN P January 2014 PowerFlex 700 with Vector Control Option Custom Firmware 5 Custom Firmware Parameters Advanced Parameter View must be selected parameter 196 Param Access Lvl set to 1 Advanced Parameters 692 through 699 provide various metering points for the function Refer to pages 8 and 9 for descriptions Custom Firmware Parameters File amp Parameter Name and Description Values 3 E S See User Manual for symbol descriptions 3 680 Pump Cycle Store Default 0 Disabled Used to store the torque waveform over the course of a Options 0 Disabled pump cycle This is used to determine the downstoke when 1 Enabled in Automatic or Position mode With the drive running at the desired speed change Pump Cycle Store to Enabled and press enter Over the next few cycles the waveform is stored and Pump Cycle Store changes back to Disabled If after 5 pump cycles Pump Cycle Store has not changed back to Disabled waveform variations can be excessive 2 681 Set Top of Strok Default 0 Disabled 5 Stores the top of pump stroke cycle Options 0 Disabled Zz With the drive running at the desired speed change Set Top 1 Enabled of Strok to Enabled and press enter when the rod is at the S highest position Set Top of Strok automatically changes back to Disabled 682 Pump Off Control Default
14. n algorithm that utilizes dynamic motor data thereby removing the need for external sensors Productivity can be increased by detecting a low well condition and pumping at a slower rate during the pump off condition rather than simply running the pump on a timer Rockwell Allen Bradley Rockwell Software Automation 2 PowerFlex 700 with Vector Control Option Custom Firmware This custom firmware differs from the PowerFlex 700 Vector Control standard firmware version 4 006 Series B in the following ways e Custom firmware parameters see pages 5 through 9 e Parameter 178 Sleep Time maximum value changed from 1000 to 64 800 seconds e The PowerFlex 700 Pump Jack Pump Off custom firmware cannot be updated over PowerFlex 700 firmware For additional drive information including the basic pumpjack oil well parameter descriptions and other standard firmware parameters refer to the PowerFlex 700 AC Drives Frames 0 10 User Manual Vector Control Firmware 4 001 and Up publication 20B UM002 Custom Firmware Overview This section provides an overview of the custom firmware functions Pump Off Function The pump off function can be set to use a torque baseline created when the drive is first run or the commanded speed is changed or a fixed set point A fixed set point is useful if the drive is faulting due to well conditions The drive does not create a new set point based on what can be a pump off condition B
15. rameter 53 Motor Cntl Sel to 4 FVC Vector Set parameter 641 OilWell Pump Sel to 1 Pump Jack Set the following parameters according to your equipment These settings are used to calculate the torque limits based on the gearbox size Parameter 642 Gearbox Rating Parameter 643 Gearbox Sheave Parameter 644 Gearbox Ratio Parameter 645 Motor Sheave Uncouple the motor and the load Run Autotune by setting parameter 61 Autotune to 2 Rotate Tune Raise parameter 83 Overspeed Limit to 20 Hz Set bit 6 Decel Inhibit of parameter 238 Fault Config 1 to disabled 0 Adjust parameter 153 Regen Power Lim to limit the amount the system regenerates to the DC bus TIP Ifa DB resistor is not used we recommend an initial setting of 5 Initializing the Pump Stroke Position Follow these steps to initialize the pump stroke position Pump Stroke Position Initialization Steps Step Parameter Description 1 680 Pump Cycle Store Set with the drive operating at normal speed The drive then calculates the peaks and valleys of the torque signal This is used to determine the downstroke the next time the drive is started 2 681 Set Top of Strok Enable Press Enter when the rod is at the top of the stroke The parameter value changes back to Disabled and the top of stroke position is stored in testpoint 688 Top of stroke occurs when the horse head is at its highest point 3 689
16. unt is Units 0 1 maintained through power cycle Rockwell Automation Publication 20B INO20C EN P January 2014 PowerFlex 700 with Vector Control Option Custom Firmware 9 Custom Firmware Parameters cont a Parameter Name and Description Values E S See User Manual for symbol descriptions 3 698 PumpOff SleepCnt Default 0 0 Shows the number of times a sleep condition has occurred Min Max 0 0 60000 0 since this parameter was reset Count is maintained through Units 0 1 power cycle 699 Day Stroke Count Default Read Only Shows stroke count for the past 24 hours This is a rolling Min Max 0 0 65535 00 counter updated every hour Units 0 1 Uses the powered up clock for timing Once the initial 24 hour period has elapsed it is stored in a 14 day 5 buffer This is an array from 0 13 at testpoint 732 with 732 0 being the current day 732 1 the previous day and so on As each day is stored the Pump Off Count for that 24 hour period is stored in testpoint 731 The array is indexed with value in testpoint 730 With this set up you can access parameters 234 and 235 to view the data and then set parameters 236 and 237 to testpoint 730 to change the day The elapsed time for the current day is shown in testpoint 728 The strokes per hour for the past 24 hours are shown at testpoint 733 This array goes from 0 23 New Selection for Existing Parameters For parameter 361 366 D
17. x x x x x x x x x 0j0 0 0 0 pls 14 13 12 1110 9 8 7 6 5 4 3 21 0 x Reserved v p Bit 3 Option Descriptions Pos Filter Sets level of filtering on torque for position calculation 0 Light 1 Heavy Used to remove extra peaks in the waveform Pos Offset Adjusts correction factor for motor slip in position calculator Set bit if torques and position count are drifting apart Pos Min Trq Adjust the minimum torque threshold for the position detector 0 10 1 Auto Detect Min Torque Cycle PO Pos Use positive level changes for Pump Off in cycle mode 0 Off 1 0n Baseline Dis Disables the calculation of a new torque baseline each time the drive is started The drive uses the torque baseline that was previously calculated and saved Rockwell Automation Publication 20B INO20C EN P January 2014 8 PowerFlex 700 with Vector Control Option Custom Firmware Custom Firmware Parameters cont Parameter Name and Description Values See User Manual for symbol descriptions Group File No Related 690 Pump Off Status Read Only Status of the Pump Off function Pump Stopped A pump off condition was detected and the drive stopped sleeping Cycle Used The cycle torque is used for the pump off detection TopOf Stroke The internal position is between 0 500 Top of stroke is 0 of a pending pump off condition x SESESSS BESS ELS g x x x
18. x x x x xlo ojo olo olo o eeonition rie pis 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 y Reserved Bit Option Descriptions Pump Off Enbl Pump off control enabled Pump Slowed A pump off condition was detected and the drive is running at reduced speed PumpOff Alrm A pump off condition was detected but has not yet triggered event This is a warning a Pump Stable The pump is running at a stable speed and not calculating the baseline torque S Baseline Dis Baseline torque calculation is disabled This bit is set when 689 Pump Off setup bit 4 is enabled or when any of the Digital InX Sel parameters are set to selection 61 692 9 Cycle Torque Default Read Only Shows the average torque for a full cycle Min Max 100 0 200 0 Units 0 1 693 Lift Torque Default Read Only Shows the average rod lift torque Min Max 100 0 200 0 Units 0 1 694 Drop Torque Default Read Only Shows the average rod dropping torque Min Max 100 0 200 0 Units 0 1 695 Stroke Pos Count Default Read Only Shows the pump cycle position The top of the strokeisO Min Max 0 15000 and rolls over at 10 000 Units 0 1 696 Stroke per Min Default Read Only Shows the strokes per minute Min Max 0 00 50 00 Units 0 01 697 Pump Off Count Default 0 0 Shows the number of times a pump off condition has Min Max 0 0 60000 0 occurred since this parameter was reset Co
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