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Application Guide - Rockwell Automation

1. ControlLogix to a 20 COMM C the same Class Instance and Attribute codes apply when doing the message with a SLC a PLC 5 The codes also apply for the 20 COMM E 20 COMM D and 20 COMM R Message Configuration Messagel_Control J X Configuration Communication Tag Message Type CIP Generic ki a Set Attribute Single Source Element p 40_PositionCt ype Source Length E Bytes Service Ela fio Hex Class 93 Hex eaan A Instance 740 Attribute fa Hes Nenta 2 Enable lt 4 Enable Waiting C2 Stark a Done Done Length 0 2 Error Code Extended Error Code T Timed Out Error Path Error T ext Cancel Apply Help The communication path for this example is set to the name of the PowerFlex700S with 20 COMM C shown under the I O Configuration Message Configuration Messagel_ Control X Configuration Communication Tag FFOOS Browse PF FOUS 20D AP004A EN E doc Page 9 of 10 Application Guide Initial System Set up Be sure to complete the Motor Control Motor Data Feedback Config Pwr Circuit Diag Direction Test Motor Tests and Inertia Measure portions of the Start up routine in the HIM Note that the PowerFlex 700S parameters should be programmed as shown in the beginning of this application guideline before Starting the following procedure 1 Please note that the Stegmann Hi Resolution absolute encoders provide absolute position feedback for up to 4096 motor
2. SCANport host products must not be directly connected together via 1202 cables Unpredictable behavior can result if two or more devices are connected in this manner ATTENTION Risk of injury or equipment damage exists Parameters 365 Encdr0 Loss Cnfg 394 VoltFdbkLossCnfg let you determine the action of the drive in response to operating anomalies Precautions should be taken to ensure that the settings of these parameters do not create hazards of injury or equipment damage ATTENTION Risk of injury or equipment damage exists Parameters 383 SL CommLoss Data 392 NetLoss DPI Cnfg let you determine the action of the drive if communications are disrupted You can set these parameters so the drive continues to run Precautions should be taken to ensure the settings of these parameters do not create hazards of injury or equipment damage Page 2 of 10 Application Guide Description The absolute point to point positioning mode may be configured to operate in an absolute mode in firmware revision 1 14 or later The absolute mode allows the point to point position regulator to remain active at all times even when the drive is stopped and restarted In this application guideline a Stegmann Hi Resolution multi turn encoder is also used Stegmann Hi Resolution encoders provide absolute position feedback for up to 4096 motor revolutions These Stegmann encoders can be used to remember their position during power loss for up to 4096 motor re
3. other bits off configures the drive for 2 wire control so that we only need to send one signal to start and Stop the drive from our controller P222 Motor Fdbk Sel 5 FB Opt Port0 This selects the Stegmann Hi Resolution feedback option as the primary feedback source P365 Encdr0 Loss Cnfg 0 Ignore Encoder 0 is not used in this application so the drive is set to ignore it P367 FB Opt0 Loss Cnfg 2 FiltCoastStop Configures the drive to fault and perform a coast stop when feedback loss from the Stegmann is detected P740 Position Control 656770 bits 1 7 8 10 17 and 19 on All other bits are off This is the setting for P740 immediately after a power loss Setting bit 1 Speed Out En allows the output of the position loop to enter the speed regulator Setting bit 7 Absolute Mode allows the drive to track position while stopped and while bit 1 Speed Out En is off Setting bit 8 Xzero Preset causes all of the accumulated registers of the position regulator to be loaded with the following after a power loss P762 Mtr Posit Fdbk P757 Abs Posit Offset The accumulated registers include parameter 744 PositRef EGR Out parameter 747 Position Cmd and parameter 763 Act Motor Posit Bits 17 and 19 are on because they are factory default settings but are not significant for this application guideline Note that the value of P740 will be changed by a message instruction from the controller after power loss and
4. revolutions On the Stegmann Hi Resolution encoder one motor revolution equals 1048576 counts Prior to coupling the motor to the load power up the drive and observe the position feedback value in parameter 762 Mtr Posit Fdbk P762 has a range of 2147483648 counts 2048 revs to 2147483647 2048 revs Manually rotate the motor until a position feedback value is reached that will prevent the encoder from reaching either the positive or negative limit of P762 during full travel of the load Being careful not to rotate the motor couple the motor to the load 2 Turn P151 Logic Command bit 13 PositionEnbl off Then turn P151 Logic Command bit 13 PositionEnbl back on At this point the accumulated registers P744 PositRef EGR Out P747 Position Cmd and P763 Act Motor Posit are loaded with the following P762 Mtr Posit Fdbk P757 Abs Posit Offset Because P757 Abs Posit Offset was set to 0 P744 PositRef EGR Out P747 Position Cmd and P763 Act Motor Posit get loaded with the following P762 Mtr Posit Fdbk Therefore all of the registers have the same value as the absolute Stegmann encoder 3 Assuming that the controller program is running and communicating to the PowerFlex 700S cycle power on the PowerFlex 700S The program will perform the power up re reference and load P758 Pt Pt Posit Ref with the same value as P744 PositRef EGR Out P747 Position Cmd Now the Pt Pt reference is set so that it corresponds to the a
5. set to a negative speed p40 PositionChrl EchoBactk 1 Py41_ Position Status 4 UsewlogRey lt PF 005 UseretinedData 4 1 gt lt PFFO0S UsePetinedD ata O 4 gt PFYOOS O Jog d e a After the user releases UserJogFwd or UserJogRev and the drive is no longer enabled and P740 bit 1 speed output enable is still off we indicate that the jog is complete We must also load P758 Pt Pt Posit Ref with the value in P763 Act Motor Posit so that the drive does not move when started in point to point mode The user s Pt to Pt reference PtPtRotationalRef is also recalculated so that the drive does not move when started in point to point mode 20D AP004A EN E doc Page 6 of 10 Application Guide When the user is not requesting a jog and the drive ts not enabled or if the user requested a normal start then the jog i complete p40 PositionCtrl Echob ack 1 UsenlogFiwd Userlog ew PF O05 Enabled PFF005 User efinedD ata 4 1 gt F e i JogComplete Joglomplete MOV JogCompleteR eset ONS Move Source Pes ActMotorPosit PF 005 UserDetinedD ataf 2097152045 Dest Pie PrPtPosithet PFF005 0 Use efnedD ata 0 gt 2097152000 Dl Divide Source 4 PES ActMotorPostt PF 005 UserDetinedD ataf 20971528048 1046576 Source B PtPtRotationalA ef 2000 0 Dest Detecting Communications After a Power up In order to perform a re refer
6. Allen Bradley Powerfiex Topic Drive Product Introduction User Information Related Publications Application Guide Absolute Point to Point Positioning PowerFlex 700S Phase Control An Application Guide provides generic information on features and functions of drive products and their implementation Application Guides are not specific to any one application but generically discuss application techniques and or functions as part of an application Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www ab com documents gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 document are included solely for illustrative purposes Because of the many variables and requirements associated with any particular in
7. bsolute feedback from the Stegmann encoder Note that if the controller is not running or communicating to the drive verify P740 bits 1 7 8 10 17 and 19 are on Then manually set P758 Pt Pt Posit Ref P747 Position Cmd Position Regulator Tuning Note The speed loop of the drive must be tuned prior to tuning the Position Loop Refer to the Speed PI Regulator Basic Speed Regulator Tuning with Gear Box section of the PowerFlex 700S Reference Manual for details on tuning the speed regulator Typically parameter 768 PositReg P Gain should be set between 1 5 to 1 3 of the speed regulator bandwidth BW found in parameter 90 Spd Reg BW However parameter 768 may be set higher using lead compensation on the Position Regulator Output This is done by configuring the Lead Lag filtering on the position regulator output speed trim 2 filter in a lead configuration making the Lead filter 1 BW Example BW 40 r s setting parameter 25 Strim2 Filt Gain equal to 5 and parameter 26 Strim2 Filt BW equal to 200 will effectively cancel the 1 40 sec lag This will allow a higher position gain for increased stability Tuning parameter definitions Parameter 768 PositReg P Gain 4 Default Sets the position regulator bandwidth Parameter 761 Pt Pt Filt BW 25 Default Sets the bandwidth of a low pass filter This filter affects smoothness at the start of deceleration A high filter bandwidth will produce a more square deceleration torq
8. e do this so that P758 Pt Pt PositRef has the correct absolute value When the PFVO0S comms are ok and the 005 is in point to point e reference mode load P758 with Ped We do this so that P758 PtPtPosithet has the corect absolute value even if the motor was rotated while the dive was powered down P41 Position Status 4 PFFO0S Comms_OK lt PFFO0S UserefinedD ata O 4 gt MOM Move Source Prd Posittmd PFFOOS User efinedD ataf Je 2097152000 Dest Pre PtPtPosithet PFFO0S 0 UserDetinedD atal 2097152000 Rung 6 checks that once communications is okay we are in point to point re reference mode and P758 Pt Pt Posit Ref has been set equal to the accumulated registers we acknowledge the re reference is complete The user s Pt to Pt reference PtPtRotationalRef is also recalculated so that the drive does not move when started in point to point mode First check if the PFYOOS comme are ok Then when the 7005 ts in point to point re reference mode and P758 is equal ta P 4 acknowledge that the powerup re reference is complete Py41_ Position Status 4 PFFOOS CommsOK lt PFYO0S UserDetinedD ata 0 4 gt GU 1 j Equal Source 4 Pr58_PtPtPostAet_EchoB ack PF 005 UserDetinedD atala 2097152000 Source B Pr4r_FPostCmd PF 005 UserDetinedD atali Je 2097152000 FowerpheRet_Complete Fowerdp_ResetRotationalA et ONS E ONS Divide Source A Pra Positlmd PF 005 UserDetin
9. edD ata J 2097152000 Source B 1048576 Dest FPtPA otationalA et 2000 0 Setting the PowerFlex 700S for Point to Point Mode after a Power up Re reference or a Jog After a power up re reference is completed or a jog is completed Rung 7 performs a one shot to move the appropriate setting to P740 Position Control for point to point control and enables the message to change P740 Alter a powerup re reterence i completed or a jog i completed perform a oneshot to load the pt to pt mode setting for P740 Position Control and enable the message to change P40 PowermpReRet Complete PtPtSetting UNS MOV ONS Move Source pr40 PositionChrl PrPtSetting JogComplete B55 46 Dest p40 PositionCtrl BS 746 PtPtSetting_MegEn 20D AP004A EN E doc Page 8 of 10 Application Guide Message Instruction to set P740 Position Control in Volatile Memory When setting P740 Position Control after a power up or for a jog we use a message instruction to write the value to volatile memory see the explanation on page 2 for why we use a volatile message instruction to change P740 When a request to change P740 to its normal setting or its jog setting i made execute the message to change P40 PtPtSetting_MegEn MSG Type CIP Generic Message Control Messagel_Contral JogSetting_MegEn Below is the configuration for setting P740 in volatile memory Although this particular message configuration was for
10. ence for the Pt to Pt reference we must first detect when the drive powers back up after a power loss To do this we look at when the controller reestablishes communications with the 20 COMM module The method by which the user can detect that communications comes back varies by controller and by the communication network used Below is an example of detecting communication between ControlLogix and a 20 COMM C Gets the comm status of the PFYOUS with 20 COMM C Gav 5 Get System Value Class Name MODULE Instance Name PF F005 Attribute Hame Entry Status Dest PFFOOS Comm Status 16897 When the upper 4 bits of the PFYOOS comm status are egual to 4 hes communications is OF MEQ PFFOOS _ Comms OF E Mask Equal Source PFFYOOS Comm _ Status 16897 Mask 164000 Compare 16 4000 20D AP004A EN E doc Page 7 of 10 Application Guide Initializing the Point to Point Reference after a Power up During initial power up P740 was set to its initial value of 656770 which is bits 1 Speed Out En 7 Absolute Mode 8 Xzero Preset 10 Pt Pt ReRef 17 and 19 all on On power up the drive automatically sets the accumulated registers P744 PositRef EGR Out P747 PositCmd and P763 Act Motor Posit equal to P762 Mtr Posit Fdbk Rung 5 checks that the drive is in point to point re reference mode by looking at P741 Position Status bit 4 Pt Pt ReRef Mode Then we can change P758 Pt Pt PositRef to the same value as the accumulated registers W
11. er optic cable connectors General Precautions ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference Allen Bradley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as under sizing the motor incorrect or inadequate AC supply or excessive surrounding air temperatures may result in malfunction of the system ATTENTION Only qualified personnel familiar with the PowerFlex 700S AC Drive and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC amp DC terminals of the Power Terminal Block refer to Chapter 1 in the PowerFlex 700S User Manual for location The voltage must be zero ATTENTION Risk of injury or equipment damage exists DPI or
12. es but are sent out as 32 bit integers or 2 16 bit integers Refer to the appropriate 20 COMM section of the PowerFlex 700S Reference Manual for details on handling floating point data with various networks and controllers Parameter Settings P16 Speed Ref Sel 0 Zero Speed This ensures that the sole source for speed reference is the position regulator There are several ways to accomplish this but by using this method the jog speeds may still be used to manually move the load When using the jog function the position regulator must be disabled to allow the jog reference to move the load Applied LogicCmd Speed Ref Sel Speed Ref 1 Spd Ref1 Divide Speed Ref 2 Spd Ref2 Multi Jog Speed 2 l Speed Ref 4 C14 4 5 Speed Ref 15 Speed Ref DPI P17 Jog Speed 1 100 RPM Sets the speed for a jog forward P18 Jog Speed 2 100 RPM Sets the speed for a jog reverse 20D AP004A EN E doc Page 4 of 10 Application Guide P151 Logic Command Bit 13 PositionEnbl on All other bits off This parameter although called logic command does not come from the controller Setting bit 13 PositionEnbl enables the position regulator to allow tracking position while stopped and while parameter 740 Position Control bit 1 Speed Out En is turned off P153 Control Options bit 0 Bipolar Sref on all other bits off Bit 0 enables a bipolar speed reference so we can send a positive and negative jog speed All
13. for doing jogs P740 is not set by a datalink from the controller because datalinks write to volatile memory not written to EEPROM so during power up any parameters written to by a datalink are temporarily set to zero P740 cannot be set to zero because bit 8 needs to be permanently set even on power up or the accumulated registers will be reset to zero Instead of a datalink we set P740 directly in the drive so that bits 1 7 8 and 10 17 and 19 are set in non volatile memory and will always be on during power up Then when we need to change P740 a message instruction is used to write to volatile memory P742 Posit Ref Sel 2 Pt to Pt This selects point to point mode and selects parameter 758 Pt Pt Posit Ref as the reference Posit Ref Sel source for the position regulator Position Control Position Status Pt Pt ReRef PtPtRRef Act P757 Abs Posit Offset 0 When P757 Abs Posit Offset 0 the accumulated registers get loaded with the following value after a power loss or toggling of P151 bit 13 P762 Mtr Posit Fdbk P757 Abs Posit Offset P762 Mtr Posit Fdbk 0 Mtr Posit Fdbk P838 Digln1 Sel 0 Not Used Set to Not Used for AC input applications Digln1 is a default of 14 PreChrg Disc which is used only for common dc bus applications P850 ParamAccessLevel 1 Advanced Set to allow access to all parameters from the HIM 20D AP004A EN E doc Page 5 of 10 Application Guide Contr
14. oller Configuration Controlling the PowerFlex 700S in Point to Point Mode For starting in Pt to Pt mode the drive was configured for 2 wire maintained start Rung 0 checks to see that the P740 Position Control bit 1 Speed Out En is on and that the drive is not in re reference mode before allowing a start Rung 1 sends the user s Pt to Pt reference to the drive when the drive is not in re reference mode and after the drive is enabled PtPtRotationalRef can be scaled by the user for any desired units In this example PtPtRotationalRef was scaled so that 1 unit equals 1 motor revolution The Stegmann counts 1048576 22 counts per motor revolution When user requests a start for point to point mode the speed output must be enabled and we must not be in re eference mode before starting the PFFOOS p40 PositionCtrlEchoB ack 1 PY41_ Position Status 4 UserStart_PtPt lt PFO0S UseretnedD ata 4 1 gt lt PF O05 ee etnedD ata O 4 gt PF 005 0 Start f When not in point to point e reference mode and the drive is enabled P758 is calculated from the rotational reference where a value of 1 equals 1 motor rew Pr4l_Fostion Status 4 PFFO0S CommsOK lt PFFO0S UseDetinedData O 4 gt PF700S IEnabled k UL i Multiply Source PtPthotationalH et 18 47652 Source B 1048576 Dest Pree PrPtPosithet PFYO05 0 UserDetinedD ata 0 gt 1410 Performing a Jog After the user requests the jog UserJogFwd o
15. r UserJogRev Rung 2 performs a one shot to move the appropriate value to P740 Position Control and request a enable the message to change P740 The value for P740 is 655744 bits 7 8 17 and 19 on The significant setting here is that bit 1 speed output enable is off so that the output of the point to point loop is no longer going to the speed regulator Rung 3 sends a jog forward command to the drive while the user is requesting the jog and we verified that P740 bit 1 speed output enable is off and the drive is not in re reference mode Rung 4 sends a jog reverse command When the user commands a jog and the message to change P 40 is not enabled perform a oneshot to set P740 for jogging and execute the message to change P740 UsentogF wid JogSetting ONS MOM 2 ONS Move Source P40 PositionCtrl JogS etting Userloghey E557 44 E Dest p40 _PositionCtr 655 46 JogSetting_MegEn When the user requests a jog forward the speed output must be disabled and we must not be in e reference mode before sending the PF 00S a command to jog using jog speed 1 Jog speed 1 Is set to a positive speed p40 PositionChrl EchoBack 1 P41 Position Status 4 UserlogFiuvd lt PFFO0S UserbefinedData 4 1 gt lt PFYO0S UsePetinedD atal0 4 gt PF FO0S 0 og 3 a R T When the user requests a jog reverse the speed output must be disabled and we must not be in re reterence mode before sending the PF O0S a command to jog using jog speed 2 Jog speed 2 iz
16. stallation 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 document Reproduction of the contents of this document in whole or in part without written permission of Rockwell Automation Inc is prohibited The following publications should be referenced and followed when operating configuring or commissioning this drive product These publications may be found on the automation book store at www theautomationbookstore com Publication Title Pub Number PowerFlex 700S Phase Control User Manual 20D UM001 PowerFlex 700S Phase Control Reference Manual PFLEX RM002 PowerFlex 700S Phase Control Firmware Release Notes 20D RNO04 PowerFlex 700S Phase Control Quick Start 20D QS001 20 COMM x User Manuals 20COMM UM00x Also the Application Set AS_PF700S_AbsPtPtPosition is used in conjunction with this Application Guide AD Alien bradiey Balance am DODGE BDC WELL dian Rockwell 20D AP004A EN E doc Sept 19 2003 Automation Precautions gt PePePPERPPRP gt D 20D AP004A EN E doc Application Guide Class 1 LED Product ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fib
17. to store and select the point to point positions send the selected point to point position reference to the drive and trigger the power up initialization of the drive s position loop Although the initial commissioning configuration values are set at the drive parameter level in this example they may also be set from the controller if necessary An optional manual jog function is also described in this example 20D AP004A EN E doc Page 3 of 10 Application Guide Drive Configuration Required Links soe E Parameter Parameter Parameter 22 Speed Trim2 318 Posit Spd Output Default Link Destination Name Source Name Purpose Parameter Parameter Data Out A1 Int Position Status Position Regulator Status Word Data Out A2 Int Position Cmd Accumulated Position Command Data Out B1 Int Act Motor Posit Accumulated Motor Position Feedback Data Out B2 Int Data In A1 Echo back of Pt Pt Posit Ref for initialization process Data Out C1 Int Position Control Echo back of Position Control Optional Links Parameter Parameter 715 XReg Spd LoLim lt 714 Data In B2 Real Minimum Positioning Speed scaled so 1 per unit P4 Motor NP RPM 776 XReg Spd HiLim lt 716 Data In C1 Real Maximum Positioning Speed scaled so 1 per unit P4 Motor NP RPM Note P759 760 775 and 776 are all floating point In the controller they can be floating point tags or address
18. ue one with a higher level of jerk Typical values are 5 to 100 rad sec A Zero value will bypass the filter Tail out is influenced mainly by parameter 768 If parameter 768 is set too high this will result in unstable operation at the end of the move Do not attempt to set the accel decel rates of the point to point position regulator faster than can be accomplished by the speed regulator bandwidth Attempting to do so will cause instability in the position regulator Do not attempt to operate at the torque limits of the drive motor combination 20D AP004A EN E doc Page 10 of 10
19. vs As presented in this application guideline an external controller and a 20 COMM x module on the drive may be used when absolute positioning is required Although not shown in this application guideline DriveLogix may also be used when absolute positioning is required Below is a block diagram of the Point to Point Position Regulator Posie Perap lt 744 gt PositRef EGR Out Or FS N Position Cmmd See Interpolated Direct 77741 F77 D Position Control Diagram I ar Ra pa C747 Page 6 PositRef EGR Mul PositRef EGR Div Position Control Position Status Pt Pt ReRef PtPtRRef Act Posit Offset 1 Posit Offset 2 X Offst SpdFilt Position Control X Offset Pol Position Control X Offset Ref Logic Ctrl State Position En 157 03 Logic Cntrl State 8G5 Output Enable Posit Spd Output Mtr Posit Edbk Position Error r SI from Speed Posit lt 762 gt o gt 769 gt K318 Fdbk 9H2 W to Speed Control l Position Status Regulator 3A2 Point to Point Position to Point Position wE X Spd LLim C741 X Spd HLim 2 lt 763 X Act Motor Posit Bie celine XReg Spd an XReg Spd HiLim PositReg P Gain ST Pt Pt Filt BW Pt Pt Accel Time P l Overview The example presented in this paper is a point to point application requiring absolute positioning A Stegmann Hi Resolution encoder is used for absolute position feedback An external controller is used

Application Guide - Rockwell Automation

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