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Allen-Bradley PowerFlex 755 User Manual

Allen-Bradley PowerFlex 755
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Rockwell Automation Publication MOTION-UM003K-EN-P - January 2019 327
Out of Box Configuration for PowerFlex Drives Appendix B
Why Does The Axis Reverse Direction When Stopped and Started?
While an axis is jogging at its target speed, you stop the axis. Before the axis
stops completely, you restart the jog. The axis continues to slow down and then
reverses direction. Eventually the axis changes direction again and moves in the
programmed direction.
Example
You use a Motion Axis Stop (MAS) instruction to stop a jog. While the axis is
slowing down, you use a Motion Axis Jog (MAJ) instruction to start the axis
again. The axis continues to slow down and then moves in the opposite
direction. Eventually it returns to its programmed direction.
Look For
Cause
When you use an S-curve profile, jerk determines the acceleration and
deceleration time of the axis:
An S-curve profile has to get acceleration to 0 before the axis can speed
up again.
If you reduce the acceleration, it takes longer to get acceleration to 0.
In the meantime, the axis continues past 0 speed and moves in the
opposite direction.
S-curve profile in the
instruction that starts
the motion.
Stop Type is set to a specific type of
motion, such as Jog or Move.
The stopping instruction changes
the deceleration. For example, the
Change Decel operand of an MAS
instruction is set to No. This No
means that axis uses its maximum
deceleration rate.

Table of Contents

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Allen-Bradley PowerFlex 755 Specifications

General IconGeneral
CategoryAC Drive
Amperage2.2…1470 A
Output Voltage0 to Input Voltage
Output Current2.2…1470 A
EnclosureIP20, IP30, IP54
CommunicationsEtherNet/IP, ControlNet, DeviceNet
I/ODigital, Analog, Encoder, Relay
SafetySafe Speed Monitor
Protection FeaturesOvercurrent, Overvoltage, Undervoltage, Overload, Short Circuit, Ground Fault, Overtemperature
Operating Temperature-10°C to 50°C (14°F to 122°F)
Storage Temperature-40°C to 70°C (-40°F to 158°F)
Humidity5…95% noncondensing
AltitudeUp to 1000m (3300ft) without derating
Voltage200-240V AC, 380-480V AC, 500-600V AC, 690V AC
Input Voltage200-240V AC, 380-480V AC, 500-600V AC, 690V AC
Control MethodSensorless Vector

Summary

Components of a Motion System

Controller, Communication, Drive, and Software Options

Overview of Logix controllers, EtherNet/IP network requirements, and necessary software for integrated motion.

Controller and Ethernet Communication Module Options

Details on controller types and minimum Studio 5000 Logix Designer versions for motion and safety applications.

Integrated Motion on EtherNet/IP Drive Software Options

Lists required software versions for Studio 5000 Logix Designer and RSLinx Classic for integrated motion systems.

Integrated Motion on EtherNet/IP Drives

Details the EtherNet/IP drives available for integrated motion control applications.

Configuration and Startup Scenarios

Outlines the two main approaches to setting up an integrated motion solution: connecting hardware first or configuring software first.

Help for Selecting Drives and Motors

Guides users on using Motion Analyzer to select appropriate drives and motors based on application requirements.

Create a Project for Integrated Motion on the EtherNet/IP Network

Create a Controller Project

Step-by-step instructions for creating a new project in Logix Designer application for motion control.

Set Time Synchronization

Explains the importance and configuration of CIP Sync for time synchronization in distributed motion control applications.

Add an Ethernet Communication Module

Provides instructions on how to add an Ethernet communication module to a Logix Designer project if needed.

Configure Integrated Motion Control Using Kinetix Drives

Add a Kinetix EtherNet/IP Drive

Instructions for adding Kinetix 350, 5500, or 6500 EtherNet/IP drives to a Logix Designer project.

Configure the Safety Category - Kinetix 5500 Drives

Details on configuring the safety category for Kinetix 5500 drives with integrated safety connections.

Configure the Power Options

Guides users on setting power options, bus regulator action, and shunt resistor type in Logix Designer.

Configure Digital Inputs

Explains how to enter digital input values for Kinetix 5500 and 6500 drives in Logix Designer.

Create an Associated Axis

Describes the process of creating an axis and associating it with a Kinetix drive within the project.

Create a Motion Group

Instructions for creating a motion group to organize and manage motion axes within the Logix controller.

Set the Base Update Period

Details on configuring the Base Update Period (RPI) for Ethernet communication between controller and motion module.

Configure the Axis Properties

Guides on configuring axis properties using dialog boxes, adapting to feedback configuration choices.

Configure the Associated Axis and Control Mode

Explains how to configure associated axis properties and determine the control mode based on attributes.

Specify the Motor Data Source

Details on selecting the origin of motor configuration values: database, nameplate, or nonvolatile memory.

Display Motor Model Information

Describes how the Motor Model category displays information based on motor type and data source.

Assign Motor Feedback

Explains how to select and configure motor feedback devices based on general dialog box settings.

Configure the Load Feedback

Details how to configure load feedback information from devices coupled to the load-side of mechanical transmission.

Configure the Master Feedback

Guides on configuring master feedback when the General category is set to Master Feedback.

Configure Feedback Only Axis Properties

Instructions for creating external encoder modules and configuring feedback-only axis properties.

Configure Integrated Motion Control Using Kinetix 5700 Drives

Add a Kinetix 5700 EtherNet/IP Drive

Instructions for adding a Kinetix 5700 EtherNet/IP drive, including DC-bus power supply configuration.

Configure the DC-bus Power Supply and Associate an Axis

Steps to configure the DC-bus power supply and associate an axis with the Kinetix 5700 drive.

Configure the Regenerative Bus Supply

Instructions for configuring the regenerative bus supply for Kinetix 5700 drives, including selecting the correct supply.

Continue Inverter Configuration

Details on defining feedback options for each axis after establishing Kinetix 5700 inverters in Logix Designer.

Configure the Inverter Drives

Procedure for configuring Kinetix 5700 inverter drives, including single-axis and dual-axis types.

Configure Module Definition

Guides on selecting safety application mode, connection mode, and power structure for module definition.

Configure the Power and Safety Options

Steps to configure power options and safety settings for Kinetix 5700 drives in Logix Designer.

Configure Digital Inputs

Explains how to configure digital inputs for Kinetix 5700 drives, including selecting input functions and descriptions.

Create an Associated Axis and Establish Feedback Assignments for an Inverter Drive

Details on defining feedback options for each axis and establishing feedback port assignments for Kinetix 5700 drives.

Create a Motion Group

Instructions for creating a motion group to manage Kinetix 5700 axes, ensuring proper configuration.

Set the Base Update Period

Guides on setting the Base Update Period (RPI) for Ethernet communication for Kinetix 5700 drives.

Configure the Axis Properties

Details on configuring axis properties for Kinetix 5700 drives, including general, motor, and feedback settings.

Configure the Associated Axis and Control Mode

Explains how to configure associated axes and determine the control mode for Kinetix 5700 drives.

Specify the Motor Data Source

Guides on selecting the motor data source (Catalog Number, Nameplate, or Motor NV) for Kinetix 5700 drives.

Display Motor Model Information

Describes how to display motor model information based on the selected motor type and data source.

Assign Motor Feedback

Instructions for assigning motor feedback for Kinetix 5700 drives, including selecting feedback type and units.

Configure the Load Feedback

Details on configuring load feedback information for Kinetix 5700 drives, including device specification.

Configure the Master Feedback

Guides on configuring master feedback for Kinetix 5700 drives, ensuring proper information entry.

Configure Integrated Motion Using a PowerFlex 755 Drive

Add a PowerFlex 755 Drive

Step-by-step instructions for adding a PowerFlex 755 drive to a Logix Designer project.

Select a Peripheral Feedback Device and Slot Assignment

Guides on selecting peripheral feedback devices and assigning ports/channels for PowerFlex 755 drives.

Select an I/O Device

Instructions for selecting an I/O card as a peripheral device on port 7 for PowerFlex 755 drives.

Assign a Power Structure

Details on assigning the appropriate power structure for a PowerFlex 755 drive configuration.

Configure Power Options

Guides on setting bus regulator action, shunt resistor type, and configuring power limits for PowerFlex 755 drives.

Configure Digital Inputs

Explains how to enter digital input values for PowerFlex 755 drives based on peripheral device configuration.

Create an Axis for a PowerFlex 755 Drive

Step-by-step guide to creating an axis and associating it with a PowerFlex 755 drive in Logix Designer.

Establish Feedback Port Assignments

Instructions for associating an axis to a PowerFlex 755 drive by manually establishing motor feedback port/channel assignments.

Create a Motion Group

Guides on creating a motion group to organize axes for PowerFlex 755 drive configuration.

Set the Base Update Period

Details on configuring the Base Update Period for Ethernet communication and motor feedback for PowerFlex 755 drives.

Configure the Axis Properties

Instructions on configuring axis properties for PowerFlex 755 drives, including general, motor, and scaling settings.

Configure the Associated Axis and Control Mode

Explains how to configure associated axes and determine control modes for PowerFlex 755 drives.

Specify the Motor Data Source

Guides on selecting the motor data source (Catalog Number, Nameplate, or Drive NV) for PowerFlex 755 drives.

Configure Integrated Motion Using a PowerFlex 527 Drive

Set the Network Configuration

Instructions for setting network configuration (IP address, gateway, subnet mask) using the drive's LCD display.

Add a PowerFlex 527 Drive

Step-by-step guide to adding a PowerFlex 527 drive to a Logix Designer project.

Configure the PowerFlex 527 Drive

Guides on configuring the drive's safety connection type: hard-wired or integrated safety connections.

Configure the Drive with Hard-wired Safety Connections

Instructions for configuring PowerFlex 527 drives with hard-wired safe torque off (STO) connections.

Configure the Drive with Integrated Safety Connections

Details on configuring PowerFlex 527 drives with integrated safety connections using Motion and Safety mode.

Configure Power Options

Guides on setting PWM frequency, bus regulator action, and shunt resistor type for PowerFlex 527 drives.

Configure Digital Inputs

Explains how to enter digital input values for PowerFlex 527 drives, including Home and Registration inputs.

Create an Axis for a PowerFlex 527 Drive

Steps to create and configure an axis for a PowerFlex 527 drive after adding it to the project.

Create the Motion Group

Instructions for creating a motion group to organize axes for PowerFlex 527 drive configuration.

Configure the Axis Properties

Guides on configuring axis properties for PowerFlex 527 drives, covering general, motor, and feedback settings.

Configure the Associated Axis and Control Mode

Explains how to configure associated axes and determine control modes for PowerFlex 527 drives.

Axis Scheduling

About Axis Scheduling

Explains how Axis Scheduling improves controller performance by reducing utilization and allowing different update rates.

Timing Model

Describes the general timing models for integrated motion on EtherNet/IP: One Cycle and Two Cycle.

Axis Scheduling Configuration

Details on using the Axis Schedule Panel in Studio 5000 Logix Designer to configure update periods.

Configure the Update Periods

Step-by-step instructions for configuring Base, Alternate 1, and Alternate 2 update periods for axes.

Motion Utilization

Explains how to interpret utilization metrics in real-time and adjust configuration to manage controller performance.

Configuration Examples for a Kinetix Drive

Example 1: Position Loop with Motor Feedback Only

Demonstrates configuring an axis for Position Loop with only motor feedback using a Kinetix 6500 drive.

Example 2: Position Loop with Dual Feedback

Illustrates configuring an axis for Position Loop with dual feedback using a Kinetix 6500 drive.

Example 3: Feedback Only

Shows how to create a feedback-only axis using the AUX Feedback port as Master Feedback on a Kinetix 6500 drive.

Example 4: Kinetix 5500 Drive, Velocity Loop with Motor Feedback

Demonstrates configuring a Kinetix 5500 drive for Velocity Loop with motor feedback.

Example 5: Kinetix 350 Drive, Position Loop with Motor Feedback

Illustrates configuring a Kinetix 350 drive for Position Loop with motor feedback.

Example 6: Kinetix 5700 Drive, Frequency Control with No Feedback

Shows configuring a Kinetix 5700 drive for Frequency Control with no feedback.

Example 7: 842E-CM Integrated Motion Encoder with Master Feedback

Demonstrates configuring an 842E-CM encoder with master feedback for a feedback-only axis.

Axis Configuration Examples for the PowerFlex 755 Drive

Example 1: Position Loop with Motor Feedback Via a UFB Feedback Device

Demonstrates configuring a PowerFlex 755 drive axis for Position Loop with motor feedback via a UFB device.

Example 2: Position Loop with Dual Motor Feedback Via a UFB Feedback Device

Illustrates configuring a PowerFlex 755 drive axis for Position Loop with dual motor feedback via a UFB device.

Example 3: Velocity Loop with Motor Feedback Via a UFB Feedback Device

Shows configuring a PowerFlex 755 drive axis for Velocity Loop with motor feedback via a UFB device.

Example 4: Velocity Loop with No Feedback

Demonstrates configuring a PowerFlex 755 drive axis for Velocity Loop with no feedback.

Example 5: Frequency Control with No Feedback

Illustrates configuring a PowerFlex 755 drive axis for Frequency Control with no feedback.

Example 6: Torque Loop with Feedback

Shows configuring a PowerFlex 755 drive axis for Torque Loop with motor feedback.

Axis Configuration Examples for the PowerFlex 527 Drive

Example 1: Frequency Control with No Feedback

Demonstrates configuring a PowerFlex 527 drive axis for Frequency Control with no feedback.

Example 2: Velocity Control with Motor Feedback

Illustrates configuring a PowerFlex 527 drive axis for Velocity Control with motor feedback.

Example 3: Position Control with Motor Feedback

Shows configuring a PowerFlex 527 drive axis for Position Control with motor feedback.

Commission an Axis

Scaling

Explains how to specify axis motion in desired units by configuring scaling factors and load types.

Hookup Tests

Details on performing hookup tests to check cabling, polarity, and encoder functions for axis setup.

Polarity

Information on setting motor, motion, and feedback polarity, and how to verify settings.

Autotune

Guides on using Autotune to improve performance by automatically adjusting tuning parameters.

Load

Details the characteristics of the motor load, including inertia, torque offset, and backlash compensation.

Load Observer

Explains the Load Observer feature for estimating mechanical load and compensating for disturbances.

Adaptive Tuning

Describes the Adaptive Tuning feature that continuously adjusts loop gains and parameters for changing load conditions.

Test an Axis with Motion Direct Commands

Instructions on using Motion Direct Commands to issue motion commands online for testing and troubleshooting.

Access Motion Direct Commands for an Axis or Group

Details on accessing Motion Direct Commands via the Controller Organizer for groups or individual axes.

Understanding STO Bypass When Using Motion Direct Commands

Explains STO bypass functionality and considerations when using Motion Direct Commands with safety controllers.

Homing

Guidelines for Homing

Provides guidelines on configuring homing procedures, including mode, sequence, position, offset, direction, and speed.

Examples

Presents examples of active and passive homing sequences to illustrate different homing methods.

Active Homing

Details the active homing mode, including axis activation, motion cancellation, and home sequence configuration.

Passive Homing

Explains passive homing mode where the controller redefines position based on encoder marker or home sensor.

Absolute Position Recovery (APR)

Describes APR feature for retaining machine reference or absolute position after power cycles or reconnections.

APR Faults

Details conditions that generate APR faults, including attribute changes and axis feedback changes.

Saving an ACD File Versus Upload of a Project

Explains how saving a project as an .ACD file can help recover absolute position after a download.

Manual Tune

When to Manually Tune an Axis

Provides a process to determine if manual tuning is required after checking software defaults and Autotune results.

Current Tuning Configuration

Describes the Manual Tune dialog box, displaying current tuning configuration and loop response settings.

Loop Responses

Explains how to enter values for system bandwidth and system damping, affecting loop gains.

Motion Generator and Motion Direct Commands

Introduces Motion Generator for basic control and Motion Direct Commands for manual tuning and testing.

Additional Tune

Provides access to advanced tuning parameters like feedforward, compensation, filters, limits, and planner.

Feedforward Parameters

Guides on adjusting velocity and acceleration feedforward parameters using the Feedforward tab.

Compensation Parameters

Details on inputting scaling gain and friction offset values using the Compensation tab.

Filters Parameters

Explains how to input torque values, including low pass and notch filters, using the Filters tab.

Limits Parameters

Guides on inputting peak, velocity, and acceleration or deceleration limits using the Limits tab.

Planner Parameters

Details on inputting maximum values for acceleration and deceleration using the Planner tab.

Configure Torque Values

Instructions for configuring advanced servo loop settings like torque values.

Monitor Tags with the Quick Watch Window

Explains how to use the Quick Watch window to monitor program tags while executing commands.

Use Motion Generator

Guides on using the Motion Generator for basic control of a closed-loop servo axis.

Status, Faults, and Alarms

Faults and Alarms Dialog Box

Displays the status of faults and alarms in the controller for an axis, with options to clear logs.

QuickView Pane

Provides a quick summary of faults and alarms related to the selected axis in the Controller Organizer.

Data Monitor

Explains where to read and write values assigned to specific tags, both online and offline.

Drive Status Indicators

Directs users to publications for complete information on drive status indicators.

Connection Faults and Errors

Provides information on connection conditions between controller and module, and common connection errors.

Troubleshoot Faults

Identifies types of motion faults and provides guidance on troubleshooting them.

Manage Motion Faults

Explains how to configure motion faults to cause a major fault and shut down the controller.

Configure the Exception Actions for AXIS_CIP_DRIVE

Details on setting exception actions to define how an axis responds to different types of faults.

Inhibit an Axis

Instructions on how to block the controller from using an axis that has faulted or is not installed.

Example: Inhibit an Axis

Provides a graphical example of inhibiting an axis, including verification and trigger conditions.

Example: Uninhibit an Axis

Illustrates the process of uninhibiting an axis, including trigger conditions and verification.

Digital I/O Status Indicators

Explains how to view axis status, including digital I/O indicators, and their meanings.

Parameter Group Dialog Boxes

Parameter Dialog-box Listings

Describes parameter group dialog boxes and how to access associated parameters via the dialog box.

Out of Box Configuration for PowerFlex Drives

Program a Velocity Profile and Jerk Rate

Describes how to program velocity profiles (Trapezoidal, S-curve) and jerk rate for motion instructions.

Choose a Profile

Compares Trapezoidal and S-curve profiles, considering cycle time and smoothness for acceleration/deceleration.

Use % of Time for the Easiest Programming of Jerk

Explains how to use % of Time to specify jerk, simplifying acceleration/deceleration programming.

Velocity Profile Effects

Summarizes the differences between Trapezoidal and S-curve profiles regarding ACC/DEC time and motor priority.

Jerk Rate Calculation

Provides formulas for calculating jerk parameters for S-curve profiles in engineering units.

Enter Basic Logic

Describes motion control instructions and programming languages available in Studio 5000 Logix Designer.

Example Motion Control Program

Illustrates a Ladder Logix example that demonstrates homing, jogging, and moving an axis.

Download a Project

Step-by-step instructions for downloading a project to a controller, including mode selection and confirmation.

Choose a Motion Instruction

Guides on selecting motion instructions and checking availability as Motion Direct Commands.

Troubleshoot Axis Motion

Helps troubleshoot common situations encountered when running an axis, such as acceleration or overshoot issues.

Why Does My Axis Accelerate When I Stop It?

Explains why an axis might accelerate briefly before decelerating when a stop instruction is issued.

Corrective Action

Provides corrective actions for issues like axis acceleration/deceleration and jog restart delays.

Why Does The Axis Reverse Direction When Stopped and Started?

Explains potential causes for axis reversal when stopped and restarted, often related to S-curve profiles.

Programming with the MDSC Function

Details programming motion with the MDSC functionality, illustrating slave speed control from master.

PowerFlex Out-of-Box Configuration

Provides initial out-of-box settings for PowerFlex drives before application-specific configuration.

Recommended Out-of-Box Settings

Lists recommended default settings for PowerFlex 527 and 755 drives for ramp velocity and current limits.

Setting the ACO/AVO Attributefor PF527 Drives Only

Explains how to set the ACO/AVO attribute for PowerFlex 527 drives to configure analog output for current or voltage.

Glossary

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