Powerflex 700s Phase 2 - Disable Control Motion

[MarceAA]

Hello.
We have a Powerflex 700s phase II firmware 4.002, but the encoder card is burned. We want to disable it to use the Drive without motion control. We try some configurations found it in the web, but the parameters mentioned are different of the parameters that we have in the Drive. When we start it from the HIM, the Drive stop immediately but we don't have any failure.

We have these parameters configuration:
Parameter 1 = 460 V
Parameter 2 = 140 Amp
Parameter 3 = 60 Hz
Parameter 4 = 1785 RPM
Parameter 5 = 125 Hp
Parameter 6 = HP
Parameter 7 = 4 Poles
Parameter 10 - Speed Ref 1 = 100.00
Parameter 12 - Speed Ref 2 = 0.00
Parameter 27 - Speed Ref A Sel - 12 [DPI Port 1 - HIM]
Parameter 28 - Speed Ref B Sel - 1 [Speed Ref 1]
Parameter 222 - Sensorless [Mtr Fdbk Sel Pri]
Parameter 223 - Motor Sim [Mtr Fdbk Sel Alt]
Parameter 365 = 1 [Alarm]
Parameter 485 = 0 [FOC]

During the validation tests, we used 'Drive Executive Lite' to check the Parameters and the status was 'At Limit' the Parameter with the Warning was 344 - OL ClsLp CurrLim. But none Alarm.
Then we used CCW Software to check it too. We saw a warning in Parameter 50 – Selected SpdRefB = 178500.00.

We start the drive, but it stops immediately without any alarm or value in the Parameter 677 = 0, maybe it was so quicky the change that we couldn't see a value. If we press the Stop button from the HIM, We can see this Stop command in the Parameter 677.
After that we changed these parameters into to Alarm
Parameter 368 – Cnv NotLogin Cfg = 1 [Alarm]
Parameter 370 – HiHp InPhsLs Cfg = 1 [Alarm]
Parameter 371 – Mtr OL Trip Cnfg = 1 [Alarm]
Parameter 374 – Motor Stall Cnfg = 1 [Alarm]
Parameter 379 – Ext Flt/Alm Cnfg = 1 [Alarm]
Parameter 381 – PreChrg Err Cnfg = 1 [Alarm]
Parameter 382 – MC Cmd Lim Cnfg = 1 [Alarm]
Parameter 391 – DPI CommLoss Cfg = 1 [Alarm]
Parameter 392 – NetLoss DPI Cnfg = 1 [Alarm]
Parameter 394 – VoltFdbkLossCnfg = 1 [Alarm]
Additionally, the Parameter 406 - Power Loss Mode = 2 [Continue]

We Started the Drive and start moving but the effect we saw was the Drive start moving to Forward and then changes to Reverse.
The Start command was from the HIM and the same effect was even when We start it with the Jog button from the HIM. So, the Motor looks like dancing moving to Forward and then to Reverse, like the Drive doesn't have the correct feedback.

The drive stops until one of these alarms:
Code 10 = Drive Powe Loss
Code 42 = DC Bus Undervolt [We are not using any break for the motor]
And the Value of Parameter 677 = 0.

¿Do you have any idea why the Drive try to start in both directions?
¿Any recommendation?

Thank you.

 

[TugboatEng]

I have done this on this drive but not in some time. Parameter 222 to sensorless is correct. You also need to set the fault response to ignore. If you have it on alarm your PLC may still default to stop. Generally, you're going to need to increase your minimum speed.

DC Bus Undervoltage indicates a different fault. Do you have the manual? It has troubleshooting instructions for each fault condition. The manual is available free online through Allen-Bradley.

No brake would typically result in DC Bus Overvoltage.

Your drive is very old and considered to be at end of life by the manufacturer. It is possible to get yours repaired like new but they will recommend replacing with the 753 series.

 

[MarceAA]

Hi TugboatEng, Thanks for your help.

I don’t have it connected to the PLC now. We are testing it just in manual before connect It to the PLC.

We had to enable all these Alarms because the drive was stopping immediately without any alarm. But not all the alarms can be set to ignore, for example the Parameter 365 Fdbk LsCnfg Pri - just have 2 options [1 = Alarm. 2 =FitCoastStop].

¿Do you know why the Drive send the both directions command???

¿Do you remember the firmware of the Drive that you modified ???

¿Is It possible that you can share with me a backup of that Drive??? to verify the other parameters please.

Thank you.

 

[TugboatEng]

If you have your drive in senseless mode then parameter 365 should be irrelevant.

What have you done to troubleshoot the DC bus undervoltage? I believe this issue needs to be corrected before any other troubleshooting.

 

[iop95]

What motor type is connected?

 

[MarceAA]

Hi TugboatEng,

Thank you.

We disabled all the Alarms and the 365 passed to FitCoastStop. But the Drive stop immediately without any alarm, the Drive try to start but immediately the Drive stop.
And in the Parameter 677 = 0.

We tested with a Lights structure in place of the motor, but we didn't have that problem.

At this moment we are waiting for another motor to review if the problem continue in this new one.

Additional, I want to understand why the Drive sent both directions command at the moment of we enable all the alarms even when we just send the forward command. It looks like the drive doesn't find the reference and send the other direction command trying to find it.

 

[MarceAA]

Hi iop95

Thank you.

We are using a AC - Three Phase Synchronous Motor.
Any recommendation?

 

[iop95]

3 phase synchronous motors need a rotor position feedback (encoder/resolver).
So drive can't be in sensorless mode as is FOC. This mode is ok for induction motor.
May you provide p/n of motor or documetation? Are you sure is synchronous? At param 4 is set 1785rpm...


Seems that FOC motor model/control is not ok, switching fast to negative current reference and go to limit.

Change P153/bit25 to 1 to do autotune test.
If not working, try these parameters:
P10=1
P11=1
P12=0
P27=12
P28=1
P222=2
P223=2
P485=3

If it's ok, change P485=0 (FOC mode) and see if is ok or P344 is in warning again.

 

[MarceAA]

Hi iop95

Thank you.

We are waiting for the new motor because the actual doesn't have the Identification plate, this one was rebuilder and they don't have the correct data. Sorry.

We are goanna try with your recommendations, and in that moment I'll send you the p/n.