VSD Training - Zest WEG GroupWEG VSD Training 2 Power & Torque N P T N T p nT P 9550 9550 2 N P T...

1

Motor Production:

56000 per day

10 millions per year

Nº of Employees:

22000

Company Covered Facilities:

646292 m2

Company Open Area: 1880771 m2

Amount shipped from Brazil:

1269 containers per year

WEG

VSD Training

2

Power & Torque

N

PT

TNPnTp

9550

95502

N

PT

9550

p = Power (watts)

n = Rotational speed (revs per second)

P = Power (kW) (Ability to deliver Torque to the load at rated Speed)

N = Rotational speed (revs per min) (P002)

T = Torque (Nm) (available on shaft) (P009)

Simplified Power Formula

N = 120f p

3

Definitions

Work = Force (N) X Distance (meter)

Power - Measure of Work done in a unit of time -

(Rate of doing work) (kW) (Torque x Speed)

Torque = Force (N) X Radius (meter)

Load Torque - Actual torque produced, is determined

by the demand of the load.

Motor Torque – T available on the shaft (T=kΦI)

Types of Loads

Loads can be grouped into five categories:

Variable Torque or Parabolic Torque ±60% of all loads

Constant Torque ±35% of all loads

Constant Power or Linear Torque

Hyperbolic Torque

Impact Loads (non-defined torque)

4

Variable Torque

Torque

Fans/Exhausts

Centrifugal pumps

(Flow control)

Centrifugal mixers

Blowers

0

2NT 3NP

1500 rpm

Parabolic curve

P1

P2

1000

n

T

Fans/Exhausts

Centrifugal mixers

Variable Torque

Centrifugal pumps

5

Operation of a Centrifugal Fan

Operating

Point

Constant Torque

f (Hz)

Mostly Friction loads

Belt Conveyors

Crushers

Piston Compressors

Extruders

Rolling Mills

Cranes

T

0

kT

NPN

T=kΦI

P = TxN

9550

6

Constant Torque

T

n

Cranes

Conveyors

Constant Power - Linear Torque

T

100 (Hz) 0

Centre Driven Winders

Lathes

Rotary cutting machines

kP

NT 1

50 (Hz)

Increasing F and not V

Flux (Φ) and Torque decrease

P = TxN (T decrease) (N increase)

9550

7

Calender

Constant Power - Linear Torque

T

0 f (Hz)

Hyperbolic Torque Constant Power

T

f (Hz) 0

Cutters

Drillers

Winders/unwinders

Paper Coilers

21

NT

Constant P

Rated Speed

Hyperbolic Torque

8

Machine tool Constant Power

Constant Cutting Force

Surface Speed = 2π x Radius x Speed

T= Force x Radius

Power = Torque x Speed (Constant Power)

Center Driven Winder

9

T

n

Winder

Hyperbolic Torque

Non-defined Torque

t (s)

T (kgfm)

0

T (kgfm)

0 t (s)

Beam Pumps

(Petrol

extraction)

Bagasse Dosers

(Sugar Cane)

10

T

t

Beam Pumps

Non-defined Torque

Torque Power Curve

1.

0

100 (Hz) 0

0.5

0.0 Frequency (f)

V

O

L

T

A

G

E

V

F

50 (Hz)

Speed (N) 1500 RPM 3000 RPM

Torque

Power

kT

NP

kP

NT 1

11

Understanding the Volts / Hertz ratio

F

VandIT

When the VSD changes the frequency it controls the voltage

simultaneously to keep V/F ratio constant

Because the V/F ratio remains constant, T is proportional to current

Current normally determined by the load

Flux is controlled by the VSD

Motor Theory of Operation

12

AC Motor Hardware and Operation

Electric motors are literally the driving force behind all

automation systems used in the industry, commerce and

buildings

Motors consume about 45% of all electrical energy

produced in the world

About three quarters of application like power pumps, fans

and compressors make use of AC motors, particular

squirrel cage motors

To regulate the amount of energy consumed by motors we

must make used of VSD’s

Basic AC Motor Construction

../My Documents/My Pictures/Rotor.bmp

../My Documents/Animation/Induction-motor-3a.gif

13

AC motor Hardware and Operation

Resulting Field and Motor Rotation

Motor Animation/MIT.EXE

../My Documents/DIRECTION OF ROTATION.docx

14

Ac motor hardware and operation

The rotor and stator magnetic fields are attracted to one another

and cause the rotor to follow the stator’s electromagnetic field;

Important:

The poles of an AC motor are stationary. It is the magnetic field

generated by the poles which actually rotates.

AC Motor Hardware and Operation

Stator & Rotor Interaction

Motor Animation/MIT.EXE

15

The rotor voltage UR is a proportional, function of slip s.

A rotor voltage of 10% corresponds to a slip of 10%

% slip = N synch – N rotor x 100

N synch

200%

Tstart– Starting or

Locked rotor torque

1410 RPM 1500 RPM

Slip Synchronous Speed

Normal slip range To

rqu

e &

cu

rre

nt

100%

Tn – Nominal torque

225%

Tbr – Breakdown

torque

VSD operating area

Motor speed – torque curve & VSD operation

Rotor 0 RPM, magnetic field 1500 RPM

Current

Rated Torque

(Full load Torque)

150% Torque

No Load Torque

Pull-up Torque

600% Current

(Lock Rotor Current)

16

No. of poles Synchronous speed Typical actual speed

2 3000 2980

4 1500 1480

6 1000 990

8 750 740

Motor speed can be changed by changing

The number of poles

Pfe: flux density; magnetic induction; freq; quality of ferromagnetic material

Pj: current flowing in stator windings and rotor bars

Pmec: depend on speed; Fan and Friction

Motor Efficiency (P = Pfe + Pj +Pmec)

Thermal Classes

VSD Theory of Operation

../My Documents/Efficiency Curve.docx

../My Documents/Thermal_Classes.docx

17

Reasons for VSD use Speed

Quality

Increase production

Energy savings

Maintenance saving

Optimal process speed

Characteristics of a VSD

Converts AC to DC to simulated AC which is able to be

controlled.

In this process the voltage and current waves become

distorted because of the pulsed output from the VSD.

18

Basic VSD construction

Basic VSD Construction

../My Documents/Drives_All/Drive General/Line Reactors and AC Drives1.doc

../My Documents/Drives_All/Expansion Boards.docx

../My Documents/Drives_All/SUPER DRIVE Foto.docx

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Line/Load Reactor

Three Types of Control (P202)

VVVF or Scalar or V/F

Sensoreless vector

Closed loop vector

Based on PWM –

Pulse Width Modulation

20

PWM resulting current

Old technology 750Hz switching

PWM resulting current New technology 1.25 – 10kHz switching

21

T

T

1) Ref A: 200 Volt 2 ms

VSD voltage and current waveforms

VSD voltage and current waveforms

T

T

1) Ref A: 5 A 5 ms

22

VVVF Scalar or V/F

Speed control accuracy 1%

Torque response time 0.3 Sec.

Minimum speed (10:1) 5Hz

While this type of control is good for many applications, it is not well suited for higher dynamic performance, very low

speeds, or applications that require direct control of motor

torque

Speed control accuracy: 0.5%

Torque response time: 6 mSec.

Minimum speed: (100:1) 0.5Hz

A separate adaptive controller uses information gained during

auto tuning, actual reference information, and motor feedback information

to give independent torque and flux control.

This allows continuous regulation of the motor speed and torque.

The torque output is consistent from no load to full load over a very

wide speed range.

The motor has a speed/torque characteristic that is very similar to its

DC counterpart.

Sensoreless Vector

23

TT

TT

T

T

1) Degrau: 2 Volt 200 ms 2) Torque: 1 Volt 200 ms 3) Velocidade: 1 Volt 200 ms

dY: 7.67 Volt Y: 0 Volt

Sensorless vector control gives smooth

Operation and high dynamic response

Channel 1

Load Step

Channel 3

Speed

Channel 2

Torque Current 15RPM and a 100% load torque step

U V W

+ + +

- - -

+ - -

+ + -

+ - +

- + +

- - +

- + -

Vector Control Principal

Simplified switching

Possible switch combinations

Resulting voltage vectors

U

V

W

24

IS

ia

ib

ic

α

β

iα

iβ

Vector Control Principal VSD AC output

Vector addition &

Calculation of flux & torque currents

Resultant rotor current & flux calculation

Isd

Isq Is

α

E

Us

β

a b c

Added Vector sum r

s

Vector Control Block Diagram

../../My%20Documents/Vector%20explain_PP.doc

../My Documents/Vector explain_PP.doc

25

Closed Loop Vector

Speed control accuracy: 0.01%

Torque response time: 6 mSec.

Minimum speed: 0Hz

Make use of encoder for feedback

VSD Motor Selection

26

VSD Motor Selection

Sizing Model ID

VSD Characteristics

Voltage vs Frequency

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

0 10 20 30 40 50 60 70Hz

VO

LT

AG

E

VSD Motor Selection

../My Documents/Drives_All/Sizing Table.docx

../My Documents/Drives_All/Sizing Table.docx

../My Documents/Drives_All/Model ID.docx

27

VSD Characteristics

Torque vs Frequency

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

0 10 20 30 40 50 60 70Hz

To

rq

ue

(N

m)

VSD Motor Selection

VSD Characteristics

Power vs Frequency

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

1.1

0 10 20 30 40 50 60 70Hz

PO

WE

R (

KW

)

VSD Motor Selection

28

Motor Speed - Torque Curve & VSD Operating Area

Speed

Operating

area

Ts

Slip

To

rqu

e

Tn

Tbr

By controlling voltage

and frequency a VSD

controls a motor on the

“straight line” part of a

motor characteristic

curve so that torque is

proportional to current

VSD Selection Motor de-rating Curve

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

2.1

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Frequency corresponding with minimum and maximum constant speed

Co

nsta

nt

perm

issab

le o

utp

ut

torq

ue (

T)

as a

rati

o o

f n

om

inal to

rqu

e (

Tn

)

T forced vent

T constant

T overload

Reduced flux Reduced cooling

29

EFFECT OF PULLEY/GEAR RATIOS

Power - kW Speed - RPM Torque - Nm Power - kW Speed - RPM Torque - Nm

100 1500 637 1 1 100 1500 637

100 1500 637 10 1 100 150 6367

100 1500 637 1 10 100 15000 64

100 1500 637 1 1 95 1500 605

100 1500 637 10 1 95 150 6048

100 1500 637 1 10 95 15000 60

Note: Output power will decrease slightly based on the efficiency of the pulleys or gearbox being used. Generally a 5% loss is a

safe figure. This is shown in the 2nd three examples above.

Note: Motor selection must always be based on the power, speed and torque required at the motor shaft, not the values on the

secondary side of the pulleys or gearbox. Using the pulley or gearbox ratio, convert the given load values to motor shaft values.

INPUT OUTPUT

EFFECT OF PULLEY/GEAR RATIOS

RATIO

Motor Speed – Torque Curve & VSD Operation

At all times maximum torque is

limited to motor breakdown

torque – BDT / Tbr

2VBDT

2

150

NBDTHzNAt

Constant Voltage

Operation

Constant Power

Operation

30

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

2.0

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Frequency corresponding with minimum and maximum constant speed

Co

ns

tan

t p

erm

issa

ble

ou

tpu

t to

rqu

e (

T)

as a

ra

tio

of

no

min

al to

rqu

e (

Tn

)T forced vent

T constant

Tbr = 2

Tbr = 2.5

Tbr = 3

T overload

Effect of Motor Design Breakdown Torque

A VSD produces a pulsed voltage that in turn produces

a near sinusoidal waveform.

A VSD maintains constant/optimum motor flux.

Torque is proportional to current.

Motor control is always on the low slip “straight line”

part of the motor curve.

Summary

31

1. At all speeds : Additional heating due to harmonics.

2. <50Hz : Reduction in cooling airflow.

3. >50Hz : Field weakening due to reduced flux

Reasons for Reduction in Torque

VSD Installation

32

Installation Introduction

VSDs are considered to be “Industrial Electronic” items and as such

should be able to withstand rough working conditions.

This is true.

However, fact is, the better the installation, the less problems and greater

reliability the user will enjoy.

Installation Considerations for AC Drives

ANDRE & SON’S INC, CO.

Founder & President

Vanlines

?

Line Transients

Harmonics

Input Impedance

Grounding

&

Bonding

Common Mode & Capacitive Coupling

Reflective Wave

33

Mechanical Installation

As for as possible avoid the following:

Direct exposure to sunlight, rain, high moisture and sea air

Exposure to corrosive liquids or gasses

Exposure to excessive vibration

Conductive dust, oil or any conductive particles or materials.

Mechanical Installation

Environmental conditions:

Temperature: 0…40ºC – nominal conditions

0…50ºC - with 2% current derating for each

ºC degree above 40ºC.

Relative Air Humidity: 5% to 90%, non-condensing

Maximum Altitude: 1000m – nominal conditions.

1000 - 4000m – with 1% current derating for

each 100m above1000m.

34

Cooling Airflow

1. Always ensure sufficient room and

ventilation for cooling air flow.

2. Sufficient space – top, bottom and sides.

3. Avoid direct sunlight.

Hints:

1. Use panel fans if in doubt.

2. Remember that trunking impedes air

flow.

3. Rather allow more flow and space

than the minimum requirements.

4. Allow for heating from other

components within the VSD panel.

5. A sealed, clean air conditioned

environment is best.

Panel Ventilation

A totally sealed panel circulates the VSD hot air causing a

steady temperature rise.

Panel design must allow for hot air to be vented.

35

Proper Installation

IP Rating and Implications

IP Rating refers to the degree of

protection.

The first numeral refers to protection

against solids.

The second numeral refers to protection

against liquids.

IP21 is suitable for a clean substation.

IP42 is suitable for a dusty substation.

IP54 provides dust and liquid protection.

IP65 is totally sealed.

IP43 is the best practical degree of

protection without going to great

expense and technical difficulty.

IP Rating may not be dependant on the

use of filters

36

IP Rating and implications

CFW-08 LINE

NEMA 4X / IP56

The Type 4X protection degree

assures protection against dust,

dirt and directed water jets.

IP Rating and Implications

37

Electrical Installation

Important notes:

The AC input voltage must be compatible with the VSD rated voltage.

Capacitors for power factor correction are not required at the input (R, S, T) and they MUST NOT be connected at the output (U, V, W).

If more than 25% of the transformer load is VSDs the power factor correction capacitors will require special design to cater for harmonics.

The VSD MUST be earthed for safety purposes (resistance≤10Ω).

Harmonics

Harmonic producing equipment

– VFD’s

– Electronic Ballasts

– UPS

Harmonics.

38

Harmonic Spectrum Analysis.

50 Hz 250 350 550 650 850 950

Switching Frequency

1.25 Khz

10 Khz

39

Motor Reflected Wave Pulse

(A) Unterminated (B) Reactor at Drive (C) Terminator

Poor Wiring Practice: Unshielded Cable w/o ground

40

Better Wiring Practice: 3 Conductor & Ground in Conduit

Cable Charging Current Paths

Long motor cables (longer than 100m) can cause excessive capacitance to ground.

This can cause nuisance E11 ground fault trips immediately after the inverter has

been enabled.

41

Cable Charging Current Exceeding Rated Phase Current

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

Fuses

To protect the installation

input, Correctly rated high

speed fuses should be used

../../My%20Documents/A%20VSD%20Info%20Deon/Presentations/CFW09%20scanned%20images.ppt

42

Contactor A contactor is not required

If customer practice demands the use

of a contactor, it should be on the

VSD input. A early break – late make

control contact must break the VSD

enable input.

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

Line Reactor The use of a line reactor is

always advisable

A line reactor is required when

line impedance low

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

43

EMC Filter May be required depending on

customer specification and

installation environment

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

Load Reactor Required for motor cable lengths >100m

Reduces Dv/dt and Vpeak values at

motor terminals

A 2% reactor is suitable in most cases

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

../My Documents/Word_Docs/DV_DT.doc

44

VSD output wiring

Cables must be correctly sized for

the motor FLC as per SABS

standards or other local regulations.

Cable shielding/armouring must be

properly earthed.

VSD output cables should be run

separately from other cables.

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter

(Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

Control wiring Keep seperate from power cables

Cross power cables at 90º

Use screened cables for analogue

signals

OTHER

LOADS

CAPACITOR

BANK

Controls

HMI

Filter (Optional)

VSD

Load

Reactor

AFW PANEL Ground

Line

Reactor

45

VSD Commissioning

Never touch a PC board without ESD precaution

Check that all connections are correct and tight.

Verify that the VSD is correctly rated for the motor.

Uncouple the load from the motor, or ensure that the load

may be safely turned.

Check that the VSD voltage selection plug is correctly set.

(On 525V supplies rather select the 550/575V plug setting)

Check that the control card analogue dipswitches are

correctly set.

Pre-Power Checks

46

1. Check that the supply voltage is within acceptable

range.

2. Power up the VSD

3. Check that the power up was successful.

4. If new then reset to factory setting P204 option(6)

Initial Power up

CC9- Control Card Terminal Connection

47

VSD Programming

The CFW09 HMI

It is a very simple and functional interface

to operate and program the inverter.

Visualization and Parameter Changes

Status Indication

Fault Indication

Inverter Operation

On/Off,

Jog Function,

Forward/Reverse

Local/Remote

Detachable

48

Use of the CFW09 HMI

7 segment LED Display

with 4 digits

Liquid Crystal Display

with 2 lines of 16

alphanumeric

characters

Start Key

Stop Key

Local/Remote Key

“ Prog ” Key

Increase Key

Decrease Key

FWD/REV Key

Jog Key

Parameters Description

To simplify the parameters understanding, they were

grouped according to their functions:

• Read Only Parameters - P001...P099

• Regulation Parameters – P000,P100…P199

• Configuration Parameters - P200...P399

• Motor Parameters - P400 ... P499

• Special Function Parameters – P500 ... P599

49

On the first power up the CFW09 automatically runs through

an automatic start-up routine which guides the user to enter

the minimum essential parameters.

The user only needs to press the up, down and program

buttons to move through the routine.

Automatically guided Start-up Routine

Automatically guided start-up routine

50

1. Reset the Drive to Factory defaults (P204=6)

2. P201 – Language

3. P296 – Supply voltage (Drive)

4. P400 – Motor voltage

5. P401 – Motor full load current

6. P403 – Motor frequency (50Hz)

7. P402 – Motor RPM

8. P404 – Motor kW

9. P406 – Motor ventilation

Note: The drive will be in V/F mode

PRACTICAL TASKS

During this start-up routine the following parameters are set:

Nameplate

1. P000 – Access code (Set to 5 to change parameters)

(when-ever you change the control mode it will require a password)

1. P100 – Acceleration time, set to 2s

2. P101 – Deceleration time, set to 2s

3. P133 – Minimum speed, set to 0

4. P134 – Maximum speed, set to 3000

Change the following Parameters:

PRACTICAL TASKS

51

1. Now save these settings so that we can load them

again if we want to. Set P204 = 10, (Save User Default 1)

(There are two memory areas, User Default 1 and 2)

2. Put the drive in remote mode, and Start the drive via

digital input 1 and change direction with digital input 2. (Speed-Reference via Analog in 1)

Saving The Parameter Settings:

PRACTICAL TASKS

P202 – Operation Mode selection possibilities

0 - V/F 60Hz

1 - V/F 50Hz - default setting for the South African market

2 - V/F adjustable – to be used for non standard motors.

3 - Sensorless Vector

4 - Vector with encoder

V/F 50Hz is sufficient for most applications and is the

recommended mode for centrifugal pumps and fans.

Vector provides more accurate control and quicker torque

response and is recommended for demanding applications.

Information - P202 Options

52

Set P202 = 3 – Sensorless Vector, the CFW09 once again

follows an automatically guided start-up routine. The final

step of this routine is P408 – Self tuning

P408 – Self-tuning – the purpose of this is to measure

certain motor values to enable the more accurate

sensorless vector control.

Program the Drive for Sensorless Vector:

PRACTICAL TASKS

Set P408 = 1: No rotation: The motor remains stationary during the

self-tuning routine. Thus, P410 must be set to zero before starting

the self-tuning routine. If P410 ≠ 0, the self-tuning routine will keep

the existing value

Other options:

P408 = 2: Run for Imr: The value of P410 is estimated with the

motor rotating. This option shall be executed without load coupled

to the motor.

Program the Drive for Sensorless Vector:

P408 = 3: Run for Tm: The value of parameter P413 (Mechanical

Time Constant - Tm) is measured with the motor rotating. It shall be

run, preferentially, with the load coupled to the motor.

P408 = 4: Measure Tm: It estimates only the value of P413

(Mechanical Time Constant – Tm) with the motor rotating. It shall be

run, preferentially, with the load coupled to the motor.

PRACTICAL TASKS

53

1. Once again go to P204, this time set it to 11. This will save

the vector setup to User Default 2.

2. Set P265 = 2, this will make Din-3 the General Enable

switch which will Enable or Disable the inverter completely

and switch the magnetizing current off.

3. Start and test drive (cannot start unless DI-3 closed)

Info:

(We can easily load V/F settings by programming P204 = 7

and Vector settings by programming P204 = 8)

Useful Parameter Settings:

PRACTICAL TASKS

Other Useful Parameter Settings:

1. Push the start button consecutively after starting, to view

important feedback parameters like:

a) P002 Motor speed

b) P003 Motor current

c) P005 Motor frequency

d) P006 VSD status

e) P007 Motor Voltage

f) P009 Motor Torque

g) P070 Motor current and Speed

PRACTICAL TASKS

54

Dynamic Braking Parameter Settings: (Drive in Vector Mode)

Dynamic braking is already active, to see the effect;

1. Set P153 = 800; start the drive, speed-up to 1500 and

now stop the drive

(Drive trips on E01; Why?)

2. Set P154 to braking resistor ohm value (52Ω)

3. Set P155 to braking resistor power rating (0.3 kW)

(Otherwise the braking resistor will not be protected)

4. Adjust P151 = 675 volts

5. Test again (no tripping)

PRACTICAL TASKS

Optimal Braking Parameter Settings

(Vector mode only; P202 = 3 or 4)

With P153 = 800, and P151 = 675 volts, optimal braking is active

New patented method to decelerate an induction motor;

without using dynamic braking resistors.

Optimal braking dissipates braking energy in the motor

It is not very effective until;

1. Set P150 = 0 “with losses”

2. Start and Stop and monitor the difference

Use only up to 55kW

PRACTICAL TASKS

55

Multispeed Parameter Settings:

1. Reload V/F settings P204 = 7

2. Set P221 = 8 (Local speed reference = multispeed )

"E24" until P266 = 7 been programmed (2-speeds)

The error should reset itself

3. Set; P267 = 7; P268 = 7 (4 and 8 speeds)

4. Start and use Digital Input 4 to 6 to change the speed

settings (see next slide)

PRACTICAL TASKS

P124 to P131 – Multispeed Regulation Parameters:

0V = Off / Open

24V = On / Close

(To change the factory settings, program P124 – P131)

PRACTICAL TASKS

56

Electronic Potentiometer Set-up:

Electronic potentiometer uses selector switches to change speed

like the keypad up/down buttons;

1. Set P221 = 7

(E-24 error until the Dig-Inputs is programmed)

2. Set P266 = 0 (not used)

3. Set P267 & P268 = 5

4. Close DI-6 and start Drive (min speed “0” motor do not turn)

5. Test by closing and opening DI-5 (n/o) quickly to Increase

speed and opening and closing DI-6 (n/c) to decrease the

speed

PRACTICAL TASKS

Stop Mode Parameter Settings:

1. Set P204 = 7 (Reset V/F settings)

(Normally when you stop the drive, it ramps down

according to deceleration time P101)

2. Set P232 = 1 (for applications requiring coasting after a

stop command)

3. Start and run motor up to 1500 RPM. Stop and monitor

The next Slide will introduce a solution

PRACTICAL TASKS

N.B: Do not start again while the motor still turns

This will cause a harsh ramp up from zero speed

57

Flying Start Parameter Settings:

1. Set P320 = 1 To enable flying start and prevent problems

from the previous slide

2. Start the drive while the motor shaft is still spinning, and

monitor. (This action only aloud without an encoder)

PRACTICAL TASKS

Ride Through Parameter Settings:

Ride through allows the drive to carry on working without a trip in

the event of a “power dip”

The drive will survive on energy that it takes out of the motor,

(regen) so the amount of time that the drive can ride through

depends on the motor/load inertia.

1. Set P320 = 2

2. Start the drive, speed up to 2000 RPM

3. Switch the power off and back on before the motor

comes to a rest. (This will prevent E02)

(It works better in sensorless Vector mode)

4. Set P204 = 8 (upload sensorless vector)

5. Repeat steps 1 to 3 (password necessary for new mode)

6. Set P320 = 0 (back to default)

PRACTICAL TASKS

58

Magnetizing flux parameter settings:

1. Set P211 = 1 Zero Speed Disable: (This will switch-off

the magnetizing current in Sensorless Vector mode

when the motor has reach almost zero speed, which

depends on P291)

2. Set P291= 20% (Factory setting 1% of speed) you can

set at what speed the magnetizing current must be

switched off.

PRACTICAL TASKS

Password Parameter Settings:

To change the password from 5 to any other number

1. Scroll to P200 set to off

2. Set P200 to on again, and press program

(The display reverts to P000 and shows the current pass code)

3. Change it now to your new code (ex. 77) and press

program. (make sure the value of P000 has reverted to 0)

Your new password has successfully been entered

4. Test by trying to change the acceleration time.

PRACTICAL TASKS

59

Analog Output-1 calibration:

1. Set P204 =7 (Upload V/F mode again)

2. Put Drive in Remote mode

3. Speed drive up to 2000 rpm by using Analog input 1 and

monitor P002 on the keypad 4. Adjust P252 while monitoring Analog output 1 on the meter)

Fine tune to give the same reading

PRACTICAL TASKS

Speed Indication Parameter Settings:

To change the speed indication in P001/P002 to something

more useful like m/s:

Change the r; p; m in P207,P216 & P217 respectively

to m; /; s (any ascii character), then change the scaling

factor in P208 (@base speed) then insert the decimal

point in the right position by:

Setting P210 to:

0 for no decimal point

1 for comma left of LSD character

2 for comma in the middle of display

3 for comma to right of MSD

PRACTICAL TASKS

60

End of Practical Tasks

(Ask for Final Task)

P220 – Local / Remote Selection

Defines the source of local and remote commands and reference signals.

61

Analogue Input Parameter Settings

Analogue Output Parameter Settings

62

Digital Input Parameter Settings

Digital

and Relê

Output

Settings

63

End of Course

Thank You

1

Reading Parameters

P000 to P099

Pg 118

Measurements

Inverter Status

Digital Inputs Status

Digital Output Status

Analog Inputs

Analog Outputs

Last Faults

P000 – Access

Pg 09

Motor Speed and Current

Fieldbus Monitoring

Software Version

P000 - Parameter Access

Range – 0 to 999

Password – 005

P200 = 1 (Password active)

Pg 119

Reading Parameters

2

P001 - Speed Reference

Range – 0 to P134

Unit – P207, P216 and P217

Scale – P208 and P2100.5 s Filter for P002

Factory default – rpm

P002 - Motor Speed

Pg 119

Reading Parameters

P003 - Motor Current

Range – 0 to 2600A

Unit – A

P004 - DC Link Voltage

Range – 0 to 1235V

Unit – V

P005 - Motor Frequency

Range – 0 to 1020Hz

Unit – Hz

Pg 120

Reading Parameters

Pg 119

300 x 3.4 = 1020 Hz

120 x 3.4 = 408 Pg 441

3

P006 - Inverter Status

rdy = Inverter is ready to be started

run = Inverter is enabled

Sub = Inverter is disabled + Undervoltage

EXY = Inverter is in a fault condition

Pg 120

Reading Parameters

P007 - Motor Voltage

Range – 0 to 800V

Unit – V

P009 - Motor Torque

Range – 0 to 150%

Unit – % Torque Current

P010 - Output Power

Range – 0 to 1200kW

Unit – kW

Pg 120

Reading Parameters

4

P012

Digital

Inputs

P013

Digital and

Relay

Outputs

0 = Inactive1 = Active

LED Display =Decimal value for an

8 bits number

Pg 120

Pg 121

Reading Parameters

00101000 = 40 (dec)

P014 – Last Fault

P015, P016,P017 – Fourth Previous Fault

P060 – Fifth Error

P061, P062, P063,P064,P065 – Tenth Error

Range – 0 to 70

Pg 122

Pg 124

Reading Parameters

5

P018 - Analog Input AI1' Value

Range of -100 to 100




Pg 122

Reading Parameters

Unit – %

Pg 165

Pg 167

Pg 122

Range – 0 to 100

Unit – %

proportional to the temperature

P022 – WEG’s use

P023 - Software Version

Reading Parameters

6

P025 – A/D Conversion Value of Iv

Range – 0 to 1023

512 ≅≅≅≅ 0A

P026 – A/D Conversion Value of Iw

Pg 122

Reading Parameters

P027 – Analog Output AO1

Range: 0 to 100

P028 - Analog Output AO2



Pg 123

Unit – %

Reading Parameters New V3.7x

7

P040 - PID Process Variable

Range – 0 to P528

Unit – P530, P531 and P532Scale – P528 and P529

Pg 123

Reading Parameters

P042 – Powered Time

RangeLCD: 0 to 65530hLED: 0 to 6553h (x 10 – it would not fit)

This value remains stored even when the inverter is turned OFF.

Pg 123

Reading Parameters

8

P043 – Enabled Time

Range – 0 to 6553h

This value remains stored even when

inverter is turned OFF.

P204 = 3 resets this counter

Pg 123

Reading Parameters

P044 – kWh Counter

Range – 0 to 65535kWh

This value remains stored even when inverter is turned OFF.

P204 = 4 resets this counter

Indicates the energy consumed by the motor

Pg 124

Reading Parameters

9

P070 – Motor Speed and Motor Current

Pg 124

P002 and P003 in the same parameter

make the start-up easier

The LED display shows the speed

Reading Parameters

Shows the command word value set through the

network

Pg 124

P071 – Command Word

1 0 0 0 0 0 1 1 = 83h

0 0 0 0 0 0 1 1 = 03hLCD display = 33539 the number in decimal

LED display = 8 3 0 3 in hexadecimal

Reading Parameters

10

P072 – Fieldbus Speed Reference

Pg 124

Shows the speed reference value set through

the Fieldbus network

LCD shows the value in decimal

LED shows the value in hexadecimal.

Reading Parameters

RangeLCD: 0 to 65535LED: 0 to FFFFh

Pg 125

Pg 10

Regulation Parameters

P100 to P199Ramps

Current Regulator

Speed References

Speed Limits

I/F Control

V/F Control

Adjustable V/F

DC Link Voltage Regulation

Overload Currents

Speed Regulator

Flux Regulator

11

Pg 125

P100 – Acceleration Time

Range – 0.0 to 999

Unit – second

Factory – 20 s

P102 – Acceleration Time 2

P103 – Deceleration Time 2

P101 – Deceleration Time


Softens accel / decel changes

“Keeps the bottles upright”

Less mechanical stress - lower maintenance

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T j

T jT j

T j

TAccel TDecelTAccel

Decel X 2

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Decel

Accel X 2T

P104 – S-Ramp

12

Pg 126

Range – P133 to P134

P120 – Speed Reference Backup

Reference – HMI,

EP,

serial,

fieldbus and

PID setpoint (P525)

Options – 0 (inactive)

1 (active) Factory

P121 – Keypad Speed Reference


Pg 125

Like a memory position

Pg 129

P136 – Manual Torque Boost = I x R


Range – 0 to 9

Factory – 1

13

Pg 131

Range – -10% to +10%

Unit – %

Factory – 0%


P138 – Slip Compensation

Pg 136

Pg 135

Range –

Depends on P296

Unit –DC Volt

Factory –Depends on P296


P151 – DC Link Voltage Regulation Level

To avoid E01

P202 = 0, 1, 2 (V/Hz) or 5 (VVW)

14

Pg 138


P153 – Dynamic Braking Voltage Level

Range – Depends on P296

Unit – DC Volt

Factory – Depends on P296

Pg 139


P155 – DB Resistor Power Rating

Range – 0 to 500

Unit – Ω

Factory – 0Ω

P154 – Dynamic

Braking Resistor

Range – 0.02 to 650

Unit – kW

Factory – 2.6kW

0 = Disables E12

E12 = Braking Resistor

Overload

15

Pg 140


P156 – Motor overload current at 100% speed



Notes:

2) Motor Parameters.

7) P295

12) 1.3 x P295

1.6 x P295

1.8 x P295

Motor Data

Pg 118

Pg 140


Pg 214

16

Pg 145

P169 – Maximum Output Current


Note:

7) P295

Range – 0.2xP295 to 1.8xP295

Unit – A

Factory – 1.5xP295

P202 = 0, 1, 2 (V/Hz) or 5Pg 118

Pg 145

Slow reaction

P169 – Maximum Output Current


17

Pg 145


P169 – Maximum Forward Torque Current

Note:

7) P295

Range – 0 to 180

Unit – %

Factory – 125%

P202 = 3 or 4 (Vector)

P170 – Maximum Reverse Torque Current

Formula in the manualPg 118

Pg 146


P171 – Maximum FWD Torque at max speed

P202 = 3 or 4 (Vector)

P172 – Maximum REV Torque at max speed

Note:7) P295

Range – 0 to 180

Unit – %

Factory – 125%

Formula in the manualPg 118

18

Pg 148

Pg 12

Configuration Parameters

P200 to P399

Generic Parameters

DC Braking

Local/Remote Definition

Stop Mode Selection

Analog Inputs Analog Outputs

Digital Inputs Digital Outputs

Nx, Ny, Ix, N=0, N=N* and Tx

Inverter Data Skip Speed

Serial Communication

Flying Start/Ride-Through

Mechanical Braking Operation

Torque Current Polarity Indication

Load Detection Parameters

VVW Control

Pg 149

P204 – Load/Save Parameters


3 = Reset P043 (e h)

4 = Reset P044 (kWh)

5 = Load WEG 60Hz6 = Load WEG 50Hz

7 = Load User 18 = Load User 2

10 = Save User 111 = Save User 2

Pg 178

19

Pg 150

P205 – Display Default


Parameter shown on the display, after the power-up

Factory

Pg 152

P209 – Motor Phase Loss Detection


Factory

Simultaneously during at least 2 seconds:i. P209 = active;

ii. Enabled Inverter;iii. Speed reference over 3%;

iv. | Iu – Iv| > 0.125xP401 or| Iu – Iw| > 0.125xP401 or| I – I | > 0.125xP401.

20

Pg 153

P214 – Line Phase Loss Detection


Factory

Simultaneously during a minimum time of 3

seconds:i. P214 = active;

ii. Enabled inverter;

Does not exist:200V P295 up to 28A;400V P295 up to 24A;600V P295 up to 14A

Disabled with

Ride-Through

Pg 153

Pg 155

P215 –Copy Function


Factory

It transfers:i. Current Parametersii. User 1

iii. User 2

Vx.yz

Check the software version at P023

P218 – LCD Display Contrast Adjustment

Range – 0 to 150 Factory = 127

21

Pg 156


P220 Local/Remote Selection Source

Factory

Pg 156

Local

P221 - Reference


Remote

P222 - Reference

Factory = 0 Factory = 1

22

LocalP223 - FWD/REV

Selection


RemoteP226 - FWD/REV

Selection


Pg 157

Pg 157


Local

P224 - Start/Stop Selection

Remote

P227 - Start/Stop Selection


23

Pg 157


LocalP225 - JOG

RemoteP228 - JOG


P122 – JOG

Pg 126Pg 160

Pg 196

Pg 195


P295 – Inverter

Rated Current

Range – 0 to 81

Unit – (A)

Factory – Model

P296 – Inverter Rated Voltage

Range – 0 to 8

Unit – (V)

Factory – Modeland market

P297 - Switching Frequency

Range - 0 to 3 (1,25 to 10kHz)

Unit – (kHz)

Factory – Model

24

Pg 199

P303 – Skip Speed 1



Factory = 600rpm

Range = P133 to P134

P306 – Skip Band Range

Factory = 900rpm

Factory = 1200rpm


Factory – 0 rpm

Range – 0 to 750 rpm


Pg 200

P308 – Serial Address Range – 1 to 30

Factory – 1

P309 – Fieldbus

Factory

SuperDrive and Modbus Pg 199

25


Pg 200

P312 – Type of Serial Protocol

Factory

P351 – Delay for E33

P352 – Delay for E34

P353 – Delay for N<Nx – Brake Activation

P354 – Speed Regulator Integrator Reset Delay

P355 – Delay for accepting new Start/Stop

commands

P356 – Ramp Enabling Delay

Mechanical Brake Operation Logic

Pg 207


26

P361 – Load Detection


P362 – Stabilization Speed

P363 – Stabilization Time

P364 – Slack Cable Time

Pg 209Pg 208


P365 – Slack Cable Level

P366 – Lightweight Level

P367 – Overweight Level

P368 – Speed Reference Gain


Pg 209


27

Pg 213

Pg 29

Motor Parameters

P400 to P413

Motor Nameplate Data

Measured Parameters

Pg 213

Motor Parameters

P400 – Motor Rated

Voltage

Range – 0 to 690

Unit – V

Factory – P296


Current

Range – 0 to 1.3 x P295

Unit – A

Factory – P295Notes: 1) Disabled

12) 1.3 x P2951.6 x P2951.8 x P295

Notes: 1) Disabled2) P296Pg 118

28

Pg 213

Motor Parameters

Range – 0 to 18000

Unit – rpm

Factory – 1750 (1458)

Unit – Hz

Factory – 60 (50)

Notes: 1) Disabled

2) P296

11) Market

120Hz if P202 = 3 or 4 (Vector)

300Hz if P202 = 0, 1, 2 or 5 (V/Hz and VVW)

Pg 151

P402 – Motor RatedSpeed


Frequency

Pg 118

Pg 214

Motor Parameters

P404 – Motor

Rated Power

Range – 0 to 50

Unit – hp/kW

Factory – 4

(1.5hp/1.1kW)

P405 – EncoderPPR Unit – ppr

Factory – 1024

Notes: 1) Disabled

Pg 213

Notes: 1) Disabled

Range – 250 to 9999

P202 = 4 (Vector with Encoder)

Encoder (EBA, EBB and EBC Pg 247

Pg 118

29

Pg 214

Motor Parameters

P406 – Motor Ventilation

Factory

12:1: 5Hz for 60Hz

4.2Hz for 50Hz

Sensorless (P202=3)Pg 140

Motor Parameters

P408 – Run Self-tuning

Factory

1 and 2 for P202 = 3 (Sensorless)

1, 2, 3 and 4 for P202 = 4 (Encoder)

E1

3

1 for P202 = 5 (VVW)Pg 215

30

P410 – Motor Magnetizing Current (Imr)

Pg 216

• Manual setting

• Self-tuning

• Rated voltage

• Motor torque• Nominal Speed

Motor Parameters

P409 – MotorStator Resistance

Range – 0.000 to 77.95 ΩΩΩΩFactory – 0.00 ΩΩΩΩ

P411 – Motor Flux

Leakage InductanceRange – 0.00 to 99.99Factory – 0.00 mH

Current regulator

Range – 0.0 to 1.25xP295

Factory – 0.0 A

Coherent with no

load current

Range – 0.000 to 9.999 s

Factory – 0.000 s

Pg 218

Motor Parameters

P412 – Rotor Time

Constant (Tr)

Flux Regulator

• Rated voltage

• Motor torque – Nominal Speed

31

• Manual setting

• Table

• Encoder – Measured

Pg 218

Sensorless

• Impossible to measure

• Optimization

Attention!

Encoder measurementaccelerates motor twice

Motor Parameters

P413 – Mechanical Time Constant (Tm)

Range – 0.00 to 99.99Factory – 0.01 s

Speed Regulator

Pg 219

Special Function – PID

P520 to P536

Parameters set automatically:P223 = 0 (always forward),P225 = 0 (JOG disabled),

P226 = 0 (always forward), P228 = 0 (JOG disabled),P237 = 3 (PID process variable) and

P265 = 15 (Manual/Automatic).Pg 148

32

END

Exersice 1

A conveyor drive is to be accelerated from zero to a speed of 1500 rev/min in10 secs. The moment of inertia of the load JL = 4.0 . The torque of the conveyor load, referred to the motor shaft, is a constant at 520 Nm. The motor being considered is a 110 kW, 1480 rev/m motor with a JM = 1.3 . Is this motor adequate for this duty?

2kgm

2kgm

33

Solution

The total torque of the motor must be greater than the sum of Tload and Taccelaration

TM > TA + TL Nm

Torque accelaration

−=

t

n1n2 JtTA

60

2π

Total inertia of drive system

JTOT =4.0 +1.3 = 5.3

During accleration the dynamic torque required

TA = 83.25 Nm

TL = 520 Nm

2kgm

−=

10

015005.3TA

60

2π

34

TTOT = TL + TA Nm

TTOT = 520 + 83.25 = 603.25 Nm

Total motor torque

TN=709.8 Nm

Answer: Yes the motor is suited for the drive requirements

1480

110 x 9550T =

Exersice 2

A 5.5 kW motor of rated speed 1430 rev/min and rotor inertia of 0.03 drives a machine at 715 rev/min via a 2:1 pulley and belt drive. The inertia of the mechanical load is 5.4 , running at 715 rev/min at full rated speed. If the load is a constant torque load with an absorbed power of 4.5 kW at 715 rev/min, what is the acceleration time for this drive system from standstill to full load speed of 715 rev/min? Assume that the full motor torque is 150% of rated torque and is constant over the acceleration period.

2kgm

2kgm

35

Solution

When a motor drives the mechanical load through a gearbox or pulley the inertia must be referred to the motor shaft.

JM = Inertia at the motor shaft

JL = Inertia at the load shaft

2

2

LM

d)(MotorSpee

)(LoadSpeedJJ =

The rated output torque of the motor given by:

The maximum output power is 150% during the acceleration period

TM = 1.5 x 36.7 = 55.05 Nm

The absorbed power of the load is 4.5kW @ 715rpm which gives a load torque of

60.1Nm715

4.5 x 9550T ==

36.7Nm1430

5.5 x 9550T ==

36

This needs to be converted to the motor shaft by the pulley ratio

The acceleration torque is the difference between max motor torque and load torque to the motor shaft

30.05Nm1430

71560.1TLM ==

)NmT(TT LMMA −=

25Nm30.05)(55.05TA =−=

The inertia of the mechanical load referred to motor shaft is

2Tot 1.38kgm0.031.35J =+=

2

2

2

LM kgm1430

7155.4T =

2M 1.35kgmJ =

37

To calculate the overall acceleration time we use the following formula

t=Total acceleration time is sec

JTot=Moment of inertia of motor and load

n=Final speed of the drive system in rpm

TA=Acceleration torque of the drive system

A

TotT

n1)(n2Jt

−=

60

2π

Assuming the the accleration torque remains constant over the acceleration period the minimum acceleration time is

25

0)(14301.38t

−=

60

2π

sec3.8=t

38

Braking Resistor Calculation


L2

MT

2L

2M

2T

J Gr J J

kgm inertia Load J

ratioGear GR

kgm inertiaMotor J

kgm inertia Total J

++=

=

=

=

=

39


power brakingpeak Pb

0 to b from time iondeccelarat Total t2- t3

speed rotationalangular

60

n2 rad/s speed rotationalangular Rated b

=

=

=

==

ωω

ω

πω

0

t2-t3

0) - bb( x Jt Pb

ωωω=


resistor brake of Value Rdb

voltage bus DC of Value Vd

modulechopper through flowing current Min Id

Rbd

Vd Idb

resistor braking allowable Max Rdb

power brakingPeak PB

Bus DC the of Value Vd

Pb

Vd x Rdb

2

=

=

=

=

=

=

=

=9.0

40


Rad/s in speedmotor lower 0

Rad/s in speedmotor rated b

power brakingpeak Pb

process of time cycle total t4

0-b edeccelarat to time elapse t2-t3

W in ndissipatioresistor brake dynamic Average Pav

b

0-b

2

Pb x

t4

t2-t3( Pav

=

=

=

=

=

=

=

ω

ω

ωω

ω

ωω)()


A 100 horsepower, 460 volt motor and drive is accelerating and decelerating as depicted in Figure. The period or t4 is equal to 60 seconds. The rated speed is 1785 RPM and is to be decelerated in 6.0 seconds to 1000 RPM. The motor load can be considered purely as an inertia, and all power expended or absorbed by the motor is absorbed by the motor and load inertia. The load inertia is directly coupled to the motor and the motor plus load inertia is given as 19.22

Calculate the necessary values to choose an acceptable Chopper Module and Dynamic Brake Resistor.

2kgm

VSD Training - Zest WEG GroupWEG VSD Training 2 Power & Torque N P T N T p nT P 9550 9550 2 N P T...

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Transcript of VSD Training - Zest WEG GroupWEG VSD Training 2 Power & Torque N P T N T p nT P 9550 9550 2 N P T...