T64 - Drive Application Success with PowerFlex 750 … · T64 - Drive Application Success with ......

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T64 - Drive Application Success withPowerFlex® 750-Series AC Drives

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Predictive Maintenance

2


Predictive Maintenance

3

1 to 350 HP (0.75 to 250 kW)Frames 1 to 7

350 to 2000 HP (250 to 1400 kW)Frames 8 to 10

Heatsink fan

Internal fan

Machine bearing

Machine lubrication

Motor bearing

Motor lubrication

Relay output contacts (I/O Port)

Overall heatsink fan

Individual heatsink fans

Individual cabinet fans

Internal fan

Machine bearing

Machine lubrication

Motor bearing

Motor lubrication

Relay output contacts (I/O Port)


Predictive Maintenance Configuration

4

Protection → Predictive Maintenance Parameters

PowerFlex® 750-Series HIM

Studio 5000 Logix Designer™

Connected Components Workbench


Configuration for Heatsink Fan

5

Temperature

Derate

Data from Fan Vendor

Calculation for Total Life

Total Life

470 [PredMaintAmbTemp] - User Defined

Ambient temperature around the drive in ⁰C• Temperature inside cabinet for wall mount

• Inlet temperature for floor mount

• Set to maximum temperature

Example: 40⁰C

488 [HSFan Derate] - User Defined

Derate to account for environmental factors• Less than one for harsh environment

• Poor air quality

• Vibration

Example: 0.5

489 [HSFan TotalLife]

Total number of hours expected

for life of heatsink fan

Example: 15300 Hours

Data pre-programmed in drive



6

Measure and Calculate Time

Running

Elapsed Life

Reset

+-

Total Life

Elapsed Life

Remain Life



490 [HSFan ElpsdLife]

Accumulated hours of heatsink fan run time

Example: 6000 Hours

471 [PredMaint Rst En] & 472 [PredMaint Reset]

Use P471 to enable reset, then P472 to select

predictive maintenance counter to reset

Example: 1 = HS Fan Life

491 [HSFan RemainLife]

Remaining number of hours until

estimated end of life for heatsink fans

Example: 9300 Hours



7

/

Elapsed Life

Total Life

Event Level

>= EventYes

490 [HSFan ElpsdLife]

Accumulated hours of heatsink

fan runtime

Example: 6000 Hours



492 [HSFan EventLevel] – User Defined

Percent of total life where event is triggered

Example: 80%



8

Event Action

Event

Alarm

Minor Fault

Major Fault Coast Stop

Major Fault Ramp Stop

Major Fault Current Limit Stop

0 Ignore

1 Alarm

2 Flt Minor

3 FltCoastStop

4 FltRmpStop

5 Flt CL Stop

Enable

Disable

950 [Minor Flt Cfg]

493 [HSFan EventActn] - User Defined

• Ignore – default, controller integration

• Alarm – does not stop drive or prevent

starting, notifies user of condition

• Minor fault – does not stop drive, but

prevents it from starting

• Major faults – coast stop, ramp stop,

current limit stop


Predictive Maintenance in Studio 5000®

9

Heatsink fan parameters added with Datalinks

Ladder logic to compare runtime

Datalinks in PF755

Module Definition

Predictive Maintenance can be used in both integrated and standalone

applications to help reduce downtime


Diagnostic Parameters

10

Integration with Logix allows for custom monitoring of drive diagnostics


Automatic Device Configuration

11


Automatic Device Configuration (ADC)

EtherNet/IP

2:00 AM

Stratix 6000™ /8000 / 5700

IP AddressFlash

Configuration


Designing a System for ADC

13

1. Stratix™ switch – Automatically assigns IP

Address

2. Firmware Supervisor – Flashes the drive and

peripherals

3. Logix controller automatically downloads all

configuration files to replaced drive

System Requirements

Standard feature for PowerFlex® 755 with

embedded EtherNet/IP ports

EtherNet/IP options for PowerFlex® 753

ControlLogix® or CompactLogix™ Controller

Stratix 5700™, 6000, 8000 or switch

Studio 5000® (RSLogix 5000) v20.00 or newer


Network Topologies and Switches

14

Topologies ConfigurationAutomatic assignment

of EtherNet/IP address

Manually load

EtherNet/IP

Star - Stratix 2000™

Yes No Required

Star - Stratix 5700™, 6000, 8000

Yes Yes No

DLR

Yes No Required


Configuration

15

Electronic Keying – ‘Exact Match’ is

required for Firmware Supervisor

ControlFLASH firmware kits installed

and stored in controller

Enable ADC for drive and selected

peripherals

Configuration Tips

Upload drive configuration to project

before enabling

Enable ADC after commissioning

With ADC, Logix owns configuration - other

configuration tools should not be used to

configure drive


Integrated Motion with PowerFlex® 755

16


PowerFlex® 755 is native device in Studio 5000®

Motion instruction-based programming Diagnostics and drive maintenance

Position, velocity, or torque control

Synchronized drive control Simple and complex profile for 1 drive to

100+ drives Coordinated motion between PowerFlex®

and Kinetix® drives

Motion instruction programming Positioning Gearing Camming

PowerFlex® 755 with Integrated Motion

17

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Paper Unwind/RewindBenefits of Integrated Motion

Synchronization along the whole

line is easy with Integrated Motion

Mix of control modes

Torque

Velocity

Position

Mix of Products

PowerFlex® 755

Kinetix® 5500

Logix Controller

Kinetix®

5500

Kinetix®

5500

Kinetix®

5500

PowerFlex®

755

PowerFlex®

755


Custom Code and Reuse

19

Customized code is easy to create

Ladder Logic

Structured Text

Function Block

Standardized instruction set

Add On Instructions (AOI) makes

code easy to reuse


Motion Control Programming

Electronic gearing can be programmed between axes

One master axis, one slave axis

Slave motion occurs based on gearing relationship to master axis

Ratio may be changed programmatically rather than replacing equipment

Output speed is 10 times the input speed

Master Slave 1

2:1 ratio

Slave 2

2:1 ratio

Slave 3

1:2 ratio

T64 - Drive Application Success with PowerFlex 750 … · T64 - Drive Application Success with ......

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