PowerFlex® 700 Pump Energy Savings

Equipment List

Computer with DriveObserver and RSLinx Classic

1203-SSS Smart Self-powered Serial Adapter, 1203-SFC Serial Cable and 1202-C10 DPI Cable

or

1203-USB Converter, 20-HIM-H10 Cable and USB Cable

PowerFlex 700 (Series B) Drive Demo

Pump Demo

Note: This lab requires 230V three-phase power.

Lab Objectives and Prerequisites

This lab demonstrates the benefits of using a variable speed drive instead of a simple motor starter and throttle to control flow in a pumping system. Variable speed drive systems save mechanical wear and a great deal of energy.

Students should have some experience with DriveObserver and RSLinx software. Performing the DriveObserver lab would satisfy this requirement.

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Document Conventions

Throughout this workbook, we have used the following conventions to help guide you through the lab materials.

This style or symbol: Indicates:

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:

identify a hazard

avoid the hazard

recognize the consequences

Words shown in bold (e.g., DriveObserver or OK)

Any item or button that you must click on, or a menu name from which you must choose an option or command. This will be an actual name of an item that you see on your screen or in an example.

Words shown in bold italics, enclosed in single quotes (e.g., 'Controller1')

An item that you must type in the specified field. This is information that you must supply based on your application (e.g., a variable).

Note: When you type the text in the field, remember that you do not need to type the quotes; simply type the words that are contained within them (e.g., Controller1).

The text that appears inside of this gray box is supplemental information regarding the lab materials, but not information that is required reading in order for you to complete the lab exercises. The text that follows this symbol may provide you with helpful hints that can make it easier for you to use this product. Most often, authors use this “Tip Text” style for important information they want their students to see.

Note: If the mouse button is not specified in the text, you should click on the left mouse button.

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Setting-up the Demo

Connecting and Energizing the Demo

ATTENTION: Hazardous voltages exist beneath the drive cover.

Contact with circuits under the cover can result in death or serious injury by electric shock. Do NOT remove the drive cover.

1. De-energize the drive.

2. Connect the 1203-SSS serial converter. If you are using the 1203-USB communications adapter, skip to the next step.

1. Connect the d-shell end of the 1203-SFC cable to the COM1 serial port on the computer.

2. Connect the other end to the 1203-SSS serial converter.

3. Connect the one end of the 20-HIM-H10 cable to the drive.

4. Connect the other end to the 1203-SSS serial converter.

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5. Connect the 1203-USB converter.

Connect the A style (larger) end of the USB cable to a USB port on the computer.

Connect the B style (smaller) end of the USB cable to the converter.

Connect the RJ45 end of the 20-HIM-H10 cable to the drive.

Connect the other end to the converter.

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6. Prepare the control switches. Position IN4 and IN5 switches in the LEFT (Off) position. By default these inputs command the drive to run at preset speeds. Positioning these in the LEFT position, allows you to control the drive speed with the potentiometer. Position the IN6 switch in the RIGHT (On) position. This will turn the “Enable” input on, allowing the drive to run.

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7. Make the following connections as shown below:

Motor to the External Motor connector on back of the drive demo.

Flow sensor to External I/O connector on back of drive demo.

230V ac power to the drive demo.

8. Apply power to the drive demo by pulling the red EMERGENCY STOP on the Power Loss

demo.

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Configuring RSLinx

1. If you are using a 1203-SSS communications adapter, note which serial port it is connected to.

2. If you are using a 1203-USB converter, determine which serial port is assigned to it:

Open the Windows Control Panel and double-click on System.

In the System Properties window, click on the Hardware tab and then click Device Manager.

In the Device Manager treeview, expand the Port (COM & LPT) group. The assigned COM port is shown in parenthesis at the end of the Allen-Bradley 1203-USB entry.

3. Start RSLinx Classic. Double-click on RSLinx icon on your desktop or in the Windows Start menu select Programs > Rockwell Software > RSLinx > RSLinx to start RSLinx.

Typically, you need to configure RSLinx settings only once on each PC unless your communication connection method changes.

4. In the menus, select Communications > Configure Drivers. The Configure Drivers dialog box

will open.

5. Look in the list of Configured Drivers. If you see a driver whose name begins with “AB_DF1”, select it and click Delete.

6. In the Available Drivers selection box, select “RS-232 DF1” and click Add New.

7. When prompted for a name, click OK.

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8. Enter the appropriate data in the Configure RS-232 DF1 Devices dialog box.

Select 1770-KF2/1785-KE/SCANport for Device.

If you are using a 1203-SSS communications adapter select the Comm Port where the adapter is wired, and then select 38400 for the Baud rate.

If you are using a 1203-USB converter, select the serial port assigned to the driver for Comm Port, and then select 115200 for the Baud Rate.

Click OK to close the dialog box.

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9. Verify that the driver that you just configured is listed in the Configured Drivers list with a status of “Running”. Note: If the Status is “Conflict”, other software may be using the serial communication port or you

may have two RSLinx serial drivers programmed for the same serial port:

Delete duplicate drivers

If another serial software package, such as DriveExplorer, is running, close it.

Then stop and re-start the RSLinx serial driver.

10. Click Close, to close the Configure Drivers dialog.

11. In the menus, select Communications > RSWho…. The RSWho dialog will open.

You should see both a computer (Workstation) and the connected drive device (AB_DF1-1, Data Highway Plus). If this is not the case, verify that you have properly connected the PC to the drive using the adapter and that power to the drive is on. If you check all these things and the connected drive device still does not appear, verify your device driver settings and try other baud rates (i.e. 9600, 19200, 38400) and computer communication ports (i.e. COM1, COM2).

Note: At this time, the drive device may be depicted by a question mark icon labeled “Unrecognized Device”. The serial driver will work.

Note: If you cannot get the drive device to appear and communicate, contact an instructor.

12. Close RSLinx.

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Using DriveExecutive to Configure the Drive

1. Double-click the DriveExecutive icon to start the software.

2. If the Danger dialog appears, read it and click OK.

3. Maximize the DriveExecutive window, so it fills the entire screen.

Connecting to the Drive with DriveExecutive

1. Select Drive > Connect to Drive…

The Connect to Drive window will open. Click on the AB-DF1 driver you created.

2. Expand the device tree under your AB-DF1 driver.

A. Click once on the AB DPI object (this is the converter connected to the drive), and click OK.

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B. Wait while the software uploads the settings in the drive.

C. After the software has connected to the drive it will display a window like this:

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Resetting the Drive’s Settings to Factory Defaults

1. In the linear list view, locate parameter 197 [Reset To Defaults]. Change its value to 1 – Factory, and press enter.

2. Clear the resulting fault by pressing the button on the drive’s Human Interface Module (HIM).

Configuring the Drive

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Using DriveObserver to Monitor the Drive

To perform this portion of the lab, you will use DriveObserver software.

1. Double-click the DriveObserver icon on the Windows desktop (or in the Windows Start menu select Programs > DriveTools > DriveObserver) to start the software.

2. Select File > New. The Set New Chart Sampling screen will open.

3. Select a sampling period of 300 milliseconds. Leave all the other settings as is, then click OK.

Adding Traces

1. If a file is not already open, select File > New.

2. If the Add Trace screen is not already open, select Chart >Add traces…

3. In the Add Trace screen, click the Add Node button.

4. Navigate from the Workstation, through the AB_DF1 driver to the drive (address 01) and double-click on the icon for the AB DPI object (the drive).

5. Back in the Add Trace screen, select the following parameters from the linear list of the node by clicking the checkbox in front of the desired parameters: 1 [Output Freq], 3 [Output Current], 12 [DC Bus Voltage], and 415 [Encoder Spd].

6. Click OK.

Recording Data

1. Start the drive by pressing the button on the HIM.

2. In the DriveObserver toolbar, click the Record button. DriveObserver now displays new data.

3. If you want to stop recording data, click the Stop button.

TIP: Double clicking a parameter in the table beneath the chart will open the Edit Trace screen, so that you can change the color, minimum & maximum values, line format, etc.

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Default Power Response and Logic Ride Through

1. On the Power Loss Demo set the DROPOUT TIME selector switch to 1/60, and the MULTIPLIER thumbwheel to X 2 to create a power interruption time of 33 ms.

2. Start the drive by pressing the button on the HIM, and run the motor at 60 Hz. (use the speed potentiometer to the right of the drive to get to 60 HZ).

3. If DriveObserver is not already recording, start recording data.

4. Remove input power to the drive for 33ms by pressing the SINGLE SHOT button on the Power Loss Demo module.

5. Using DriveObserver, observe the output frequency and bus voltage during the power interruption. Also note whether the drive experienced a fault.

6. Repeat the above steps for an interruption of 1.5 seconds (1/2 X 3 on the Power Loss demo module).

Clear any faults by pressing the button on the drive’s HIM if necessary.

7. Disable the Under Voltage Fault by resetting parameter 238 [Fault Config 1] / bit 1 [UnderVoltage] to a value of 0. Then, retest with a power interruption for 1.5 seconds.

8. Stop the drive by pressing the button on the drive’s HIM.

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Inertia Ride-Through

When a drive, which has been configured for inertia ride through, senses an interruption in incoming power, it can reduce the output frequency and convert the kinetic energy of the load’s inertia into electrical energy to maintain the dc bus voltage.

1. Change the value of parameter 184 [Power Loss Mode] to a value of 1 – Decel. This enables inertia ride through.

2. Enable the Power Loss Fault. Set parameter 238 [Fault Config 1] \ bit 0 [Power Loss] to a 1.

3. Set the Power Loss demo module to 1/2 X 8 or 4 seconds.

4. Start drive and run the motor at 60 Hz. If DriveObserver has stopped recording, restart it.

5. Remove input power to the drive for 4 seconds by pressing the SINGLE SHOT button on the Power Loss Demo module. Observe the performance of the drive.

6. Increase the value of parameter 185 [Power Loss Time] from 0.5 seconds to 6 seconds. Repeat the above steps and observe the performance of the drive.

7. Estimate the inertia ride through time for 60 Hz (1800 RPM).

Start by calculating the Moment of Inertia (J) of the flywheel.

Mass (m) = 14.5 kg Radius (r) = 0.1524 meters. J = kgm2.

Calculate the Stored Energy (W)

Speed (n) = 1800 RPM. W = watt-seconds.

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The average power consumption for the drive and motor is 100 watts. Understand that this figure includes friction and windage losses in the motor, which vary with motor speed.

Estimate the Ride through Time. Time (in seconds) = Stored Energy (in watt-seconds) / Average Power Consumed (in watts). Estimated ride through time =_________________________________.

8. Change the value of parameter 185 [Power Loss Time], so it exceeds the time you calculated in the last step. Run the drive in ride through mode and remove power. Measure and compare the time against your calculated value. Push and hold the INFINITE button to remove input power. On the drive’s HIM, watch the value of parameter 415 [Encoder Speed]. When the value approaches zero (about 5 Hz), release the drop out button. Experiment to determine how long you can hold the button without tripping the drive.

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Flying Start

1. Change the value of parameter 184 [Power Loss Mode] to 0 - Coast.

2. Change the value of parameter 155 [Stop/Brk Mode A] to 0 - Coast.

3. Start the drive and run at 60 Hz. If DriveObserver has stopped recording, restart it.

4. Press the stop button and wait ten seconds. Press the green start button. Observe the operation of the drive.

5. Stop the drive, then change the value of parameter 169 [Flying Start En] to 1 - Enabled.

6. Start the drive and run at 60 Hz. If DriveObserver has stopped recording, restart it.

7. Press the stop button and wait ten seconds.

8. Press the green start button. Observe the operation of the drive.

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Notes:

www.rockwellautomation.com

Power, Control and Information Solutions

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Publication DHQ-DM032D-EN-P – December 2006 Copyright © 2006 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.