Application Techniques PowerFlex 700S and PowerFlex 755 Drives Tuning Catalog Numbers Important User Information Read this document and the documents that are listed in the Additional Resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions and requirements of all applicable codes, laws, and standards. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual. Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited. Throughout this manual, when necessary, we use notes to make you aware of safety considerations. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. 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 a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Table of Contents Preface Summary of Changes . 7 Additional Resources . 8 Chapter 1 Background Inertia. 9 Definitions of Mechanical Terms . 11 Backlash . 11 Resonance . 11 Bandwidth. 12 PowerFlex Control Loops. 14 PowerFlex Position Loop. 14 PowerFlex Velocity (Speed) Loop . 16 PowerFlex Torque Control. 18 Damping Factor. 19 PowerFlex Inertia Adaption. 19 Benefits of Inertia Adaption . 20 How Inertia Adaption Works . 20 PowerFlex 700S Drive Inertia Adaption Configuration . 21 PowerFlex 755 Drive Inertia Adaption Configuration . 24 PowerFlex Load Estimate and Load Observer. 26 Benefits. 26 How Load Observer and Load Estimate Work . 26 PowerFlex 700S Drive Load Estimate Configuration . 27 PowerFlex 755 Drive Load Observer Configuration . 29 Chapter 2 Tuning Configuration and Setup PowerFlex 700S Drive Startup Wizard . 32 Motor Control Configuration . 33 Motor Data . 34 Feedback Configuration . 35 Direction Test . 35 Auto Tune. 36 Inertia Auto Tune Test . 37 PowerFlex 700S Drive Additional Setup . 38 PowerFlex 700S Drive Movement Configuration for Tuning . 40 PowerFlex 755 Drive Startup Wizard . 41 Motor Control Configuration . 41 Motor Data . 42 Feedback Configuration . 43 Direction Test . 44 Auto Tune. 44 Inertia Auto Tune Test . 45 PowerFlex 755 Drive Additional Setup. 46 PowerFlex 755 Drive Movement Configuration for Tuning . 48 Rockwell Automation Publication DRIVES-AT004B-EN-P - March 2020 3 Table of Contents Chapter 3 Tuning Using Bandwidth PowerFlex 700S Drive . 52 Velocity (Speed) Loop Tuning Procedure. 53 Changing the Damping Factor (Z) . 57 Position Loop Tuning Procedure (if Used) . 59 PowerFlex 755 Drive . 59 Velocity (Speed) Loop Tuning Procedure. 60 Changing the Damping Factor (Z) . 63 Position Loop Tuning Procedure (if Used) . 65 Chapter 4 Manual Tuning Drive Setup. 70 Velocity (Speed) Loop Tuning . 70 Position Loop Tuning (if Used) . 74 Chapter 5 Regulator Compensation Filters Torque Reference Notch Filter . 78 Using the Torque Notch Filter . 81 Tools for Determining Resonant Frequencies. 83 Speed Regulator Lead/Lag Filters . 83 Using the Lead/Lag Filter . 86 Mechanical Backlash Application Example . 89 Inner Loop System Rolloff . 90 Lead/Lag Filter Application Example . 92 Chapter 6 Encoder Feedback Filters PowerFlex 700S Drive Encoder Feedback Filter. 95 Hardware Filter Time Constant . 96 PowerFlex 700S Drive FIR Filter . 96 Configuring the FIR Filter in the PowerFlex 700S Drive . 97 PowerFlex 755 Drive Encoder Feedback Filter . 98 Configuration Steps . 99 Appendix A PowerFlex 755 Drive and CIP Using CIP Motion Control Loop Relationships with PowerFlex Drives . 101 Example of Rationalizing PowerFlex Gains to CIP Gains . 102 PowerFlex 755 CIP Motion Drive Configuration . 102 PowerFlex 755 CIP Motion Drive Setup . 103 Drive Creation and Configuration . 104 PowerFlex 755 CIP Motion Axis Configuration . 106 4 Rockwell Automation Publication DRIVES-AT004B-EN-P - March 2020 Table of Contents Appendix B Creating a Trend with Studio 5000 PowerFlex 700S Drive Logix Designer Setup . 113 Logix Designer Application for Tuning PowerFlex 755 Drive Logix Designer Setup. 115 Trend Properties Dialog Box . 117 Name Tab . 117 General Tab. 117 Display Tab . 118 Pens Tab. 118 X-Axis Tab . 120 Y-Axis Tab. 120 Sampling Tab . ..