Getting to Know The PowerFlex 525 - Connected Components Workbench

Summary

This video demonstrates the process of connecting a drive using Connected Components Workbench (CCW) software, including the configuration of motor parameters and feedback devices. It covers setting up the motor, encoder, and tuning for optimal performance, emphasizing the importance of correct motor settings like pole count and RPM. The video also discusses features such as s-curve acceleration, frequency control, and communication settings, along with troubleshooting steps. The tutorial highlights the use of Ethernet over serial connections for faster setup and explores options for improving mechanical wear and tear using s-curve adjustments.

Takeaways

• 😀 Connection to the drive can be done via Ethernet or a USB serial adapter, with Ethernet being the preferred option due to its higher speed.
• 😀 The software used to connect to the drive is Connected Components Workbench (CCW), which is available for free on Rockwell's website.
• 😀 When setting up the drive, a basic startup wizard is used, with options to configure parameters like motor overload current, motor nameplate current, and motor poles.
• 😀 The encoder feedback device is optional, as the drive is initially configured for sensorless vector control, meaning it doesn't rely on the encoder for speed regulation.
• 😀 Brake resistors can be used for the drive, with standard Rockwell resistors recommended, but users should exercise caution when using non-standard resistors to avoid damage.
• 😀 A key step in setup involves tuning the motor, where a static tune is done if the motor is connected to the load, and a rotating tune is performed for more accurate results.
• 😀 The rotating tune addresses both voltage drops across windings (static tune) and flux current (rotating tune), which is crucial for correct motor performance.
• 😀 Motor tuning is important for speed regulation, and the software also allows for setting the max frequency, enabling or disabling reverse operation, and defining acceleration and deceleration times.
• 😀 The S-curve feature is useful in reducing mechanical wear and tear by smoothing out the starting and stopping motion of the motor, and can be adjusted to help with acceleration and deceleration.
• 😀 The software offers flexibility in speed control methods, including the use of the onboard potentiometer (Drive Pot) and Ethernet/IP input for speed references, with caution regarding conflicting speed references.
• 😀 The drive's terminal connections, relay outputs, and analog outputs are clearly displayed in the wizard, making the setup process more intuitive, with predefined frequencies and parameters to simplify configuration.

Q & A

What is the primary method of connecting to the drive in this script?

The primary method of connecting to the drive is via Ethernet, as it is faster than other options such as using a USB serial adapter.

What software version is being used to connect to the drive in the script?

The software version being used is Connected Components Workbench version 12, which was released in March of the previous year.

What is the difference between the Ethernet connection and the 12/03 USB serial adapter for connecting to the drive?

The Ethernet connection is faster and preferred for communication with the drive, while the 12/03 USB serial adapter is used when there is no Ethernet network available, but it is slower than Ethernet.

How are the motor parameters set in the script?

The motor parameters such as overload current, nameplate current, number of poles, RPM, and power are configured in the software. The nameplate current is set to 0.025 (rounded to 0.03), and the motor's RPM is set to 1600.

What is the role of the encoder in this setup?

The encoder is used for position feedback, though the drive is currently set to senseless vector control, meaning it isn't using the encoder for speed regulation.

What is the purpose of the dynamic brake resistor, and what is the recommendation about its use?

The dynamic brake resistor is used for braking applications, and it is recommended to use a Rockwell standard brake resistor, which has a 5% duty cycle rating. If a custom resistor is used, caution is required to ensure it has thermal protection and is properly monitored.

What does the 'S-Curve' setting in the drive configuration do?

The 'S-Curve' setting helps reduce mechanical wear and tear on components like belts and pulleys by smoothing out the start and stop of the motor, preventing sudden movements.

Why is it important to uncouple the motor from the load during the tuning process?

It is important to uncouple the motor from the load to avoid causing mechanical stress during the tuning process, which can affect the accuracy of the tuning and potentially damage the system.

What is the significance of the motor's flux current in this setup?

The flux current is crucial for the motor's operation, as it determines how much current is needed to generate the magnetic flux that makes the motor rotate. This is particularly important for induction motors, which require a certain level of current for proper operation.

How does the software handle multiple speed references in the drive configuration?

The software ensures that no two speed references are set to the same value. For example, if Ethernet/IP is used for speed reference, another reference, such as Drive Pot, must be used to avoid conflicts.