PowerFlex-700变频器调试与故障排除培训资料.ppt

PowerFlex 700 变频器调试与故障排除山东省冶金设计院自动化公司 李刚SDMLG001126.COMPowerFlex 700 变频器硬件结构PowerFlex 700 Drive OverviewProcessor and I/OPowerFlex 700 DriveControl PanelComputerMotorEncoder(optional)PowerFlex 700 Replacement Policy Frames 0-4:These frames are considered remove and replace due to their very small size and the fact that it is far easier and more cost effective to repair them in a Rockwell repair facility than in the field.Simple parts like front covers,conduit plates,fans,brake resistors and cassettes will be the only items available as kits.Frames 5&6:Some customers have a desire to repair larger frame drives rather than send them to the factory for repair.To help facilitate field repair,we will offer more spare components along with the simpler components previously mentioned(fans,covers,etc.).These kits will include circuit board assemblies,MOVs,current transformers,fan transformers and power devices just to name a few.For power devices,our team is working on the full heatsink as a replacement component for Frames 5&6 instead of individual IGBTs and other like components.This will make it a bit easier to repair in the field without errors due to improper torquing or application of thermal grease.All kits will include repair instruction including torque values as required.PowerFlex 700 Frame 5 PowerFlex 700 变频器报警判断及清除Alarmsl l一类报警:l l只显示一种状态，不会引起变频器停车。只显示一种状态，不会引起变频器停车。l l可通过参数可通过参数259 Alarm Config 1259 Alarm Config 1更改设置更改设置l l二类报警:l l阻止操作者在未正确设置之前启动变频器。阻止操作者在未正确设置之前启动变频器。l l不能通过参数更改设置不能通过参数更改设置l l永远使能永远使能二种类型的报警:Alarms一类报警引起黄色状态灯常亮:Status LEDAlarms二类报警引起黄色状态灯闪烁:Status LEDAlarms报警也会在HIM上显示报警图标：Alarm IconCommon Drive Alarmsl lDigital input alarmsl lStop asserted alarmsDigital Input Drive Alarmsl l因数字输入功能定义有冲突引起的报警l l三种类型:l lDig In ConflictADig In ConflictA，数字输入功能冲突，数字输入功能冲突l lDig In ConflictBDig In ConflictB，配置启动输入，未配置停止。，配置启动输入，未配置停止。或其他功能冲突。或其他功能冲突。l lDig In ConflictCDig In ConflictC，不止一个物理输入被配置成相，不止一个物理输入被配置成相同的输入功能。同的输入功能。Digital Input Drive AlarmsDigital Input Drive AlarmsDigital Input Drive Alarmsl lForward/ReverseForward/Reversel lSpeed Select 1Speed Select 1l lSpeed Select 2Speed Select 2l lSpeed Select 3Speed Select 3l lRun ForwardRun Forwardl lRun ReverseRun Reversel lJog ForwardJog Forwardl lJog ReverseJog Reversel lRunRunl lStop Mode BStop Mode Bl lBus Regulation Mode BBus Regulation Mode Bl lAcc2/Dec2Acc2/Dec2l lAccel 2Accel 2l lDecel 2Decel 2Auto/ManualAux FaultClear Faults(CF)Decel LimitEnableEnd LimitExcl LinkFast StopFind HomeFlt/MicroPosHold StepHome LimitJog 2Jog1LocalMOP DecMOP IncDig In ConflictC：More than one physical input has been configured to the same input function.Multiple configurations are not allowed for the following input functions.PI EnablePI HoldPI InvertPI ResetPos Sel 1-5Precharge EnProf InputPwr Loss LvlRedefine PosRun LevelRun w/CommRunFwd LevelRunRev LevelSpd/Trq Sel1-3StartStop CFTorque Setpt 1UserSet Sel1-2Vel OverrideStop Asserted Drive Alarmsl lStop Asserted Caused byl lImproper Wiring for Start/StopImproper Wiring for Start/Stopl lPossible loss of logic power supplyPossible loss of logic power supplyl lPossible missing jumper for logic common&Possible missing jumper for logic common&P/S CommonP/S Commonl lActual stop command is being issuedActual stop command is being issuedl lStop Asserted will generate and Alarm message on the HIM display and cause the STS LED to blink Yellowl lCauses for Stop Asserted are not listed in the User ManualThe Alarm Queue当引起报警的条件不再存在时，报警会自动清除.最近八个报警队列可通过以下清除:l lLCD HIMl lDriveExplorer softwarel lDriveExecutive softwareThe LCD HIM Alarm QueueFAt SpeedAuto26.01Hz1Alm Q#:A#1Precharge ActiveAlarms Numberin the QueueAlarm CodeAlarm TitleThe DriveExplorer Software Alarm QueueDrive StatusAlarms Numberin the QueueAlarm CodeAlarm TitleThe DriveExecutive Software Alarm QueueDrive StatusAlarm CodeAlarm TitlePowerFlex 700 变频器故障清除Faults三种故障类型:TypeNameDescription1制动复位运行Auto-Reset Run当此类故障发生,变频器试图自动复位故障.如果引起故障的条件不再存在,故障将被自动复位，变频器将自动重启动。174Auto Rstrt Tries 175Auto Rstrt Delay2不可复位Non-Resettable此类故障一般需要送修变频器或马达。引起故障的条件必须排除，故障才能清除。故障在重上电后被复位。3用户定义User Configurable此类故障可以通过参数设置，使能不使能 选择动作或忽略故障情形。238Fault Config 1Faults当故障发生:l l变频器输出立即中断 l l马达自由滑坡停车l l故障信息显示在HIM上FaultsOnce fault occurs:l lFault condition is latched,requiring fault reset action to clear latched condition.l lIf fault condition still exists after reset,drive will fault again.l lAdditional data on status of drive at time of fault is recorded:l lOnly a single copy of this information Only a single copy of this information l lAlways related to most recent faultAlways related to most recent faultl lWhen another fault occurs,this data is When another fault occurs,this data is overwritten with new dataoverwritten with new dataFaultsParameters latched into non-volatile drive memory:NameNumberMeaningFault FrequencyParameter 224Drive output frequency at the time of the faultFault AmpsParameter 225Motor amps at the time of the faultFault Bus VoltsParameter 226Unfiltered DC Bus volts at the time of the faultStatus 1 FaultParameter 227Drive condition at the time of the faultStatus 2 FaultParameter 228Drive condition at the time of the faultAlarm 1 FaultParameter 229Alarm condition at the time of the faultAlarm 2 FaultParameter 230Alarm condition at the time of the faultFault Queuel l八个故障事件排列l l包括故障代码和发生时间。l l先进先出(FIFO)排列l l存于非易失性存储器Fault Queue故障排列显示在:l lLCD HIMl lDriveExplorer softwarel lDriveExecutive softwareThe LCD HIM Fault QueueFAt SpeedAuto26.01Hz1Flt Q#:F#85Port 5 DPI LossFaults Numberin the QueueFault CodeFault TitleAccum:131:55:51.240Time StampThe DriveExplorer Software Fault QueueDrive StatusFaults Numberin the QueueFault CodeFault TitleTime StampThe DriveExecutive Software Fault QueueDrive StatusFault CodeFault TitleClearing a Faultl l引起故障的原因必须查明并解除后，故障才可以清除。l l要清除故障可以:l l按按HIMHIM 上的停止按钮。上的停止按钮。或或l lClick“Clear Fault”in Faults tab in Click“Clear Fault”in Faults tab in DriveExplorer softwareDriveExplorer software或或l lClick“Clear Faults.”in Faults tab in Click“Clear Faults.”in Faults tab in DriveExecutive softwareDriveExecutive softwarePowerFlex 700 变频器负载和环境因素的故障排除Load smaller than motors maximum rating:Load FaultsLoad at motors maximum rating:Load FaultsMotor OverloadLoad larger than motors maximum rating:Load FaultsLoad Faults负载故障类型:l l马达过载 Motor OverLoadl l硬件过电流HW OverCurrentl l软件过电流SW OverCurrentl l超速过限OverSpeed Limitl l安全销故障Shear Pinl l变频器过载Drive OverLoadAn incorrectly applied drive can result in component damage or a reduction in product life.Application errors such as undersizing the motor may result in malfunction of the system.Environmental Faults在如下情形下发生环境故障:l l变频器接受到太少的功率l l变频器接受到太多的功率l l变频器周围有过多的热量l l变频器内部有过多的热量ExcessiveHeatExcessiveHeatExcessiveHeatExcessiveHeatEnvironmental FaultsEnvironmental FaultsTypes of environmental faults:l l动力缺失Power Lossl l母线低电压UnderVoltagel l母线过电压OverVoltagel l散热片过温Heatsink OvrTempl l晶体管过温Trnsistr OvrTempl l控制板过温Cntl Bd OvrTempAmbient Operating Temperaturesl l0 to 40 C 周围温度l l操作在 41 and 50 C 之间的周围温度:l l除除20BC07220BC072以外所有变频器把顶部标签撤掉，以外所有变频器把顶部标签撤掉，可工作在可工作在50 C50 Cl l20BC072:20BC072:l l顶部标签撤掉，可工作在顶部标签撤掉，可工作在 45 C 45 Cl l顶部标签和通风板撤掉，可工作在顶部标签和通风板撤掉，可工作在50 C50 CRemoving the adhesive label from the drive changes the NEMA enclosure rating from Type 1 to Type Open.The vent plate can be removed by lifting the top edge of the vent plate from the chassis and rotating the vent plate out from the back plate.Minimum Mounting Clearances避免增加过多的热量:No Adhesive LabelAdhesive LabelPowerFlex 700 变频器设备故障排除Fault Code Equipment Problems设备故障类型:l l通讯口故障l l软件故障l l编码器故障l lI/O故障l l主控制板故障l l存储器故障l l其它硬件故障Fault Code Equipment Problemsl l一些设备故障可以通过以下方法得到修正:l l改变参数改变参数 l l重新上电重新上电 l l其他故障则需要更换变频器器件To avoid an electric shock hazard,verify that the voltage on the bus capacitors has discharged before performing any work on the drive.Measure the DC bus voltage at the DC+and DC-terminals of the power terminal block.The voltage must be zero.Non-Fault Code Equipment Problemsl l变频器未能:l l改变马达方向改变马达方向l l通过硬件接线启动通过硬件接线启动l l通过通过HIMHIM启动启动l l根据设定的速度相应地改变速度根据设定的速度相应地改变速度l l马达和或变频器无法升速到设定速度l l马达运转不稳定l lHIM无法控制对马达的操作l lHIM上没有显示Non-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment ProblemsNon-Fault Code Equipment Problemsl l一些没有故障码的设备问题可以通过以下方法得到修正:l l改变参数改变参数l l重新上电重新上电l l其他故障则需要重新接线或更换变频器器件谢 谢 ！