ECM & VFD Operation Tuning Parameter Identification PDF

ECM & VFD Operation Tuning Parameter Identification e gl * ECM (Electronically Commutated Motor) & Progranmable Logk Controller [ VFD (Variable Frequency Drive) tuning (PLC)...

ECM & VFD Operation Tuning Parameter Identification e gl * ECM (Electronically Commutated Motor) & Progranmable Logk Controller [ VFD (Variable Frequency Drive) tuning (PLC) parameters determine the optimal values Bump for an ECM or VFD to ensure efficient and Motor o {e stable operation of an electrical motor. ot = This process involves adjusting (tuning) fen.] i parameters such as the ECM or VFD's Powetsolice: voltage, frequency, speed, current, number of poles to match the specific requirements of the motor and load. Tuning Parameter Identification * ECMs are typically programmed for a single purpose at the factory, while VFDs can be programmed at any time to do whatever jobis required. * ECMs tuning is done within the motor (basically an internal VFD) while VFD systems use an external motor control. We'll focus on VFDs speed pm) * The main VFD program is contained in the processor's firmware & not normally accessible to the variable frequency drive user. * A parameter is a variable associated with VALY, f the operation of the VFD that can be programmed or adjusted. va(L) 2 « Parameters provide a degree of adjustment so that the user can customize the VFD to v3(L1) suit specific motor & driven equipment 5] 7Q@£ requirements.  Tuning Parameter Identification e boost 01030% % \aximum frequency 010 120Kz 1201z * The number of parameters can range from Vnimu freguency 010 1208 onr 50, for small basic VFDs, to over 200 for il ik speed seting (High speed) o 010 o d0OHz e cone larger, more complex VFDs. it opeed suring (Midopesd) Do a0oNs = * Some variable frequency drives provide P6 ulth-speed setting (Low speed) 010 d00H: 10z upload/download & parameter copy P7 Acceleration time 0 to 3600s S8 Capablhty P8 eceleration time 0 to 3600¢ Ss - lectronic thermal O/ relay A Rated invarter current peration mode selection** Oto7 o ferminal 2 frequency setting gain 010 800Hz ootz Tuning Parameter Identification Common adjustable parameters include the following: % Parameter Description | Setting Range Initial Value « Presetspeeds P0 | Toraue boost 10 30% % * Minimum & maximum speeds P1 Maximum frequency to 120Hz 120Hz. e —— == = ¢ Acceleration & Qeceleratlon rates P3| Basetraquency 10 400z om * Two- & three-wire remote control Pa | Multi-speed setting (High speed) o 400t soz modes P5 | Mult-speed sating (Wid spead) 0 300Kz some.. | P e * Stop mo@es. ramp, coast, DC injection P7 | Acceierationtime 036008 s « Automatic torque boost P8 | Decaleration time 1o 36008 s * Current limit Elactronic thermal O/ re Rated invert : ). P9 el B o S00A bt « Configurable input jog 779 | Operation mode selection** w07 ° * V/Hz settings P | s e e e N ss sons * Carrier frequency * Program password  Tuning Parameter Identification e\ % Parameter Description | ~Setting Range Initial Value Variable frequency drives come with PO Torque boost 0to 30% a% factory default settings for most P1 Maximum frequency 0to 120Hz 120Hz parameters that are more conservative in P2 Minimum frequency 0o 120Hz OHz nature. P3 Base frequency 0 to 400Kz 60 H2 P4 Multi-speed setting (High spead) 010 400Kz oz « The default value settings simplify the start- PS Multispeed setting (Midspeed) | 01 oomz sone up procedure. PG Muhbspeed seting (owspeed] | 0o s00Hz 102 * However, parameters for motor nameplate P7 Accelerstiontime 010 36008 s P8 Decolerationtime 010 36008 s data are not factory-set (unless a matched by Haconic tharmal /L raay — Rated invarter VFD & motor has been purchased) & must curent P79 Operation mode selection** Oto7? L] be entered in the field. pas ez sineon | oo e Tuning Parameter Identification In general there are three types of parameters * Tunable on the | y - Parameters can be ol M;;;:O[/ /\/ adjusted or changed while the VFD is \\ ( /' / running or stopped. Response Original Mmm - speed, Desired new speed, Desired speed (setpoint), Actual speed Deviation (error), Control Circuit PID controller output, Proportional circuit Integral circuit, Derivative circuit. Configurable - Parameters can be adjusted or changed only while the VFD is stopped. «—. Read only - Parameters cannot be adjusted.  Tuning Parameter Identification ay The VFD display shows either a parameter number or a parameter value. The VFD's parameter menu outlines what the parameter number represents& what numerical selections or options for the parameter are available. Parameter menu formats vary between make & model. This VFD has two kinds of parameters: program parameters (P-00 through P-64), which configure the VFD operation & display parameters (d-00 through d-64), which display information. Tuning Parameter Identification Examples of program parameters include: * P-00 minimum speed - Use this parameter to set the lowest frequency the VFD will output. Default settingis 0. * P-01 maximum speed - Use this parameter to set the highest frequency the VFD will output. Default set ting is 60 Hz. * P-02 motor overload current - Set this parameter to the motor nameplate full-load ampere rating. Default setting is 100 percent of the rated VFD current. * P-30 acceleration time - Use this parameter to define the time it will take the VFD to ramp up from 0 Hz to maximum speed. Default settingis 5.0 seconds. Tuning Parameter Identification Examples of display parameters include: * d-00 command frequency - This parameter represents the frequency that the VFD is commanded to output. « d-01 output frequency - This parameter represents the output frequency at the motor terminals. * d-02 output current - This parameter represents the motor current. + d-03 bus voltage - This parameter represents the DC bus voltage level. Signal Isolation ECM or VFD signal isolation in a distributed control system (DCS) refers to the process of electrically separating the ECM or VFD control signals from the rest of the DCS to prevent interference and ensure accurate and reliable operation. This is typically achieved by using opto- isolators, which are components that use light to transfer signals between circuits while maintaining electrical isolation. DCS is used to control entire plants, buildings, or processes that are vast and interconnected (as opposed to PLCs which control only one machine).  Signal Isolation ; An example of a DCS system could be an oil refinery where there are a o large number of control systems such as flow controllers which are et closed-loop controllers by which Cor valves are operated in order to obtain set values. Process P Instrumentation Electrification Process Automation Power Automation Signal Isolation * InaDCS, the ECM (actually the PLC) or VFD signals are received and processed by the control system, which then sends commands to the ECM’s PLC or VFD to control the speed and torque of the motor. * The signal isolation ensures that the signals are transmitted accurately and that the ECM’s PLC or VFD and the DCS are protected from electrical interference. * This helps to ensure stable and reliable operation of the system, even in harsh or noisy electrical environments.  ECM & VFD Speed Control Speed Control — Eddy Current Coupling * AVFD eddy current coupling (ECC)is a method of transmitting torque between two rotating shafts without a direct mechanical connection. * The coupling uses electromagnetic induction to transfer torque from a driving shaft to a driven shaft. * The driving shaft is fitted with a rotating magnetic rotor, which generates a magnetic field that passes through a non-magnetic metal coupling ring that is mounted on the driven shaft.  Speed Control — Eddy Current Coupling Circuit Motol Breaker Controlle (a ©) Motor * This magnetic field induces eddy currents in 7N —‘}\“—H-\f‘—\ the coupling ring, which generate a o magnetic field of their own. T W iy * The interaction of these two magnetic fields results in a force being applied to the I coupling ring, transmitting torque from the driving shaft to the driven shaft. Speed Control — Eddy Current Coupling * VFD eddy current couplings are used in applications where a direct mechanical connection between the shafts is not (a ©) Motor possible or desirable, such as in high-speed drives, in harsh environments, or where precise torque control is required. * Usedin other applications: « induction heating (stove tops) « Levitating (high speed trains) « electromagnetic damping (high speed train braking — no physical contact) « electromagnetic braking (zip line brakes) Speed Control — Eddy Current Coupling The coupling has the advantage of being highly efficient and providing a flexible solution for transmitting torque between shafts with different speeds and torque requirements. It also offers high reliability and stability, and is often used in industrial machinery, pumps, and compressors, among other applications. Speed Control — input signals ECMs (internally) & VFDs (externally) use both digital and analog input signals to control the speed of an electrical motor. The specific input signals used by an ECM’s PLC or VFD will depend on the specific model and the requirements of the application, but some common input signals include: « Digital * Analog Speed Control — input signals Digital input signals: « Start/Stop: A binary signal that indicates whether the motor should be running or stopped. « Direction: A binary signal that indicates the direction of rotation of the motor. « Speed Reference: A digital signal that provides the desired speed for the motor, either as a frequency or as a pulse train. * Fault Reset: A binary signal used to reset the ECM or VFD in case of a fault condition. Speed Control — input signals Analog input signals: « Speed Reference: An analog signal that provides a continuous and smooth control over the speed of the motor. « Torque Reference: An analog signal that provides a continuous control over the torque output of the motor. * Current Feedback: An analog signal that provides information on the current being drawn by the motor, which can be used for protection or control purposes. * Voltage Feedback: An analog signal that provides information on the voltage being supplied to the motor, which can be used for protection or control purposes. Speed Control — input signals * The ECM or VFD uses these input signals to control the frequency and voltage of the AC power being supplied to the motor, resulting in precise control over the speed and torque of the motor. * The input signals are processed by the ECM or VFD's control circuit, which adjusts the power supply accordingly. * The choice of input signals used will depend on the specific requirements of the application and the capabilities of the ECM or VFD.