VFD Guy

Connect with CCW. You can view the history there. It’s the latest drive software and free. Run the tech support wizard for print outs of parameters and fault history

What OS are you using? 32 or 64 bit?

Sounds like you need a position follower/electronic gearing but the 525 is not capable of that. Network latency would throw off synchronization when not using motion. Without additional hardware, I don’t think the 525 is a fit for this application 

Are you able to update to the latest v 20?

@asteroidehk  the revisions available of the drive offline are based on installed databases. Studio 30 and below use drive tools databases and 31 and up use CCW databases. If revisions are missing, update your databases files from PCDC. In any case, I think your drive is still fine to use and can be brought up to current active status by replacing the mature 20 comm e with enetr and flash updating the drive if you want to fix any known corrected anomalies. 

A Powerflex 753 is not discontinued. A comm-e might be. Just flash up the drive to v14 and you can use a 20-750-ENETR to replace the comm-e. This change will require the profile to be deleted and added as a 753 via enetr. All 750 drives are forward compatible to the latest revision

This answer can go many ways. If you can download to the plc, it’s easiest. Hopefully the parameters are saved in the plc. Inhibit Io connection. Go offline then simply download from the drive tab or synchronize. The method here depends on logix version since the AOP changed. This will auto change the drive revision in the project and send the parameters down. If you can’t download, a him copycat is easy if you have a HIM. Make sure to upload all ports and not just a single port. Note that the revision of the drive and plc will mismatch which will not allow you to use the aop but the io connection is still made   technote below may help too https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/615067 @BobLfoot downgrading is possible but may not help if he needed to go to a non secure fw which isn’t possible anymore. It really comes down to the use of the AOP. Any newer version will make an IO connection assuming keying isn’t exact but opening the AOP will show the red X or can’t merge. Keying is used for IO connection but opening and using the profile must always match the fw version of the drive

Great explanation @panic mode  AOPs are owned by Rockwell or their partner. An EDS file may just be used for linx or have enough info for an EDS AOP which can be used in logix. Reference https://literature.rockwellautomation.com/idc/groups/literature/documents/pm/1756-pm002_-en-d.pdf

Maybe just me but anytime I want to pull something into excel I just use the linx dde/opc topics. Very easy to read write tags to a plc

The feedback type and ppr would also be helpful but servo part number should tell us that

Agreed if you can ping and not see in linx, harmony files might be the issue. Delete Harmony or just make a new driver. 

This is a shared ac configuration via the black connectors on top. The red terminal blocks are the STO signals. There doesn’t appear to be Aux 24 to it. Likely a bad drive. I believe controls are fed off an SMPS which comes off the DC bus. Take the cover off the DC bus and measure there. This will tell you if the converter is functional 

Since this is a pump, I’m assuming no encoder and non FV mode. If those are true, I still feel my previous post applies. Since it’s failing at a higher speed, that means higher voltage and likely a cable or motor issue. Of course a scope on the output would give you the proof. F12 means 2x drive rated current was seen my CTs. What is the amperage of the drive?

Agreed

@ElectronGuru  yes meggering significantly higher than motor insulation can damage a motor. Many vfd rated motors are rated to 1488v. 12v higher than that won’t cause an issue. I’ve seen countless times of people meggering at only 500v and say no motor issue. A motor can see up to 2 times dc bus with ringing for short periods. So 650vdc, that’d be about 1300v and why a 500v megger would cause a false success. @PaulKim1003  it would help if you stated when the fault occurs. On every start? Acceleration? Since lowering the speed helped, did the fault only occur above certain speeds?

Assuming no parameters have changed, F12 is often cabling or the motor. Disconnect the motor at the junction box and start the drive. If it runs, the cables are good. If the issue occurs when the motor is hooked up, megger at 1500v with drive disconnected. If this occurred after replacement or commissioning then parameters are likely the issue. If settings didn’t change, likely a motor or cable issue. If F12 occurs with no leads connected then you have a drive problem. Hope this helps. Interested to hear the solution

Divide and conquer. First find out if the plc is sending a reference that makes it to the drive. Since all 10 are 0, my gut is the plc, not the drives

Are you closed loop or open loop?

I would follow this https://rockwellautomation.custhelp.com/app/answers/answer_view/a_id/524308/loc/en_US#__highlight. Keep your engineering units and do a calibration 

V6 is available on Rockwell site. I just checked my software and the V6 database installs. The latest aop moved databases on your computer. The installer tries to create a registry edit to point to the new location. If your security is like mine and prevented it, your databases are not pointed to correctly. I had to call Rockwell to show me where the reg edit was to fix

I’ve used bobs suggestion above. Works well. Also, Rockwell has a new bootp software that seems more stable than the bootp tool. It’s called Ethernet commissioning tool

Terminal 1 to 11 is the stop command which is NC. When you reach your target position, open terminal 1. I assume this will come from your plc

Use QA13283 instead. The technote you provided states that the content of that technote only applies to T drives

That technote applies to 755T drives not 755 drives. Are you using a T drive?

I agree that rotate is better than static for FV and SV modes. Static tune populates motor characteristic parameters like IR voltage drop which isn't used in V/Hz modes. So Rotate and Static only apply to SV and FV modes. Econ mode is technically part of SV. So the mode matters here. Inertia tune populates total inertia which is only used by Flux vector modes. If you read the description for parameter 76 which is populated during the inertia tune, it even states this. If you read the description for load observer parameters, it also states that it's only used in Flux vector modes, so the mode does matter. Here is right from the manual: Inertia Tune (4) – A temporary command that initiates an inertia test of the motor/load combination. The motor will ramp up and down while the drive measures the amount of inertia. This option only applies to FV modes selected in P35 [Motor Ctrl Mode]. Final test results should be obtained with load coupled to the motor. Anyway, getting to Kenny's question, I'm not sure what issues you're referring to in firmware with gearing. Do you have a technote that talks about this issue? If you are using FV mode, it is best to get an inertia tune completed. If this is not, the default of total inertia in parameter 76 will be default of 2.0 which will then affect your speed bandwidth in parameter 636. I've had projects where an inertia tune was simply not feasible so I either left 76 at default and adjusted 636 manually or played with the inertia until I got something acceptable. You can also adjust the kp and ki of the speed loop manually if 636 = 0. Hope this helps you.