Standard Release Document

VS1GV-1.22

Software: ZHH-1.22

August 24, 2009

Third Release of VS1 Firmware for EB0490A0X



Release Status:
This software is for production release on VS1 control boards EB0490A0X. This is the third in the series of releases for closed loop products.

ZHH-1.22 supports three control methods: V/F, Sensorless and Closed Vector. 



Bug Fixes and Improvements since Last Release:
1. Modbus output block PDU now shows ‘Active Fault Code’ instead of ‘Active Alarm Code’ and Motor Absolute Speed and Motor Frequency instead of repeating the Speed references in the I/O block.
2. Modbus Block Read PDU now correctly shows Bipolar.
3. P1415, Current Limit Source, now does not require a power cycle when going to/from Network Source to any other source.
4. Phase voltages U, V and W are now reset with a drive disable so that erroneous voltages are not shown in parameters P90, P91 and P92 while the drive is disabled.
5. The Sensorless Control’s flux speed observer had a scaling error, which has been corrected; this error was causing problems during regeneration and motor stops.
6. LonWorks is now serviced at 100 Hz to fix interrupt issue of running out of processing time with the Analog Expansion board.
7. A mask is now in place for communication drivers so that the upper 8 bits of the data bus are always zero. Extraneous errors in data were reported without this mask.
8. Autotune. Minimum speed is now set to zero during rotary tests otherwise the drive will not stop after a rotary test is complete.



New Features since Last Release:
1.  Now, Analog Current limiting not instantly selected when current limiting is enabled.
2.  Network Source has been added to the list of current limiting sources in parameter 1415.
3.  For Closed Vector and Sensorless Controls in speed mode and with current limiting enabled (P1414) the speed demand is now decoupled from regenerative current limits so that it is free to advance to its reference. With P1414 disabled the velocity profiler freezes the speed demand during a regenerative current limit until the current limit is alleviated. In addition, the external current limit source is always active regardless of P1414’s setting; it may be disable by selection NONE.
4.  V/F profiler. Support for 7-segment multipoint profile curves.
5.  Parameters P1642 and P1618 now have different default values: P1642, Motor R1, uses 0.0 Ohms, and P1618, 3 Point Voltage, uses 50%.
6.  The Communication Board Diagnostic screen now shows Config 2 and Config 3 registers instead of Board Status.
7.  LonWorks communication boards are now supported.
8.  Network Mode. Coil 13, Command Mode Current Limiting, can be used outside of Network Mode. When this coil is active, the current limit source is taken from Modbus; when it is inactive, the current limit source is taken from P1415. 
9.  Auto-tune R1. Ramp voltage even during initial phase of R1 tune to avoid voltage jumps.
10. A new parameter has been added for V/F Controls, P2008, Regen Adjust. When set to a non-zero value causes speed demand to ramp at the rate set by P2008 so as to reduce regenerative current so long as it is greater than 1/10 the regenerative current limit.
11. The V/F Control now uses constant power during a regenerative current limit instead of constant torque, thus the regenerative current limit is increased at the rate of 1/Speed during a stop and allows more stopping torque for this motor control.
12. New parameter. P2416, Motor Rated Horsepower has been added to the drive. It has improved the accuracy of the Newton-Meter torque readout of the drive. Parameter has been added to both quick start and motor parameter blocks. Changed the way torque is computed in the drive, remove the flux-Iq current model and replaced it with T = 5252*Hp/RatedSpeed.
13. Auto-tune. Measure Xm (ROT) has replaced Slip Frequency Tune in the One-Step Auto-tune sequence.
14. Analog Outputs. Motor torque is scaled by 2X motor rated torque.
15. Auto-tune. Removed the rotary test for slip. Was not giving accurate results for all motor types. Now this autotune command does a calculation of slip based on Xm, X2, R2, mag and motor rated amps.
16. Table Switching. During parameter table switching the table ID is held, that is, once switching has started further table ID change requests are inhibited until the current request is complete. In addition, if switching is started with the drive disabled, the drive will remain disabled until the switch is complete. If started while the drive is enabled, the drive will remain enabled (switch on the fly), but parameters that don’t have the DE (drive enable) attribute will not switch.
17. New Digital Output. Table Switching Active Digital Output has been added so that monitoring of how long it takes to switch tables can be performed. Output is only active if drive is disabled before the switch.
18. Minimum setpoint for Maximum Speed has been reduced from 10.0 Hz to 1.0 Hz.
19. Added fiber fault support for the H2F-Frame size products.
20. New parameter. P3400, PLC Lock. Transition from ON to OFF will automatically reset the PLC Mode’s Configuration words to default values providing a way to protect intellectual property.
21. New Parameter, P1678 Trickle Current Heater to allow for anti-condensation current while motor is stopped.
22. New digital output. Heater Active Digital Output is used to indicate that trickle current heating amps are flowing. PLC condition and actions to support trickle current heater functions also added.
23. Calc Model. For Sensorless and Closed Vector Control, Calc Model now estimates magnetizing current by utilizing P2416, Motor Rated Horsepower. It also estimates Slip Frequency from motor rated speed and synchronous speed. Control Base Speed is now set to Motor Rated Speed and determines where field weakening begins. Peak Current Level is limited to produce 2X motor rated torque.
24. System preemptive task scheduler timing has changed to provide more run time for lower priority tasks via the use of slotting. The scheduler runs at 8KHz so there are 8 slots to run 1ms tasks. This staggering technique allows the 1ms tasks to keep their schedule but also ensures that they don’t all run on the same 8KHz timer tick.
25. Auto-tune. Now does not allow Rotor Time Constant or Slip Frequency to change by more than 10% from Calc Model estimates.
26. V/F control. V/F motor control is now synchronized to PWM output below 10KHz. The control runs at twice the carrier frequency below 4KHz, at the carrier frequency below 10KHz and above that, it runs as before from an asynchronous 8KHz task. With synchronization the beat issue at 8KHz should be corrected.
27. V/F synchro start. Modified to handle the variable execution rate of the V/F control due to sync up with PWM.
28. PWM
    a. Double update now active below 4KHz carrier frequency.
    b. Minimum pulse filter taken from 1.21 was modified to reduce heating effects during double update. At the top of the triangle a count of Period-1 is used instead of Period during double update.
    c. Support for calling V/F control added to sine triangle and space vector interrupts (need to sync up v/f control with PWM)
    d. Removed the randomize carrier feature from the PWM. This feature is not being used.
    e. For V/F, now use a time advance for the electrical angle of 1x PWM cycle during double update and 1.5x PWM cycle during normal operation. This corrects for the Current Sample Delay between the control and PWM updates.
    f. Voltage and electrical angle are updated on both period and underflow interrupts.
29. Task Scheduling
    a. Modified to support V/F sync up with PWM. 
    b. Separated out position profiler and speed profiler so that they run on different 16KHz timing slots, this will improve task timing within the drive and free up more time.
    c. Removed the flux observer task from CV since it is not used currently within the product. This also saves time for closed vector control.
30. Vector and Sensorless Control. Anti-saturation controller has been modified to free up its integrator and allow negative values during field weakening.
31. Sensorless Control. Now the flux observer is not frozen during a reversal. It is only frozen during a stop. This smoothes out some of the transients found during qualification testing 1.21.
32. Velocity Profiler.
    a. The interpolation function that connects points from the velocity profiler has been modified to support variable frequency. This was needed to sync up the v/f control to PWM
    b. Maximum frequency foldback rate has been modified to be Rate=MotorRateFreq/Tr, units of Hz/sec. This was done to obtain standard engineering units for this feature.
33. Pulse Follower Option Card. Pulse Follower Parameter Block is no longer tied to the Pulse Follower Operating Mode, but is now exposed whenever the option card is installed.



Known Issues/Limitations:
Minimum steady attainable speed on sensorless vector control is 1 times slip frequency



Baldor Electric Co.
Drives Center
600 S. Zero St.
Fort Smith, AR 72901
USA