UNISP065

Knowledge Base Document

Technical Support Department, U79, Newtown

Title: Unidrive SP Open loop performance testing

Document Performance Product Unidrive SP

Category: Category:

Credits

Revision History
Revision Date Revising Author Released for Authorised By Comments
Website?
0 11/05/2005 Rob Francis
1.0 11/02/09 Jon Atkinson Yes Jon Atkinson

Summary of Contents
Unidrive SP Open loop vector performance testing.

Page 1 of 25
The performance data in this report is a representation of the specific tests carried out only.
All data in this report with respect to comparison of features is formed from the personal
opinion of the personnel involved, only.

CONTROL TECHNIQUES MAKES NO CLAIMS WITH RESPECT TO

THE SUPERIORITY OR INFERIORITY OF ANY PRODUCT OVER
ANOTHER PRODUCT

DETAILS OF DRIVE

MANUFACTURER:- Control Techniques

PRODUCT RANGE:- Unidrive SP 1406, 4.0kW, 380 – 440Vac
CATEGORY OF PRODUCT:- Open Loop & Closed loop mode Without Feedback

Competitor Analysis
Manufacturer: Control Techniques
Model: 1406
Rating: 4.0kW

Page 2 of 25
Contents

1.0 Introduction
1.1 Performance Testing Outline 4

2.0 Test Methods

2.1 Inrush Current 5
2.2 Current Limit Dynamic Response 5
2.3 Synchronise to a Spinning Motor 5
2.4 Shock Load 5
2.5 Speed Holding 6
2.6 Torque Speed Curves 6
2.7 Torque Produced and Drive estimated Torque Vs Frequency 6

3.0 Test Results

3.1 Drive Setup 7
3.2 Inrush Current 8
3.3 Current Limit Dynamic Response 9
3.4 Synchronise to a Spinning Motor 10
3.5 Shock Load 12
3.6 Speed Holding 13
3.7 Torque Speed Curves 16
3.8 Actual Torque Produced and Drive estimated Torque Vs 19
Frequency
3.9 Actual Torque Produced Vs Drive Estimated Torque 23

4.0 Detailed Drive Specification

4.1 Ratings 22
4.2 Dimensions 23
4.3 User software 24
4.4 Hardware 24
4.5 Performance 26
4.6 Power circuit 27
4.7 Optional extras 27
4.8 Manuals 27

A Appendix A
A.1 Test Equipment 28

Page 3 of 25
1.0 Introduction

1.1 Performance Testing

The performance data following will enable a direct comparison of the variable speed
drives tested. The drives used for the performance testing will ideally have a rating of
7.5kW allowing the same test conditions to be maintained.

In order to ensure the best performance during testing the drive should be setup
following the recommendations provided in the manuals with the drive. Final drive
setup during testing should be recorded.

The performance testing carried out will include eight standard tests with each being
carried out as specified in Chapter 2 Test Method. Additional to the performance
testing there is a detailed drive specification sheet generated from published drive
data.

Page 4 of 25
2.0 Test Methods

2.2 Current Limit Dynamic Response

The current limit test is an indication of the drives current control / speed control
whilst operating in current limit. The test is carried out applying maximum forward
reference to maximum reverse reference with no load present. For this test the
maximum speed is twice base speed, 100Hz.

The drive has dynamic braking enabled to prevent over voltage tripping, with speed
loop and current loop gains (if available) setup. The change in speed reference is
carried out using either a preset speed or by inverting the reference with a digital
input hence avoiding any ramp being introduced and ensuring drive is operating in
current limit.

The oscilloscope plot shows the change in speed, maximum forward to maximum
reverse and the current measured at the output of the drive.

2.3 Synchronise to a Spinning Motor

The plots show the drive Synchronising to a Spinning Motor both above and below
base speed.
The drive under test is synchronising to a spinning motor at 25Hz with a speed
demand to the test drive of 50Hz, and with a spinning motor of 75Hz with a speed
demand of 90Hz. The spinning motor is run under torque control with speed override,
with the torque level set to a minimum value (torque level set to enable spinning
motor to reach target speed).
If the drive is unable to synchronise to the spinning motor at the above frequencies
the tests are carried out at the nearest frequency.
Waveforms taken include, actual speed (encoder feedback) demanded speed, and
DC Bus voltage, motor voltage and output current.

2.4 Shock Load

The shock load tests are carried out at both 25Hz and 75Hz with 100% shock load
being applied at both frequencies. The drive under test is running at 25Hz / 75Hz with
100% shock load applied by enabling the loading drive.

The oscilloscope plot shows encoder speed feedback (from the monitoring Unidrive)
against time, during the period over which the step load is applied and removed.

2.5 Speed Holding

The speed holding tests compare the demanded speed to actual speed, with the
actual speed being monitored using the encoder feedback from the motor. The
graphs show speed feedback against percentage load (measured from the torque
transducer) up to the drives FLC capability. The tests are carried out from 0Hz up to
twice base speed.

2.6 Torque Speed Curves

Page 5 of 25
 The torque speed curves are an indication of the torque produced from 0Hz to twice
base speed of the motor. The graphs show torque produced at a given frequency.

2.7 Actual Torque Produced and Drive estimated Torque Vs Frequency

The Actual Torque Produced and Drive estimated Torque Vs Frequency plots are a
measure of the torque produced at the motor shaft (measured using torque
transducer) from 0Hz to twice base speed against the drives measure of torque
produced (i.e. #4.20 on Unidrive percentage torque current). The graphs show Actual
Torque Produced and Drive estimated Torque at a given Frequency.

2.8 Actual Torque Produced Vs Drive estimated Torque

The Actual Torque Produced Vs Drive estimated Torque plots are a measure of the
torque produced at the motor shaft (measured using torque transducer) from 0Hz to
twice base speed against the drives measure of torque produced (i.e. #4.20 on
Unidrive percentage torque current). The graphs show Torque Produced Vs Drive
estimated Torque at a given load percentage.

Page 6 of 25
3.0 Test results

3.1 Settings achieved

In order to obtain the best performance test results the Control Techniques drive was
setup as follows.

Open Loop set -Up

1. A switching frequency of 3kHz was selected in line with all other drives being
tested.
2. A rotating Autotune was completed giving a power factor of 0.843
3. The drive was set up in Ur_S mode 5.14 (Open loop vector control with stator
resistance check on enable), loaded until the motor reached its nominal running
temperature, then returned to Ur (Open loop vector control only) after values of
stator resistance had been updated in 5.17 as well as the voltage offset in 5.23,
then a parameter save was completed.
4. Slip compensation was setup in parameter 5.08 “Motor rated speed”, tests were
carried out with the final value of 1433rpm providing best performance.
5. Motor map setup, 380V, 9.1A, and 50Hz, 1430rpm (name plate value rpm).
6. The acceleration 2.11 and deceleration 2.21 ramps were set to 0.2, the minimum
ramp without tripping OV.
7. The current loop gains 4.13 and 4.14 were optimised to and respectively after full
load stability tests were carried out
8. The current limits 4.05, 4.06, 4.07 were raised to there maximum value of 179%.
9. Synchronise to a spinning motor 6.09 was enabled, and the synchronisation ramp
rate and start voltage were decreased to 0.5 and 8 respectively, for best
performance.

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3.3 Current Limit Dynamic Performance

The current limit dynamic performance test shows the effectiveness of the drives
current limits in controlling the current and avoiding trips during fast acceleration and
deceleration.

CURRENT LIMIT DYNAMIC PERFORMANCE

OPEN LOOP

U-PHASE CURRENT
1>
2
(CH1)

SPEED FEEDBACK
+3000 TO -3000 RPM
(CH2)

NOTE: Minimum ramp settings achieved without the drive tripping were 0.2 s/100Hz

Page 8 of 25
3.4 Synchronise to a Spinning Motor

The following shows the ability of the drive to start, synchronise and run when the
motor is already spinning. The results show correct operation of the spinning start
algorithm and the length of time taken to synchronise with the motor.

Open Loop Mode

Spin Frequency = 25 Hz
Demanded Frequency = 50 Hz

5↑
50 Hz
Encoder
25 Hz Feedback

50 Hz
Output
Frequency

0 Hz
4>

DC Bus Voltage
380V
Motor Voltage

3>
0V
2>

10A \ DIV
1> Motor Current

Time Base = 100 ms

Time taken to reach 50 Hz = 220 ms

Open Loop Mode

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 Spin Frequency = 50 Hz
Demanded Frequency = 75 Hz

75 Hz
1↑ Encoder
50 Hz Feedback
75 Hz
Output
Frequency

0 Hz
4>

DC Bus
Voltage

380V
Motor Voltage

5>

0V
6>

10A \ Div
7> Motor Current

Time Base = 100ms

Time taken to reach 75 Hz = 230 ms

Page 10 of 25
3.5 Shock Load

The following plots show the effectiveness of the motor speed control under transient
load conditions.

Open Loop

Shock Load @ 25Hz

Speed feedback Overshoot = 120 RPM

60RPM drop in
speed

100% Load
Current
1>
2

Speed feedback - 500 mV /DIV (1V = 300 rpm)

Load Current - 2V / DIV
Timebase - 200ms

Shock Load @ 75 Hz

Speed feedback
90RPM drop in Overshoot = 120 RPM
speed

100% Load
Current

1>
2

Speed feedback - 1V /DIV (1V = 300 RPM)

Load Current - 2V / DIV
Timebase - 200ms

Page 11 of 25
 3.6 Speed Holding

Open Loop Mode

Speed Holding 0Hz to 2.5Hz

160

140

120

100 2.5Hz
2Hz
Speed rpm

80
1.5Hz

60
1Hz
0.5Hz
40 0Hz

20

0
-200.00 -150.00 -100.00 -50.00 0.00 50.00 100.00 150.00 200.00

-20

Load %

Page 12 of 25
 Open Loop Mode

Speed Holding 0Hz to 10Hz

400

350

300 10Hz
8Hz
250
6Hz
4Hz
Speed rpm

200
2.5Hz
150
2Hz
1.5Hz
100 1Hz
0.5Hz
50 0Hz

0
-200.00 -150.00 -100.00 -50.00 0.00 50.00 100.00 150.00 200.00

-50

Load %

Page 13 of 25
 Open Loop Mode

Speed Holding 10Hz to 100Hz

3500

3000

100Hz
2500 90Hz
80Hz
70Hz
Speed rpm

2000
60Hz
50Hz
1500
40Hz
30Hz
1000
20Hz
10Hz
500

0
-200.00 -150.00 -100.00 -50.00 0.00 50.00 100.00 150.00 200.00

Load %

Page 14 of 25
 3.7 Torque Speed Curves

Open Loop Mode

Torque Speed Curve

0Hz to 2.5Hz

200.00

150.00

165%
150%
100.00
100%
Actual Torque %

50%
-50%
50.00 -100%
-150%
-165%

0.00
0.0 0.5 1.0 1.5 2.0 2.5

-50.00

-100.00

Frequency Hz

Page 15 of 25
 Open Loop Mode

Torque Speed Curve

0Hz to 10Hz

200.00

150.00

100.00
165%
150%
50.00
100%
Actual Torque %

50%
-50%
0.00
-100%
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
-150%
-50.00 -165%

-100.00

-150.00

-200.00

Frequency Hz

Page 16 of 25
 Open Loop Mode

Torque / Speed curve 0 to 100Hz

200.00

150.00

100.00

165%
50.00 150%
Actual Torque %

100%
0.00 50%
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0
-50%
-50.00 -100%
-150%
-100.00 -165%

-150.00

-200.00

Frequency Hz

3.8 Actual Torque Produced and Drive Estimated Torque Vs Frequency

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 Open Loop Mode

Motoring Torque produced and Drive estimated torque v Frequency

( 0Hz - 10Hz )

200.00

180.00

160.00
165% P
140.00 165% E
150% P
120.00
150% E
Torque %

100.00 100% P
100% E
80.00
50% P
60.00 50% E

40.00

20.00

0.00
0.0 0.5 1.0 1.5 2.0 2.5 4.0 6.0 8.0 10.0

Frequency Hz

Note: The Drive estimated torque parameter does not show a steady value below 1.5Hz.

Open Loop Mode

Page 18 of 25
 Motoring Torque produced and Drive estimated torque v Frequency
( 0Hz - 100Hz )

200.00

180.00

160.00
165% P
140.00
165% E
120.00 150% P
Torque %

150% E
100.00
100% P
80.00 100% E
60.00 50% P
50% E
40.00

20.00

0.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

Frequency Hz

Note: The Drive estimated torque parameter does not show a steady value below 1.5Hz.

Page 19 of 25
 Open Loop Mode

Regen Torque produced and Drive estimated torque v Frequency

( 0Hz - 100Hz )

200.00

180.00

160.00
165% P
140.00
165% E
120.00 150% P
Torque %

150% E
100.00
100% P
80.00 100% E
60.00 50% P
50% E
40.00

20.00

0.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0

Frequency Hz

Note: The Drive estimated torque parameter does not show a steady value below 2Hz.

Page 20 of 25
 Open Loop Mode

Regen Torque produced and Drive estimated torque v Frequency

( 0Hz - 10Hz )

180.00

160.00

140.00 165% P
165% E
120.00
150% P
% Torque

100.00 150% E
100% P
80.00
100% E
50% P
60.00
50% E
40.00

20.00

0.00
0.0 0.5 1.0 1.5 2.0 2.5 4.0 6.0 8.0 10.0

Frequency Hz

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 3.8 Actual Torque Produced Vs Drive Estimated Torque

Open Loop Mode

Motoring Torque Produced Vs Drive Estimated Torque 0Hz to 10Hz

200.00

180.00

160.00
0.0
140.00 0.5
1.0
% Load Estimated

120.00 1.5
2.0
100.00
2.5
80.00 4.0
6.0
60.00 8.0
10.0
40.00

20.00

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00

% Load Produced

Page 22 of 25
 Open Loop Mode

Motoring Torque Produced Vs Drive Estimated Torque 10Hz to 100Hz

200.00

180.00

160.00
10
140.00 20
% Load Estimated

30
120.00
40
50
100.00
60
80.00 70
80
60.00 90
100
40.00

20.00

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00

% Load Produced

Open Loop Mode

Page 23 of 25
 Regen Torque Produced Vs Drive Estimated Torque 0Hz to 10Hz

100.00

90.00

80.00
0.0
70.00 0.5
1.0
% Load Estimated

60.00 1.5
2.0
50.00
2.5
40.00 4.0
6.0
30.00 8.0
10.0
20.00

10.00

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00

% Load Produced

Page 24 of 25
 Open Loop Mode

Regen Torque Produced Vs Drive Estimated Torque 10Hz to 100Hz

180.00

160.00

140.00
10
20
120.00
30
% Load Estimated

40
100.00
50
60
80.00
70

60.00
80
90
40.00 100

20.00

0.00
0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00

% Load Produced

Page 25 of 25