1/23/24, 8:51 AM PowerFlex AC Drives: Fault 77 [IR Volts Range]

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ID: QA15094 | Access Levels: TechConnect

PowerFlex AC Drives: Fault 77 [IR Volts Range]

Document ID QA15094

Published Date 03/22/2023

Summary

Help & Feedback

PowerFlex AC Drives: Fault 77 [IR Volts Range]

Question
What causes the Fault F77 IR Volts Range on PowerFlex AC drive products when
trying to autotune?

Environment
20A PowerFlex 70
20B PowerFlex 700
20C PowerFlex 700H
20D PowerFlex 700S
20F PowerFlex 753
20G PowerFlex 755
25A PowerFlex 523
25B PowerFlex 525

Answer
Assuming that the motor is not defective, this is a result of an autotune failure during the
stator resistance portion of the test when in sensorless vector or flux vector control.

The fault is due to the measured voltage across the resistance of the motor value being
out of range for the given data programmed into the drive’s motor nameplate
information for a single motor attached to the drive.

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In most cases, the motor’s nameplate information programmed in the drive does not
accurately reflect the motor’s rating. This could be anything from a mis-programmed
parameter regarding the motor data or a typo on the motors nameplate tag.

Another possibility is the motor is being single phased. Verify (measure) current in all 3
legs between the drive and the motor. If one of the legs is zero find the cause. Most likely
cause is an open in the circuit between drive and motor.

Verify that there is not disconnect or breaker between the drive and the motor. Most times
the disconnect is open and there is no path to the motor.

Otherwise there may be an open in the motor, or possibly a problem in the drive.

In other cases that are common to custom or some super efficient motors, the nameplate
information reflected on the motor’s tag may not be correct to program in a drive. For
example, a 15 HP XP motor that is name plated X. In some cases this motor is actually a 20
HP rated for X, derated to 15 HP for thermal rating which is common to XP motors. When
this type of motor is attached to a drive and autotune is performed with the 15 HP
nameplate information it’s possible that IR Volt Range faults can occur. In cases like this
you will need to contact the motor manufacture to obtain a motor data sheet which will
include the correct data to program in the drive.

An alternative to gathering data from the motor manufacture is to set the drive into
Custom Volts per Hertz Mode. In this mode autotuning is not used. However this mode will
allow you to manually adjust the Start Boost, Run Boost, Break Voltage and Break
Frequency parameters. You will want to make sure the start and run boost are set to 0’s
and the break voltage and break frequency is set to a linear curve of 25% for of rated
motor voltage and 25% of motor rated frequency (constant torque application). One
should note that start and run boost should only be adjusted from 0 if it is required for the
application.

PowerFlex 755/753
Try changing Parameter 38 [PWM Frequency] to 2 kHz
Try changing Parameter 1154 [DC Offset Ctrl] to 1 [Enabled] if supercharging a motor

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1/23/24, 8:51 AM PowerFlex AC Drives: Fault 77 [IR Volts Range]

Obsolescence, Guide to replace 193-EF Obsolescence,

Replacement, Conversion with E300 and 193-EOS- Replacement, Conversion
and Migration from 193-EF SDS (without network) and Migration for 592P-S
Overload Relays to Other SMP-1 Single Phase
Products Overload Relays

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