Configuring the ACOPOSinverter P77 to use Flexible I/O control

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Introduction

There are some situations where it is required to control a Variable Frequency Drive (VFD) directly using the onboard Analog and Digital Inputs (I/O). In this situation, the VFD is not connected to a PLC via fieldbus (e.g. POWERLINK), but instead it is operating stand-alone and only controlled based on the enable/start signal (DI) and setpoint values (AI) of the configured I/O. This setup might be needed for initial testing or prototyping of the machine, small “dumb” machines (such as a simple conveyor), tuning motor parameters, or other applications.

The ACOPOSinverter P77 is the standard line in the latest generation of B&R VFDs. While it is set up by default to be controlled by a PLC via POWERLINK (with mapp Motion or Direct Control), it can be configured to use local I/O control, or “Flexible I/O” control as it is called on the P77.

This guide describes the necessary steps to configure the P77 to use Flexible I/O control.

Requirements

Overview

The Flexible I/O configuration is done by setting several parameters using the P77 keypad. The menus on the keypad are navigated with the up and down arrow keys and the enter key.

Each parameter has a unique 16-bit hex index (e.g. 0x2824), which can be accessed and configured via the keypad using its corresponding “display code” (e.g. P200.00 - Control selection). All parameters are broken into groups according to their function (e.g. Group 2), which corresponds to the hundreds place of the display code (e.g. P200.00), see below from Page 132 of the Commissioning manual. A full list of all available parameters on the P77 can be found in the Appendix on Page 186 of the Commissioning manual.

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If one parameter setting has been changed with the keypad but has not been saved in the memory module with mains failure protection, the SET display is blinking. In order to save parameter settings in the user memory of the memory module, press and hold the enter key for longer than 3 s (see below graphic from Page 20 of the Commissioning manual).

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The wiring of the I/Os (digital input and analog input) can be found in the “Project Planning” manual on Page 143. For the below procedure, as an example, DI1 is used as the “Start” (or “Run”) input for the drive and AI1 is used for the “Speed” setpoint.

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To enable Flexible I/O configuration, the “Network” control and setpoint first need to be disabled, otherwise you will run into an issue where you see “VEL:NET:NET” or “VEL:NET:AI1” on the keypad. Once those are disabled, you can configure the control mode to “Flexible I/O”, set the digital input as the “Start” command and an analog input as the “Speed setpoint”.

Procedure

Before starting, make sure the P77 is plugged in to power and the keypad module is connected and the LED screen lit up. Have your motor nameplate values ready, and connect the digital input and analog input to be used for the I/O control.

To correctly configure the ACOPOSinverter P77 for “Flexible I/O configuration” control, the following settings must be configured using the keypad, in order:

  1. Load factory default settings on the P77: P700.01 = 1
  2. Set the Motor control type to U/F for initial commissioning: P300.00 = V/f characteristic control (VFC open loop) [6]
  3. Set the DS402 control type to “MS: Velocity Mode”: P301.00 = MS: Velocity Mode [-2]
  4. Set the motor nameplate values according to the motor used: P320.xx (more information on the motor data can be found on Page 40 of the Commissioning manual)
  5. (Optional) The Enable is set to “TRUE [1]” by default, but if Enable should be set externally, set it to a digital input, e.g. DI1: P400.01 = Digital input 1 [11]
  6. (Optional) Set the “Max frequency” to your desired max scaled frequency (e.g. 60.0 Hz in the US): P430.03 Analog input 1: Max frequency value (Hz)
  7. Set the “Start” to a digital input, e.g. DI2: P400.02 = Digital input 2 [12]
  8. Set the “Control selection” to “Flexible I/O”: P200.00 = Flexible I/O configuration [0]
  9. Set the “Speed” to an analog input, e.g. AI1: P201.01 = Analog Input 1 [2]
  10. Deactivate “Network control”: P400.37 = Not connected [0]
  11. Deactivate “Network reference (Setp: Network)”: P400.17 = Not connected [0]
  12. Save settings by holding the “ENT” button for > 3 seconds

You should then see “VEL:FLEX:AIN1” on the keypad, and you should see that you are able to control the motor using the “Start” Digital Input with the speed determined by the analog input selected (in this case AI1). This confirms that you have successfully set up the P77 to use the Flexible I/O configuration.

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More Resources

To learn more about the P77, please check out the “Getting Started with ACOPOSinverter P77” Online Course, described in detail at the following Community Post: New Online Course - Getting Started with ACOPOSinverter P77

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Thanks to @Nathan_Borho for the keypad photos and for testing and validating this procedure!