Allen-Bradley PowerFlex 70 User manual

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Installation Instructions

PowerFlex®70 Adjustable Frequency

AC Drive

When reading this document, look for this symbol “ ” to guide

you through the 5 BASIC STEPS needed to install and perform a Basic

Start-Up of the PowerFlex 70. A Human Interface Module (HIM) is

required to perform the Basic Start-Up routine covered in this manual.

The information provided Does Not replace the User Manual and is

intended for qualified drive service personnel only.

For detailed PowerFlex 70 information including advanced start-up

routines, programming, application considerations and related

precautions refer to the following publications online at

www.rockwellautomation.com/literature:

To order paper copies of technical documentation, contact your local

Rockwell Automation distributor or sales representative.

To find your local Rockwell Automation distributor, visit

www.rockwellautomation.com/locations

Allen-Bradley Drives Technical Support

Title Publication

PowerFlex 70 User Manual 20A-UM001

DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and

PowerFlex 70 AC Drives

20A-UM003

PowerFlex Comm Adapter Manuals 20COMM-UM

Dynamic Braking Resistor Calculator PFLEX-AT001

PowerFlex 70 and 700 Reference Manual - Volume 1 PFLEX-RM001

PowerFlex Reference Manual PFLEX-RM004

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)

AC Drives

DRIVES-IN001

Online at… By Email at… By Telephone at…

www.ab.com/support/abdrives support@drives.ra.rockwell.com 262-512-8176

Step x

Publication 20A-IN009C-EN-P

2PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions

Installation Instructions in Other Languages

English This instruction sheet is available in multiple languages at

http://rockwellautomation.com/literature.

Select publication language and type “20A-IN009” in the search field.

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Bitte Ihre Sprache anwählen und “20A-IN009” im Suchfeld eintippen.

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Sélectionner la langue puis taper << 20A-IN009 >> dans le champ de recherche.

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http://rockwellautomation.com/literature.

Selezionare la lingua desiderata e digitare “20A-IN009” nel campo di ricerca.

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Seleccione el idioma de publicación y escriba “20A-IN009” en el campo de búsqueda.

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Seleccione a língua de publicação e entre com “20A-IN009” no espaço de busca.

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Chinese

(simplified)

从以下网页可以获得本说明书的多种语言的版本 :

http://rockwellautomation.com/literature 。

请选择出版物的语言 , 并在搜索栏输入 “20A-IN009印ٛ

Publication 20A-IN009C-EN-P

PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 3

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . .4

Step 1 Read the General Precautions . . . . . . . . . . . . . . . . . . . .4

Qualified Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Product Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Low Voltage Directive (2006/95/EC) . . . . . . . . . . . . . . . . . . .7

EMC Directive (89/336/EEC). . . . . . . . . . . . . . . . . . . . . . . . .7

General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Essential Requirements for CE Compliance. . . . . . . . . . . . . .8

Step 2 Mount the Drive – Minimum Requirements . . . . . . . .9

Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . .9

Maximum Surrounding Air Temperature . . . . . . . . . . . . . . . .9

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Step 3 Wire the Drive – Wire Recommendations . . . . . . . . .11

Terminal Block Specifications . . . . . . . . . . . . . . . . . . . . . . .12

Power & Ground Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Drive, Fuse & Circuit Breaker Ratings. . . . . . . . . . . . . . . . .14

Disconnecting MOVs and Common Mode Capacitors. . . . .21

Step 4 I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

I/O Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Hardware Enable Circuitry (Enhanced Control Only) . . . . .31

Safe Off Board Option (Enhanced Control Only) . . . . . . . .32

Encoder Interface Option (Enhanced Control Only) . . . . . .33

Step 5 Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Prepare For Drive Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . .34

Information About Start-Up Motor Tests . . . . . . . . . . . . . . .35

Appendix

First Powerup Menu Structure . . . . . . . . . . . . . . . . . . . . . . .36

Human Interface Module (HIM) Overview . . . . . . . . . . . . .37

Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Common I/O Programming Changes . . . . . . . . . . . . . . . . . .42

Troubleshooting – Abbreviated Fault & Alarm Listing . . . .43

Common Symptoms and Corrective Actions . . . . . . . . . . . .45

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Table of Contents

Publication 20A-IN009C-EN-P

4PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions

Qualified Personnel

Catalog Number Explanation

Position Number

1-3 45-78 9 10111213141516

20A B 2P2 A 3 A Y Y N N C 0

abcdefghi jkl

a

Drive

Code Type

20A PowerFlex 70

b

Voltage Rating

Code Voltage Ph.

B 240V ac 3

C 400V ac 3

D 480V ac 3

E 600V ac 3

c

ND Output Rating for Voltage Rating

Examples:

Code Amps kW (Hp)

2P2 2.2 0.37 (0.5)

022 22 5.5 (7.5)

e

HIM

Code Interface Module

0 Blank Cover

3 Full Numeric LCD

5 Prog. Only LCD

8

Wireless Interface Module -

IP66, NEMA/UL Type 4X/12

Only

g

Brake IGBT

Code w/Brake IGBT

seYY

h

Internal Brake Resistor

Code w/Resistor

seYY

oNN

l

Feedback

Code Feedback

N NA - Standard Control

0No Feedback - Enhanced

Control

15V/12V Encoder w/Enhanced

Control

j

Comm Slot

Code Version

B BACnet

C ControlNet (Coax)

D DeviceNet

E EtherNet/IP

OIRR

S RS485 DF1

N None

d

Enclosure

Code Enclosure

APanel Mount - IP 20, NEMA/UL

Type 1

C

Wall/Machine Mount = IP66,

NEMA/UL Type 4X/12 for

indoor use only

F

Flange Mount - Front Chassis =

IP 20, NEMA/UL Type 1; Rear

Heatsink = IP66, NEMA/UL

Type 4X/12 for indoor/outdoor

use

GWall/Machine Mount - IP54,

NEMA/UL Type 12

LFlange Mount with Conformal

Coat

MPanel Mount with Conformal

Coat

Only available on Frame E.

f

Documentation

Code Type

A Manual

N No Manual

i

Emission Class

Code Rating

A

Filtered

A & B Frames (Optional)

C, D, & E Frames (Standard)

N

Not Filtered

A & B Frames (Optional)

C, D, & E Frames

600V Frames A through D available only

without filter (Cat. Code N). 600V Frame E

available only with filter (Cat. Code A).

Increases size to Frame B.

k

Control & I/O

Code Control Safe-Off

N Standard N/A

C Enhanced No

GEnhanced Yes

Not available as factory installed option for

600V ratings.

Step 1 Read the General Precautions

!

ATTENTION: Only qualified personnel familiar with adjustable

frequency AC drives and associated machinery should plan or

implement the installation, start-up and subsequent maintenance of the

system. Failure to comply may result in personal injury and/or

equipment damage.

Publication 20A-IN009C-EN-P

PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 5

Personal Safety

Product Safety

!

ATTENTION: To avoid an electric shock hazard, verify that the

voltage on the bus capacitors has discharged before performing any

work on the drive. Measure the DC bus voltage at the +DC terminal of

the Power Terminal Block and the -DC test point (refer to page 13 for

location). The voltage must be zero.

!

ATTENTION: Risk of injury or equipment damage exists. DPI or

SCANport host products must not be directly connected together via

1202 cables. Unpredictable behavior can result if two or more devices

are connected in this manner.

!

ATTENTION: The drive start/stop/enable control circuitry includes

solid state components. If hazards due to accidental contact with

moving machinery or unintentional flow of liquid, gas or solids exist,

an additional hardwired stop circuit may be required to remove the AC

line to the drive. An auxiliary braking method may be required.

!

ATTENTION: An incorrectly applied or installed drive can result in

component damage or a reduction in product life. Wiring or application

errors, such as, undersizing the motor, incorrect or inadequate AC

supply, or excessive ambient temperatures may result in malfunction of

the system.

!

ATTENTION: This drive contains ESD (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly.

Component damage may result if ESD control procedures are not

followed. If you are not familiar with static control procedures,

reference Guarding Against Electrostatic Damage, publication

8000-4.5.2 or any other applicable ESD protection handbook.

!

ATTENTION: Configuring an analog input for 0-20 mA operation

and driving it from a voltage source could cause component damage.

Verify proper configuration prior to applying input signals.

!

ATTENTION: A contactor or other device that routinely disconnects

and reapplies the AC line to the drive to start and stop the motor can

cause drive hardware damage. The drive is designed to use control input

signals that will start and stop the motor. If an input device is used,

operation must not exceed one cycle per minute or drive damage will

occur.

Publication 20A-IN009C-EN-P

6PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions

Output Contactor Precaution

!

ATTENTION: The “adjust freq” portion of the bus regulator function

is extremely useful for preventing nuisance overvoltage faults resulting

from aggressive decelerations, overhauling loads, and eccentric loads. It

forces the output frequency to be greater than commanded frequency

while the drive’s bus voltage is increasing towards levels that would

otherwise cause a fault; however, it can also cause either of the

following two conditions to occur.

1. Fast positive changes in input voltage (more than a 10% increase

within 6 minutes) can cause uncommanded positive speed changes;

however an “OverSpeed Limit” fault will occur if the speed reaches

[Max Speed] + [Overspeed Limit]. If this condition is unacceptable,

action should be taken to 1) limit supply voltages within the

specification of the drive and, 2) limit fast positive input voltage

changes to less than 10%. Without taking such actions, if this operation

is unacceptable, the “adjust freq” portion of the bus regulator function

must be disabled (see parameters 161 and 162).

2. Actual deceleration times can be longer than commanded

deceleration times; however, a “Decel Inhibit” fault is generated if the

drive stops decelerating altogether. If this condition is unacceptable, the

“adjust freq” portion of the bus regulator must be disabled (see

parameters 161 and 162). In addition, installing a properly sized

dynamic brake resistor will provide equal or better performance in most

cases.

Note: These faults are not instantaneous and have shown test results

that take between 2 and 12 seconds to occur.

!

ATTENTION: To guard against drive damage when using output

contactors, the following information must be read and understood.

One or more output contactors may be installed between the drive and

motor(s) for the purpose of disconnecting or isolating certain motors/

loads. If a contactor is opened while the drive is operating, power will

be removed from the respective motor, but the drive will continue to

produce voltage at the output terminals. In addition, reconnecting a

motor to an active drive (by closing the contactor) could produce

excessive current that may cause the drive to fault. If any of these

conditions are determined to be undesirable or unsafe, an auxiliary

contact on the output contactor should be wired to a drive digital input

that is programmed as “Enable.” This will cause the drive to execute a

coast-to-stop (cease output) whenever an output contactor is opened.

Publication 20A-IN009C-EN-P

PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 7

CE Conformity(1)

Conformity with the Low Voltage (LV) Directive and Electromagnetic

Compatibility (EMC) Directive has been demonstrated using

harmonized European Norm (EN) standards published in the Official

Journal of the European Communities. PowerFlex Drives comply with

the EN standards listed below when installed according to the User and

Reference Manuals.

CE Declarations of Conformity are available online at:

www.ab.com/certification/ce/docs

Low Voltage Directive (2006/95/EC)

•EN50178 Electronic equipment for use in power installations.

EMC Directive (89/336/EEC)

•EN61800-3 Adjustable speed electrical power drive systems Part 3:

EMC product standard including specific test methods.

General Notes

•Some drives are equipped with an adhesive label on the top of the

drive. If the adhesive label is removed from the top of the drive, the

drive must be installed in an enclosure with side openings less than

12.5 mm (0.5 in) and top openings less than 1.0 mm (0.04 in) to

maintain compliance with the LV Directive.

•The motor cable should be kept as short as possible in order to avoid

electromagnetic emission as well as capacitive currents.

•Use of line filters in ungrounded systems is not recommended.

•PowerFlex drives may cause radio interference if used in a

residential or domestic environment. The installer is required to take

measures to prevent interference, in addition to the essential

requirements for CE compliance listed below, if necessary.

•Conformity of the drive with CE EMC requirements does not

guarantee an entire machine or installation complies with CE EMC

requirements. Many factors can influence total machine/installation

compliance.

•PowerFlex drives can generate conducted low frequency

disturbances (harmonic emissions) on the AC supply system. More

information regarding harmonic emissions can be found in the

PowerFlex Reference Manual, publication PFLEX-RM004.

EMC Instructions

(1) CE Certification testing has not been completed for 600 Volt class drives.

Publication 20A-IN009C-EN-P

8PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions

Essential Requirements for CE Compliance

Conditions 1…6 listed below must be satisfied for PowerFlex drives to

meet the requirements of EN61800-3.

1. Standard PowerFlex 70 CE compatible Drive.

2. Review important precautions/attention statements throughout this

manual before installing drive.

3. Grounding as described in Chapter 1 of the User Manual, publication

20A-UM001.

4. Output power, control (I/O) and signal wiring must be braided,

shielded cable with a coverage of 75% or better, metal conduit or

equivalent attenuation.

5. All shielded cables should terminate with the proper shielded

connector.

6. Conditions in Table A.

Table A PowerFlex 70 EN61800-3 EMC Compatibility

Frame(s)

Drive Description

Second Environment

First Environment

Restricted

Distribution

Restrict Motor

Cable to

40 m (131 ft)

Internal

Filter

Option

External

Filter

Input

Ferrite (1)

ADrive Only ✔✔

See PowerFlex

Reference Manual

with any Comm Option ✔✔

with Remote I/O ✔✔✔

BDrive Only ✔✔

with any Comm Option ✔✔

with Remote I/O ✔✔ ✔

C,

D,

E

Drive Only ✔

with any Comm Option ✔

with Remote I/O ✔✔

(1) Input cables through a Ferrite Core (Frames A, B and C Fair-Rite #2643102002 or equivalent,

Frames D and E Fair-Rite #2643251002 or equivalent).

Publication 20A-IN009C-EN-P

PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 9

Minimum Mounting Clearances

Specified vertical clearance requirements are

intended to be from drive to drive. Other objects

can occupy this space; however, airflow must not

be reduced and inlet air temperature must not

exceed the product specification.

Maximum Surrounding Air Temperature

Important: Some drives are equipped with an adhesive label on the top

of the chassis. Removing the adhesive label from the drive

changes the NEMA/UL enclosure rating from Type 1

Enclosed to Open Type.

Step 2 Mount the Drive – Minimum Requirements

Enclosure Rating Temperature Range

Open Type, IP 20, NEMA/UL Type 1 & Flange Mount 0…50 °C (32…22 °F)

IP54, IP 66 & NEMA/UL Type 4X/12 0…40 °C (32…104 °F)

76.2 mm

(3.0 in) 76.2 mm

(3.0 in)

Publication 20A-IN009C-EN-P

10 PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions

Table B PowerFlex 70 Frames

Dimensions

Output Power Frame Size

kW

ND (HD)

HP

ND (HD)

208…240V AC Input 400…480V AC Input 600V AC Input

Not (1)

Filtered

(2)

Filtered

IP66

(4X/12)

Not (1)

Filtered

(2)

Filtered

IP66

(4X/12)

Not (1)

Filtered

(2)

Filtered

IP66

(4X/12)

0.37 (0.25) 0.5 (0.33) A B B A B B A – B

0.75 (0.55) 1 (0.75) A B B A B B A – B

1.5(1.1)2(1.5)BBBABBA–B

2.2(1.5)3(2)BBBBBBB–B

4(3)5(3)–CDBBBB–B

5.5 (4) 7.5 (5) – D D – C D C – D

7.5 (5.5) 10 (7.5) – D D – C D C – D

11 (7.5) 15 (10) – D D – D D D – D

15 (11) 20 (15) – E E – D D D – D

18.5 (15) 25 (20) – E E – D D D – D

22 (18.5) 30 (25) – – – – D D D – D

30 (22) 40 (30) – – – – E E – E E

37 (30) 50 (40) – – – – E E – E E

(1) Not Filtered indicated if Position 13 of the Catalog Number = N.

(2) Filtered indicated if Position 13 of the Catalog Number = A.

A

E

B

D

F

C

B

AC

D E

IP20/66 (NEMA/UL Type 1/4X/12) Flange Mount

Frame

Dimension Dimensions are in millimeters and (inches) Weight (1)

kg (lb)ABCDEF

IP20 / NEMA Type 1

A 122.4 (4.82) 225.7 (8.89) 179.8 (7.08) 94.2 (3.71) 211.6 (8.33) 5.8 (0.23) 2.71 (6.0)

B 171.7 (6.76) 234.6 (9.24) 179.8 (7.08) 122.7 (4.83) 220.2 (8.67) 5.8 (0.23) 3.60 (7.9)

C 185.0 (7.28) 300.0 (11.81) 179.8 (7.08) 137.6 (5.42) 285.6 (11.25) 5.8 (0.23) 6.89 (15.2)

D 219.9 (8.66) 350.0 (13.78) 179.8 (7.08) 169.0 (6.65) 335.6 (13.21) 5.8 (0.23) 9.25 (20.4)

E 280.3 (11.04) 555.8 (21.88) 207.1 (8.15) 200.0 (7.87) 491.0 (19.33) 6.9 (0.27) 18.60 (41.0)

IP66 / NEMA Type 4X/12

B 171.7 (6.76) 239.8 (9.44) 203.3 (8.00) 122.7 (4.83) 220.2 (8.67) 5.8 (0.23) 3.61 (8.0)

D 219.9 (8.66) 350.0 (13.78) 210.7 (8.29) 169.0 (6.65) 335.6 (13.21) 5.8 (0.23) 9.13 (20.1)

E 280.3 (11.04) 555.8 (21.88) 219.8 (8.65) 200.0 (7.87) 491.0 (19.33) 6.9 (0.27) 18.60 (41.0)

Flange Mount

A 156.0 (6.14) 225.8 (8.89) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 2.71 (6.0)

B 205.2 (8.08) 234.6 (9.24) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 3.60 (7.9)

C 219.0 (8.62) 300.0 (11.81) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 6.89 (15.2)

D 248.4 (9.78) 350.0 (13.78) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 9.25 (20.4)

E 280.3 (11.04) 555.8 (21.88) 207.1 (8.15) 117.2 (4.61) 89.9 (3.54) – 18.60 (41.0)

(1) Weights include Human Interface Module (HIM).