Allen-Bradley PowerFlex 70 User manual

User Manual

PowerFlex 70 Adjustable Frequency AC Drives

Standard Control Firmware, Revision 2.xxx

Enhanced Control Firmware, Revision 2.xxx…4.xxx

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required

to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the

use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 3

Summary of Changes

The information below summarizes the changes to this PowerFlex® 70 Adjustable

Frequency AC Drives User Manual since the May 2009 release.

Parameter Updates The following parameters have been added or updated.

Additional Manual Updates The following information has been added, removed, or updated.

Description of New or Updated Parameters Page

Parameter 007 [Output Power] 22

Parameter 054 [Maximum Voltage] 25

Parameter 427 [Torque Ref A Sel] 28

Parameter 090 [Speed Ref A Sel] 33

Parameter 096 [TB Man Ref Sel] 34

Parameter 175 [Auto Rstrt Delay] 46

Parameter 213 [Speed Ref Source] 54

Parameter 238 [Fault Config 1] 58

Parameters 361…366 [Digital InxSel] 68

Description of New or Updated Information Page

Removed Chapter 1, Installation/Wiring.All installation and wiring information is now in

the PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions, publication

20A-IN009.

–

Removed Chapter 2, Startup Information. All startup information is now in the PowerFlex

70 Adjustable Frequency AC Drive Installation Instructions, publication 20A-IN009. –

Updated the Catalog Number Explanation options 11

Updates and additions to fault descriptions:

Cntl Bd Overtemp (55) 79

DB Resistance (69) 79

Encoder Quad Err (90) 79

Hardware Fault (93) 79

Fatal Faults (900…930) 80

Ground Fault (13) 80

Heatsink LowTemp (10) 80

Output PhaseLoss (21) 80

Power Down Csum (112) 81

Power Unit (70) 81

Fault Cross Reference 82

Updated EPRI/SEMIF 47 certification 89

Added information for Korean KC Registration certification 89

Added information for Drive to motor power ratio 91

Updated information for Motor overload protection 92

Added footnote 2 for information regarding watts loss with certain drives 93

Removed dimensions and fuse/breaker information. All dimensions and fuse/breaker

information is now in the PowerFlex 70 Adjustable Frequency AC Drive Installation

Instructions, publication 20A-IN009.

–

4Rockwell Automation Publication 20A-UM001N-EN-P - July 2013

Summary of Changes

Notes:

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 5

Table of Contents

Preface

About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

What Is Not in This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Catalog Number Explanation (continued) . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 1

Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Monitor File (file A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Motor Control File (file B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Speed Command File (file C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Dynamic Control File (file D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Utility File (file E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Communication File (file H). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Inputs and Outputs File (file J). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Applications File (file K). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Chapter 2

Troubleshooting

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . 86

Appendix A

Supplemental Drive Information

Certifications and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Appendix B

HIM Overview

External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Removing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Viewing and Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6Rockwell Automation Publication 20A-UM001N-EN-P - July 2013

Table of Contents

Appendix C

Application Notes

External Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Skip Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Motor Overload Memory Retention Per 2005 NEC. . . . . . . . . . . . . . . . 115

Start At Powerup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Speed Reference Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Process PI for Standard Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Voltage Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 7

Preface

The purpose of this manual is to provide you with the basic information needed

to program and troubleshoot the PowerFlex 70 Adjustable Frequency AC Drive.

About This Publication This manual is intended for qualified pJulyersonnel. You must be able to program

and operate Adjustable Frequency AC Drive devices. In addition, you must have

an understanding of the parameter settings and functions.

What Is Not in This

Publication

This manual provides basic start-up, programming, and troubleshooting

information; it does not include information for mounting, wiring, and installing

the drive. For installation instructions, refer to the PowerFlex 70 Adjustable

Frequency AC Drive Installation Instructions, publication 20A-IN009. For

detailed drive information, refer to the PowerFlex Reference Manuals,

publications PFLEX-RM001 and PFLEX-RM004.

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

Topic Page

About This Publication 7

What Is Not in This Publication 7

Additional Resources 7

Manual Conventions 8

Drive Frame Sizes 8

General Precautions 9

Catalog Number Explanation 11

Catalog Number Explanation (continued) 12

Resource Description

PowerFlex 70 Adjustable Frequency AC Drive Installation

Instructions, publication 20A-IN009 Provides the five basic steps needed to install and

perform a basic startup of the PowerFlex 70 drive.

PowerFlex 70 and 700 Reference Manual - Vol. 1,

publication PFLEX-RM001 Provides detailed information for specifications and

dimensions, operation, and dynamic brake selection for

the drive.

PowerFlex 70 Enhanced Control and 700 Vector Control

Reference Manual, publication PFLEX-RM004 Provides detailed drive information including

operation, parameter descriptions, and programming.

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

PowerFlex 70 AC Drives, publication PFLEX-UM003 Provides information for the installation and operation

of the DriveGuard Safe Torque Off option.

PowerFlex Comm Adapter Manuals, publication

20COMM-UM Provides information for the installation and operation

of the various communication protocol adapters

available for the drive.

PowerFlex Dynamic Braking Resistor Calculator Application

Technique, publication PFLEX-AT001 Provided information for determining dynamic braking

requirements and evaluating resistors for dynamic

braking.

Wiringand GroundingGuidelines forPulse WidthModulated

(PWM) AC Drives, publication DRIVES-IN001 Provides the basic information needed to properly wire

and ground Pulse Width Modulated (PWM) AC drives.

8Rockwell Automation Publication 20A-UM001N-EN-P - July 2013

Preface

You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

For Allen-Bradley® drives technical support, see Rockwell Automation Support

on the back cover of this manual.

Manual Conventions In this manual we refer to the PowerFlex 70 Adjustable Frequency AC Drive as;

drive, PowerFlex 70 or PowerFlex 70 Drive.

To help differentiate parameter names and Liquid Crystal Display (LCD) text

from other text, the following conventions are used:

•Parameter Names appear in [brackets].

For example: [DC Bus Voltage].

•Display Text appears in “quotes.” For example: “Enabled.”

Drive Frame Sizes Similar PowerFlex 70 drive sizes are grouped into frame sizes to simplify spare

parts ordering, dimensioning, and so on. A cross reference of drive catalog

numbers and their respective frame size is provided in Appendix A.

Industry Installation Guidelines for Pulse Width Modulated

(PWM) AC Drives Application Technique,

publication DRIVES-AT003

Provides basic information for enclosure systems and

environmental/location considerations (to help protect

against environmental contaminants), and power and

grounding considerations needed to properly install AC

drives.

Preventive Maintenance of Industrial Control and Drive

System Equipment, publication DRIVES-TD001 Provides a checklist to use as a guide for performing

preventive maintenance on industrial control and drive

systems.

Safety Guidelines for the Application, Installation and

Maintenance of Solid State Controls, publication SGI-1.1 Describes some important differences between

solid-state equipment and hard-wired

electromechanical devices

A Global Reference Guide for Reading Schematic Diagrams,

publication 100-2.10 Provides a simple cross-reference of common

schematic/wiring diagram symbols that are used in

various parts of the world.

Guarding Against Electrostatic Damage,

publication 8000-4.5.2 This data sheet explains the causes of electrostatic

damage (ESD), and how you can guard against its

effects.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1 Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and

other certification details.

Resource Description

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 9

Preface

General Precautions Qualified Personnel

Personal Safety

Product Safety

ATTENTION: Allow only qualified personnel familiar with adjustable frequency

AC drives and associated machinery to plan or implement the installation,

start-up and subsequent maintenance of the system. Failure to comply can

result in personal injury and/or equipment damage.

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 PowerFlex 70 Adjustable Frequency AC Drive

Installation Instructions, publication 20A-IN009 for locations). 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 can 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 can result if ESD

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

procedures, reference A-B publication 8000-4.5.2, “Guarding Against

Electrostatic Damage” 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 to start and

stop the motor. If an input device is used, operation must not exceed one cycle

per minute or drive damage can occur.

10 Rockwell Automation Publication 20A-UM001N-EN-P - July 2013

Preface

Output Contactor Precaution

ATTENTION: Nuisance tripping can occur in Standard Control firmware revision

1.011 and earlier due to unstable currents. When using a motor that is

connected for a voltage that is different from the drive (for example, by using a

230V connected motor with a 460V drive) the following adjustment must be

made to “Stability Gain” by using DriveExplorer software and a personal

computer.

Any adjustment made to “Stability Gain” must be manually restored if the drive

is reset to defaults or is replaced.

If unstable currents are still present after making the adjustment, contact the

factory for assistance.

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 can cause a fault; however, it can also

cause either of the following two conditions to occur.

•Fast positive changes in input voltage (more than a 10% increase within 6

minutes) can cause uncommanded positive speed changes; however an F25

“OverSpeed Limit” fault occurs if the speed reaches P82 [Max Speed] + P83

[Overspeed Limit]. If this condition is unacceptable. Take action 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 [Bus Reg Mode A] and 162 [Bus

Reg Mode B]).

•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 [Bus Reg Mode A] and 162 [Bus

Reg Mode B]). In addition, installing a properly sized dynamic brake resistor

provides 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 can 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 is removed from the respective motor, but the drive

continues 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 can cause the drive to fault. If any of these conditions are

determined to be undesirable or unsafe, wire an auxiliary contact on the output

contactor to a drive digital input that is programmed as “Enable.” This causes the

drive to execute a coast-to-stop (cease output) whenever an output contactor is

opened.

Motor Nameplate Voltage

Drive Rated Voltage

---------------------------------------------------------------128×

Other manuals for PowerFlex 70

Table of contents

Other Allen-Bradley Controllers manuals

Allen-Bradley

Allen-Bradley controllogix 1756-L61 User manual

Allen-Bradley

Allen-Bradley 2080-LC20-20QBB User manual

Allen-Bradley

Allen-Bradley PowerFlex 750 Series Owner's manual

Allen-Bradley

Allen-Bradley MicroLogix 1000 PLC Guide

Allen-Bradley

Allen-Bradley PowerFlex 700S User manual

Allen-Bradley

Allen-Bradley ControlLogix 1756-STRT3 Instruction manual

Allen-Bradley

Allen-Bradley SMC-3 User manual

Allen-Bradley

Allen-Bradley SLC 500 User manual

Allen-Bradley

Allen-Bradley Bulletin 505 User manual

Allen-Bradley

Allen-Bradley AADvance T9110 User guide

Allen-Bradley

Allen-Bradley 20A User manual

Allen-Bradley

Allen-Bradley PowerFlex 400 Instruction manual

Allen-Bradley

Allen-Bradley SLC 500 1747-L20 User manual

Allen-Bradley

Allen-Bradley GuardLogix 5580 User manual

Allen-Bradley

Allen-Bradley 1785-L11B User manual

Allen-Bradley

Allen-Bradley Mini-PLC-2/15 Setup guide

Allen-Bradley

Allen-Bradley ControlNet PLC-5 User manual

Allen-Bradley

Allen-Bradley powerflex 700 User manual

Allen-Bradley

Allen-Bradley 2080-LC20-20QWB User manual

Allen-Bradley

Allen-Bradley 1336 FORCE User manual

Allen-Bradley

Allen-Bradley SMC-50 User manual

Allen-Bradley

Allen-Bradley 160 SSC User manual

Allen-Bradley

Allen-Bradley micrologix 1500 User manual

Allen-Bradley

Allen-Bradley GuardPLC 1753 User manual

Popular Controllers manuals by other brands

Digiplex

Digiplex DGP-848 Programming guide

YASKAWA

YASKAWA SGM series user manual

Sinope

Sinope Calypso RM3500ZB installation guide

Isimet

Isimet DLA Series Style 2 Installation, Operations, Start-up and Maintenance Instructions

LSIS

LSIS sv-ip5a user manual

Rockwell Automation

Rockwell Automation 1769-L31 installation instructions

Airflow

Airflow Uno hab Installation and operating instructions

ABB

ABB ACS580-01 drives Hardware manual

Panasonic

Panasonic GM1 Series Reference manual

Emerson

Emerson SW93 owner's manual

AutoAqua

AutoAqua Smart ATO micro SATO-120P manual

Panasonic

Panasonic FP? Positioning Unit RTEX Technical manual

Samson

Samson Type 5824 Mounting and operating instructions

Alpha IP

Alpha IP MIOB 21001 manual

Siemens

Siemens OpenAir GMA 1 Series Mounting instructions

Surecom

Surecom SR-629 user manual

Fishman

Fishman TriplePlay installation guide

Regulus

Regulus SRS1 T Installation and operation manual