Allen-Bradley PowerFlex 70 User manual

Adjustable

Frequency AC

Drive

User Manual

www.abpowerﬂex.com

Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. “

Safety Guidelines for the Application, Installation

and Maintenance of Solid State Controls

” (Publication SGI-1.1 available from

your local Allen-Bradley Sales Ofﬁce or online at

http://www.ab.com/manuals/gi

)

describes some important differences between solid state equipment and

hard-wired electromechanical devices. Because of this difference, and also

because of the wide variety of uses for solid state equipment, all persons

responsible for applying this equipment must satisfy themselves that each intended

application of this equipment is acceptable.

In no event will the Allen-Bradley Company 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, the Allen-Bradley Company cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is prohibited.

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

Attentions help you:

•

identify a hazard

•

avoid the hazard

•

recognize the consequences

Important:

Identiﬁes information that is especially important for successful

application and understanding of the product.

DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.

PLC is a registered trademark of Rockwell Automation.

ControlNet is a trademark of ControlNet International, Ltd.

DeviceNet is a trademark of the Open DeviceNet Vendor Association.

ATTENTION:

Identiﬁes information about practices or circumstances

that can lead to personal injury or death, property damage, or economic

loss.

Shock Hazard

labels may be located on or inside the drive to alert

people that dangerous voltage may be present.

Burn Hazard

labels may be located on or inside the drive to alert

people that surfaces may be at dangerous temperatures.

Summary of Changes

The information below summarizes the changes to the PowerFlex 70

User Manual since the last release.

Description of New or Updated Information See Page(s)

Speed Reference Selection Chart clariﬁed. 1-15

Drive, Fuse & Circuit Breaker Ratings information updated A-1 – A-4

soc-2

Table of Contents

Preface

Overview

Who Should Use this Manual? . . . . . . . . . P-1

What Is Not in this Manual . . . . . . . . . . . . P-1

Reference Materials. . . . . . . . . . . . . . . . . . P-2

Manual Conventions . . . . . . . . . . . . . . . . . P-2

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-3

General Precautions. . . . . . . . . . . . . . . . . . P-3

Catalog Number Explanation . . . . . . . . . . P-5

Chapter 1

Installation/Wiring

Opening the Cover. . . . . . . . . . . . . . . . . . . 1-1

Mounting Considerations . . . . . . . . . . . . . 1-2

AC Supply Source Considerations . . . . . . 1-3

General Grounding Requirements. . . . . . . 1-4

Fuses and Circuit Breakers . . . . . . . . . . . . 1-5

Power Wiring. . . . . . . . . . . . . . . . . . . . . . . 1-6

I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Speed Reference Control. . . . . . . . . . . . . 1-15

Auto/Manual Examples. . . . . . . . . . . . . . 1-16

Disconnecting MOVs and

Common Mode Capacitors . . . . . . . . . . . 1-18

EMC Instructions . . . . . . . . . . . . . . . . . . 1-19

Chapter 2

Start Up

Prepare For Drive Start-Up . . . . . . . . . . . . 2-1

Status Indicators . . . . . . . . . . . . . . . . . . . . 2-2

Start-Up Routines . . . . . . . . . . . . . . . . . . . 2-3

Running S.M.A.R.T. Start . . . . . . . . . . . . . 2-4

Running an Assisted Start Up . . . . . . . . . . 2-4

Chapter 3

Programming

and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . 3-1

How Parameters are Organized . . . . . . . . . 3-3

Monitor File (File A) . . . . . . . . . . . . . . . . . 3-8

Motor Control File (File B) . . . . . . . . . . . . 3-9

Speed Command File (File C). . . . . . . . . 3-12

Dynamic Control File (File D) . . . . . . . . 3-17

Utility File (File E) . . . . . . . . . . . . . . . . . 3-21

Communication File (File H) . . . . . . . . . 3-29

Inputs & Outputs File (File J) . . . . . . . . . 3-33

Parameter Cross Reference – by Name. . 3-37

Parameter Cross Reference – by Number 3-39

Chapter 4

Troubleshooting

Faults and Alarms . . . . . . . . . . . . . . . . . . . 4-1

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Manually Clearing Faults . . . . . . . . . . . . . 4-3

Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . 4-7

Alarm Descriptions . . . . . . . . . . . . . . . . . . 4-7

Testpoint Codes and Functions . . . . . . . . 4-10

Common Symptoms . . . . . . . . . . . . . . . . 4-10

Appendix A

Supplemental Drive Information

Output Devices . . . . . . . . . . . . . . . . . . . . . A-1

Drive, Fuse & Circuit Breaker Ratings . . . A-1

Appendix B

HIM Overview

External and Internal Connections . . . . . . B-1

LCD Display Elements . . . . . . . . . . . . . . . B-2

ALT Functions. . . . . . . . . . . . . . . . . . . . . . B-2

Menu Structure . . . . . . . . . . . . . . . . . . . . . B-3

Viewing and Editing Parameters . . . . . . . . B-5

Removing the HIM . . . . . . . . . . . . . . . . . . B-7

Index

Preface

Overview

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

needed to install, start-up and troubleshoot the PowerFlex 70 Adjustable

Frequency AC Drive.

This manual is intended for qualiﬁed personnel. 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.

Since this

User Manual

is designed to provide only basic start-up

information, the following topics have not been included:

•

Speciﬁcations

•

Mounting Dimensions

•

Spare Parts Information

Please refer to the

PowerFlex Reference Manual

for detailed drive

information. The reference manual is included on the CD supplied with

your drive or is also available online at

http://www.ab.com/manuals

For information on… See page…

Who Should Use this Manual? P-1

What Is Not in this Manual P-1

Reference Materials P-2

Manual Conventions P-2

Drive Frame Sizes P-3

General Precautions P-3

Catalog Number Explanation P-5

Who Should Use this Manual?

What Is Not in this Manual

P-2

Overview

The following manuals are recommended for general drive information:

For detailed PowerFlex 70 information including mounting dimensions

and speciﬁcations:

•

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 display text from other

text, the following conventions will be used:

–

Parameter Names will appear in [brackets].

For example: [DC Bus Voltage].

–

Display Text will appear in “quotes.” For example: “Enabled.”

•

The following words are used throughout the manual to describe an

action:

Reference Materials

Title Publication Available Online at …

Industrial Automation Wiring

and Grounding Guidelines

1770-4.1

(1)

Not available online, contact your local Allen-Bradley Sales Ofﬁce.

Preventive Maintenance of

Industrial Control and Drive

System Equipment

DRIVES-SB001A-EN-E

www.ab.com/manuals/dr

Safety Guidelines for the

Application, Installation and

Maintenance of Solid State

Control

SGI-1.1

www.ab.com/manuals/gi

A Global Reference Guide for

Reading Schematic Diagrams

0100-2.10

(1)

Guarding Against Electrostatic

Damage

8000-4.5.2

www.ab.com/manuals/gi

Title Publication Available …

PowerFlex Reference

Manual

PFLEX-RM001A-EN-E on the CD supplied with the drive

or at

www.ab.com/manuals/dr

Manual Conventions

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Shall Required and necessary

Should Recommended

Should Not Not Recommended

Overview

P-3

Similar PowerFlex 70 drive sizes are grouped into frame sizes to

simplify spare parts ordering, dimensioning, etc. A cross reference of

drive catalog numbers and their respective frame size is provided in

Appendix A.

Drive Frame Sizes

General Precautions

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 A-B publication 8000-4.5.2, “Guarding Against Electrostatic

Damage” or any other applicable ESD protection handbook.

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:

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.

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 Figure 1.3 on

page 1-9 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:

A risk of injury or equipment damage exists in

ﬁrmware version 1.011 and earlier. When there is a combination of long

shielded motor cables, high source impedance, low speed, light motor

load and parameter 190 [Direction Mode] is set to “Unipolar” or

“Bipolar,” an unexpected change in motor direction may occur. If these

conditions exist, choose one of the following corrective actions:

•

Set parameter 190 to “Reverse Dis”

•

Set parameters 161 and 162 to “Disabled”

•

Install a properly sized Dynamic Brake resistor

P-4

Overview

ATTENTION:

Nuisance tripping may occur in ﬁrmware version

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

connected for a voltage that is different from the drive (e.g., using a

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

must be made to “Stability Gain” 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 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.

Motor Nameplate Voltage

Drive Rated Voltage

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

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