Allen-Bradley Powerflex 700 User manual

PowerFlex 700 AC Drives – Frames 0…10

Vector Control Firmware 4.001 and Up

User Manual

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

Allen-Bradley, DPI, DriveExplorer, DriveExecutive, Force Technology, PLC, PowerFlex, SCANport, 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 can 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 can be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage can be present.

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

reach dangerous temperatures.

ARC FLASH HAZARD: Labels can 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 20B-UM002G-EN-P - July 2014 3

Summary of Changes

The information below summarizes the changes to the PowerFlex 700 User

Manual, publication 20B-UM002 since the last release.

New and Updated

Information

Manual Updates

Description of New or Updated Information Page

Removed the product certifications and specifications from Appendix A. All certification and specification

information is located in the PowerFlex 700 Adjustable Frequency AC Drive Technical Data, publication 20B-

TD001.

N/A

4Rockwell Automation Publication 20B-UM002G-EN-P - July 2014

Summary of Changes

Notes:

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 5

Table of Contents

Preface

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ATEX Approved Drives & Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 1

Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Numbered List View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Monitor File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Motor Control File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Speed Command File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Utility File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Inputs & Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Pos/Spd Profile File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Parameter Cross Reference – by Number. . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Chapter 2

Troubleshooting

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Front Panel LED Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Precharge Board LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

HIM Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Common Symptoms/Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Testpoint C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . odes and Functions 96

Appendix A

Supplemental Drive Information

Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Typical Programmable Controller Configurations . . . . . . . . . . . . . . 97

6Rockwell Automation Publication 20B-UM002G-EN-P - July 2014

Table of Contents

Appendix B

HIM Overview

External & Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Removing/Installing the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Disconnecting the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Reconnecting the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Parameter Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Device Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Memory Storage Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Start Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Preferences Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Linking Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Establishing A Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Appendix C

Application Notes

Adjustable Voltage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Enabling Adjustable Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

External Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Hand-Off-Auto (HOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Lifting/Torque Proving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

TorqProve Manual Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Drive Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Installation/Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Lifting/Torque Proving Application Programming . . . . . . . . . . . . . 116

Limit Switches for Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Minimum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Motor Control Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Torque Producers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Torque Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Speed Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Motor DC Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Motor Overload Memory Retention Per 2005 NEC. . . . . . . . . . . . . . . . 123

Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Position Indexer/Speed Profiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Common Guidelines for all Step Types . . . . . . . . . . . . . . . . . . . . . . . . 124

Position Loop Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Profile Command Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Velocity Regulated Step Types and Parameters . . . . . . . . . . . . . . . . . 126

Position Regulated Step Types and Parameters . . . . . . . . . . . . . . . . . 127

Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Example 1: Five Step Velocity Profile (Time-Based and Encoder-

Based) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Example 2: Six Step Velocity Profile (Digital Input-Based) . . . . . . 131

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 7

Table of Contents

Example 3: Five Step Positioner with Incremental Encoder . . . . . 132

Power Loss Ride Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Process PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

PI Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Reverse Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Sleep Wake Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Start At PowerUp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Stop Dwell Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Voltage Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Appendix D

Instructionsfor ATEXApprovedDrives

in Group II Category (2) G D

Applications with ATEX Approved

Motors

Motor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Drive Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Start-Up & Periodic Drive Testing Requirement . . . . . . . . . . . . . . . . . . 150

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Index

8Rockwell Automation Publication 20B-UM002G-EN-P - July 2014

Table of Contents

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 9

Preface

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

to program and troubleshoot the PowerFlex 700 Adjustable Frequency AC Drive

with Vector Control.

Who Should Use this Manual? 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.

What Is Not in this Manual The PowerFlex 700 Series B User Manual provides programming and

troubleshooting information for the Vector Control drive, Frames 0…10.

Drive installation and wiring information is not in this manual, but can be found

in the Installation Instructions for your drive:

Frames 0…6 – publication 20B-IN019

Frames 7…10 – publication 20B-IN014

Literature is available online at http://www.rockwellautomation.com/literature.

Manual Conventions •In this manual we refer to the PowerFlex 700 Adjustable Frequency AC

Drive as; drive, PowerFlex 700 or PowerFlex 700 Drive.

•To help differentiate parameter names and LCD 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:

Topic Page

Who Should Use this Manual? 9

What Is Not in this Manual 9

Manual Conventions 9

Additional Resources 10

ATEX Approved Drives & Motors 10

Drive Frame Sizes 10

General Precautions 11

Catalog Number Explanation 13

Word Meaning Word Meaning

Can Possible, able to do something Shall Required and necessary

Cannot Not possible, not able to do something Should Recommended

May Permitted, allowed Should Not Not recommended

Must Unavoidable, you must do this

10 Rockwell Automation Publication 20B-UM002G-EN-P - July 2014

Preface

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

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.

ATEX Approved Drives &

Motors

For detailed information on using ATEX approved drives and motors, refer to

Appendix D.

Drive Frame Sizes Similar PowerFlex 700 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 the Catalog Number Explanation on

page 13.

Resource Description

PowerFlex 700 Standard Control User Manual, publication

20B-UM001

Provides detailed information on:

•Parameters and programming

•Faults, alarms, and troubleshooting

PowerFlex 700 AC Drive Technical Data, publication

20B-TD001

This publication provides detailed drive specifications,

option specifications and input protection device ratings.

PowerFlex Comm Adapter Manuals, publication

20COMM-UM…

These publications provide information on configuring,

using, and troubleshooting PowerFlex communication

adapters.

PowerFlex 70 and PowerFlex 700 Reference Manual,

publication PFLEX-RM001

These publications provide detailed application specific

information for programming and configuring the

PowerFlex 700 drive.

PowerFlex 70 Enhanced Control and PowerFlex 700 Vector

Control Reference Manual, publication PFLEX-RM004

Wiring and Grounding Guidelines for Pulse Width

Modulated (PWM) AC Drives, publication DRIVES-IN001

Provides basic information needed to properly wire and

ground PWM AC drives.

Safety Guidelines for the Application, Installation and

Maintenance of Solid State Control, publication SGI-1.1

Provides general guidelines for the application,

installation, and maintenance of solid-state control.

Guarding Against Electrostatic Damage, publication

8000-4.5.2

Provides practices for guarding against Electrostatic

damage (ESD)

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

other certification details.

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