Rockwell Automation PowerFlex 700S Owner's manual

PowerFlex 700S High Performance AC Drive - Phase II Control

Firmware Versions 1.xxx…7.xxx

Programming Manual

Original Instructions

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.

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 20D-PM001D-EN-P - March 2019 3

Table of Contents

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Product Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Drive Start-Up

Drive Start-Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Prepare for Initial Drive Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Start Up the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Chapter 2

Programming and Parameters

Firmware Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Parameter Data in Linear List Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Parameter Cross Reference By Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Chapter 3

Troubleshooting

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

DriveLogix5730 Controller Status Indicators . . . . . . . . . . . . . . . . . . 139

Precharge Board Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

HIM Indication of a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Fault and Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Fault/Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Appendix A

Human Interface Module Overview

External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

HIM Key Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Alternate (ALT) Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Access the Start-Up Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Device Select Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Memory Storage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Start Up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Preferences Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

4Rockwell Automation Publication 20D-PM001D-EN-P - March 2019

Table of Contents

View and Edit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Numeric Keypad Shortcut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Parameter Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Establishing A Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Remove/Install the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Appendix B

Application Notes

DPI Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Typical Programmable Controller Configurations . . . . . . . . . . . . . 160

Logic Command Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Logic Status Word. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

DPI Device Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Motor Control Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Field Oriented Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Permanent Magnet Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Volts/Hertz Control - v2.003 and Later . . . . . . . . . . . . . . . . . . . . . . . 163

Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Setting Parameter 338 [Mtr I2T Spd Min]. . . . . . . . . . . . . . . . . . . . . 164

Motor Overload Memory Retention Per 2005 NEC . . . . . . . . . . . . 165

Motors with Compatible Thermistor Ratings. . . . . . . . . . . . . . . . . . . . . . 166

Setpt 1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Setpt 2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Stop Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Sleep-Wake Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Appendix C

Control Block Diagrams

List of Control Block Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Diagram Conventions and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Appendix D

PowerFlex 700S Permanent Magnet

Motor Specifications

Compatible Permanent Magnet Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Rockwell Automation Publication 20D-PM001D-EN-P - March 2019 5

Table of Contents

Appendix E

ATEX Approved PowerFlex 700S,

Phase II Drives in Group II Category

(2) Applications with ATEX Approved

Motors

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Motor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Drive Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Safe-Off Terminal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Wiring Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Drive Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Operation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Appendix F

History of Changes

20D-PM001C-EN-P July 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

20D-PM001B-EN-P, July 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

20D-PM001A-EN-P, June 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

6Rockwell Automation Publication 20D-PM001D-EN-P - March 2019

Table of Contents

Notes:

Rockwell Automation Publication 20D-PM001D-EN-P - March 2019 7

Preface

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

start-up, program and troubleshoot PowerFlex 700S Phase II Adjustable

Frequency AC drives.

This manual is intended for qualified personnel. You must be able to program

and operate adjustable frequency AC drives. In addition, you must have an

understanding of the parameter settings and functions of this drive and

programmable controllers for PowerFlex 700S Phase II drives with DriveLogix.

Summary of Changes This manual contains new and updated information. This table contains the

changes made to this revision.

Changes to this manual for previous revisions are included inAppendix FHistory

of Changes on page 207.

Topic Page

Update front cover with firmware version and original instructions 1

Added safety publications to the Additional Resources table. 9

Added firmware compatibility information. 17

Added and/or updated parameters 455, 363, 364, 1168, 1169, and 510. All

8Rockwell Automation Publication 20D-PM001D-EN-P - March 2019

Preface

General Precautions Qualified Personnel

Personal Safety

ATTENTION: Only qualified personnel familiar with the PowerFlex 700S Drive

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 Power Terminal Block by measuring between the +DC and

–DC terminals, between the +DC terminal and the chassis, andbetween the -DC

terminal and the chassis. The voltage must be zero for all three measurements.

ATTENTION: Hazard of personal injury or equipment damage exists when using

bipolar input sources. Noise and drift in sensitive input circuits can cause

unpredictable changes in motor speed and direction. Use speed command

parameters to help reduce input source sensitivity.

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: Risk of injury or equipment damage exists. Parameters 365 [Fdbk

LsCnfg Pri]…394 [VoltFdbkLossCnfg] let you determine the action of the drive

in response to operating anomalies. Precautions should be taken to ensure that

the settings of the parameters do not create hazards of injury or equipment

damage.

ATTENTION: Risk of injury or equipment damage exists. Parameters 383 [SL

CommLoss Data]…392 [NetLoss DPI Cnfg] let you determine the action of the

drive if communications are disrupted. You can set the parameters so that the

drive continues to run. Precautions should be taken to ensure that the settings of

the parameters do not create hazards of injury or equipment damage.

Rockwell Automation Publication 20D-PM001D-EN-P - March 2019 9

Preface

Product Safety

Class 1 LED Product

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

ATTENTION: An incorrectly applied or installed drive can result in component

damage or a reduction in product life. Wiring or application errors such as under

sizing the motor, incorrect or inadequate AC supply, or excessive surrounding air

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 drive assemblies. 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: 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.

ATTENTION: Hazard of permanent eye damage exists when using optical

transmission equipment. This product emits intense light and invisible radiation.

Do not look into module ports or fiber optic cable connectors.

Resource Description

PowerFlex 700S Phase II Drive, Frames 1…6 Installation

Instructions, publication 20D-IN024

Provides youwith the information needed toinstall and

wire PowerFlex 700S Phase II frame 1…6 drives.

PowerFlex 700H and 700S Drives, Frames 9…14 Installation

Instructions, publication PFLEX-IN006

Provides youwith the information needed toinstall and

wire PowerFlex 700S Phase II frame 9…14 drives.

PowerFlex 700S Phase II Reference Manual, publication

PFLEX-RM003

Provides detailed explanations and examples of

PowerFlex 700S Phase II drive control functions and

application programming.

Drives in Common Bus Configurations, publication DRIVES-

AT002

This publication to provide the necessary guidelines,

considerations, and limitations for the proper

application of PowerFlex drives used in common bus

configurations.

Stegmann Feedback Option for PowerFlex 700S Drives

Installation Instructions, publication 20D-IN001

Provides instructions for installing the Stegmann

feedback option board for PowerFlex 700S drives.

Resolver Feedback Option for PowerFlex 700S Drives

Installation Instructions, publication 20D-IN002

Provides instructions for installing the resolver

feedback option board for PowerFlex 700S drives.

Multi-Device Interface for PowerFlex 700S Drives Installation

Instructions, publication 20D-IN004

Provides instructions for installing the multi-device

interface option board for PowerFlex 700S drives.

10 Rockwell Automation Publication 20D-PM001D-EN-P - March 2019

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.

Second Encoder Option for PowerFlex 700S Drives with

Phase II Control Installation Instructions,

publication 20D-IN009

Provides instructions for installing the second encoder

option board for PowerFlex 700S drives.

SynchLink™ Board for PowerFlex 700S Drives with Phase II

Control Installation Instructions, publication 20D-IN010

Provides instructions for installing the SynchLink option

board for PowerFlex 700S drives.

DriveLogix 5730 Controller User Manual, publication

20D-UM003

Provides information to help you develop projects for

DriveLogix controllers and establish communications

with PowerFlex 700S Phase II drives.

Safe Torque Off Option for PowerFlex 700S Phase II AC Drives

and PowerFlex 700L Liquid-Cooled AC Drives, publication

20D-UM007

The DriveGuard Safe Torque Off option, when used with

other safety components, helps provide protection to

meet the requirements for SIL CL2 and Category 3 or PL

d class applications. Safety requirements are based on

the standards current at the time of certification.

Logix5000 Controllers Common Procedures Programming

Manual, publication 1756-PM001

This publication links to a collection of programming

manuals that describe how you can use procedures that

are common to all Logix5000 controller projects.

Logix5000 Controllers General Instructions Reference

Manual, publication 1756-RM003

Provides a programmer with details about each

available instruction for a Logix-based controller.

Logix5000 Controllers Process Control and Drives

Instructions Reference Manual, publication 1756-RM006

Provides a programmer with details about each

available instruction for a Logix-based controller.

SynchLink System Design Guide, publication 1756-TD008 Provides a detailed description of SynchLink and the

products that operate on it, including:

•ControlLogix SynchLink module (1756-SYNCH)

•ControlLogix Drive modules (1756-DMxxx Series)

•PowerFlex 700S drives

Wiring and Grounding for Pulse Width Modulated (PWM) AC

Drives, publication DRIVES-IN001

Provides basic information needed to properly wire and

ground Pulse Width Modulated (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 in

the form of individual devices or packaged assemblies

incorporating solid state components.

Industrial Automation Wiring and Grounding Guidelines,

publication 1770-4.1

Provides general guidelines for installing a Rockwell

Automation industrial system.

Product Certifications website

https://compatibility.rockwellautomation.com/Pages/

home.aspx

Provides declarations of conformity, certificates, and

other certification details.

Resource Description

Other manuals for PowerFlex 700S

Table of contents

Other Rockwell Automation DC Drive manuals

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex Series User manual

Rockwell Automation

Rockwell Automation PowerFlex 755TM User manual

Rockwell Automation

Rockwell Automation Allen-Bradley 1204 Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley 1336 PLUS II User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 753 User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex Active Front End... User manual

Rockwell Automation

Rockwell Automation Allen-Bradley DRIVES HEADQUARTERS Flying Start PowerFlex... User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 750 Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley Ultra5000 User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755TS Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 7000 Series User manual

Rockwell Automation

Rockwell Automation RELIANCE ELECTRIC DC3N Series User manual

Rockwell Automation

Rockwell Automation PowerFlex 6000 User manual

Rockwell Automation

Rockwell Automation Allen-Bradley Kinetix 300 User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755T Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755 User manual

Rockwell Automation

Rockwell Automation Allen Bradley PowerFlex40 User manual

Rockwell Automation

Rockwell Automation Allen-Bradley 160 SSC Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley 35E User manual

Rockwell Automation

Rockwell Automation PowerFlex 700H User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755TS Series Service manual

Rockwell Automation

Rockwell Automation Reliance electric 6SB401 Series User manual

Rockwell Automation

Rockwell Automation Allen-Bradley PowerFlex 755 User manual

Rockwell Automation

Rockwell Automation Allen-Bradly 1397 User manual

Popular DC Drive manuals by other brands

Vincent Associates

Vincent Associates UNIBLITZ ED12DSS user manual

EKSMA OPTICS

EKSMA OPTICS DQ-100-4 Technical description

Chamberlain Garog

Chamberlain Garog D Series operating manual

Parker

Parker PDS Series user guide

Festo

Festo DGC G Series Repair instructions

Binks

Binks QS-5012-1-CE Service manual

Danfoss

Danfoss VLT 2800 Series Quick setup

ABB

ABB ACQ580-01 Series Quick installation and start-up guide

YASKAWA

YASKAWA CANopen SI-S3 Technical manual

GE D20A6 instructions

Unex

Unex MC-D-250-1000-050W-TW operating manual

Geckodrive

Geckodrive G213V manual

ABB

ABB RSYC-01 user manual

WEG

WEG DeviceNet CFW500 user manual

Siemens

Siemens SINAMICS G List manual

Siemens

Siemens SINAMICS SM150 6SL3815-7NP41-0AA1 Operating instructions & installation instructions

SOMFY

SOMFY JR RU 30 instructions

Beckhoff

Beckhoff AX8911 Documentation