Allen-Bradley PowerFlex 70 User Manual
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Allen-Bradley PowerFlex 70 User Manual

Adjustable frequency ac drives
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User Manual
PowerFlex 70 Adjustable Frequency AC Drives
Standard Control Firmware, Revision 2.
Enhanced Control Firmware, Revision 2. ...4.

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Summary of Contents for Allen-Bradley PowerFlex 70

  • Page 1 User Manual PowerFlex 70 Adjustable Frequency AC Drives Standard Control Firmware, Revision 2. Enhanced Control Firmware, Revision 2. …4.
  • Page 2 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). 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.
  • Page 3 Added footnote 2 for information regarding watts loss with certain drives 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. Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 5: Table Of Contents

    Table of Contents Preface About This Publication..........7 What Is Not in This Publication .
  • Page 6 Table of Contents Appendix C Application Notes External Brake Resistor ......... . 106 Skip Frequency.

  • Page 7: About This Publication

    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. Topic Page About This Publication What Is Not in This Publication Additional Resources Manual Conventions...

  • Page 8: Manual Conventions

    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: •...

  • Page 9: General Precautions

    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).
  • Page 10 Preface 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”...

  • Page 11: Catalog Number Explanation

    Preface Catalog Number Explanation Position Number Drive ND Rating ND Rating Code Type 400V, 50 Hz Input 600V, 60 Hz Input PowerFlex 70 Code Amps kW (Hp) Frame Code Amps kW (Hp) Frame 0.37 (0.5) 0.37 (0.5) 0.75 (1.0) 0.75 (1.0) 1.5 (2.0)

  • Page 12: Catalog Number Explanation (Continued)

    Preface Catalog Number Explanation (continued) Position Number Documentation Emission Class Control & I/O Code Type Code Rating Code Control Safe-Off Manual Filtered Standard & B Frames (Optional) No Manual Enhanced C, D, & E Frames (Standard) Enhanced Not Filtered A & B Frames (Optional) No longer available for sale.

  • Page 13: About Parameters

    Chapter Programming and Parameters This chapter provides a complete list and descriptions of the PowerFlex 70 drive parameters. The parameters are programmed (viewed/edited) by using a Light-emitting Diode (LED) or LCD Human Interface Module (HIM). You can also use DriveExplorer™ or DriveExecutive™ software and a personal computer to program the drive.

  • Page 14: How Parameters Are Organized

    The LED HIM displays parameters in numbered list order. Parameters are accessed by first selecting the file letter, then a parameter number. IMPORTANT The PowerFlex 70 Enhanced Control drive does not support the LED HIM. Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...
  • Page 15 Lvl], you have the option to display all parameters, commonly used parameters, or diagnostic parameters. Control Options Two different control options are available for the PowerFlex 70, standard and enhanced. • Standard control drives provide volts per hertz and sensorless vector operation.
  • Page 16 Chapter 1 Programming and Parameters Basic Parameter View – Standard Control Parameter 196 [Param Access Lvl] set to option 0 “Basic.” File Group Parameters Monitor Metering Output Freq M o n it Commanded Freq Output Current DC Bus Voltage F il e A Motor Control Motor Data Motor NP Volts...
  • Page 17 Programming and Parameters Chapter 1 Basic Parameter View – Enhanced Control Parameter 196 [Param Access Lvl] set to option 0 “Basic.” File Group Parameters Monitor Metering Output Freq Commanded Freq M o n it Output Current Torque Current F il e A DC Bus Voltage Commanded Torque**024 Motor Control...
  • Page 18 Chapter 1 Programming and Parameters Advanced Parameter View – Standard Control Parameter 196 [Param Access Lvl] set to option 1 “Advanced.” File Group Parameters Monitor Metering Output Freq Output Voltage MOP Frequency Commanded Freq Output Power DC Bus Voltage M o n it Output Current Output Powr Fctr DC Bus Memory...
  • Page 19 Programming and Parameters Chapter 1 File Group Parameters Utility Direction Config Direction Mode U ti li ty HIM Ref Config Save HIM Ref Man Ref Preload MOP Config Save MOP Ref F il e E MOP Rate Drive Memory Param Access Lvl Save To User Set Voltage Class Reset To Defalts...
  • Page 20 Chapter 1 Programming and Parameters Advanced Parameter View – Enhanced Control Parameter 196 [Param Access Lvl] set to option 1 “Advanced.” File Group Parameters Monitor Metering Output Freq Output Powr Fctr Torque Estimate M o n it Commanded Freq Elapsed MWh Analog In1 Value Output Current Elapsed Run Time...
  • Page 21 Programming and Parameters Chapter 1 File Group Parameters Dynamic Control Restart Modes Powerup Delay Auto Rstrt Tries Wake Level D y n a m Start At PowerUp Auto Rstrt Delay Wake Time ic C o n tr o l Flying Start En Sleep Wake Mode Sleep Level Flying StartGain...

  • Page 22: Monitor File (File A)

    Chapter 1 Programming and Parameters File Group Parameters Inputs and Outputs Analog Inputs Anlg In Config Analog In 1 Lo Analog In 2 Lo In p u ts Anlg In Sqr Root Analog In 1 Loss Analog In 2 Loss &...
  • Page 23 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Elapsed Run Time] Default: Read Only Accumulated time drive is outputting power. Min/Max: 0.0/429496729.5 Hrs Units: 0.1 Hrs [MOP Frequency] Default: Read Only Value of the signal at MOP (Motor Operated Min/Max: ±[Maximum Frequency] Potentiometer).

  • Page 24: Motor Control File (File B)

    Chapter 1 Programming and Parameters Motor Control File (file B) Parameter Name and Description Values page 14 for symbol descriptions [Motor Type] Default: “Induction” Set to match the type of motor connected. Options: “Induction” “Synchr Reluc” Important: Selecting option 1 or 2 also “Synchr PM”...
  • Page 25 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Motor OL Mode] E C v3 If “0,” [Motor OL Count], P220 is reset to zero by a drive reset or a power cycle. If “1,” the value is maintained.
  • Page 26 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions 140… [Compensation] Enables/disables correction options. 1 =Enabled 0 =Disabled x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit # Factory Default Bit Values Enhanced firmware 1.001 &...
  • Page 27 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Autotune] Default: “Calculate” Provides a manual or automatic method for Options: “Ready” setting P62 [IR Voltage Drop] and P63 [Flux “Static Tune” Current Ref] to affect sensorless vector “Rotate Tune”...
  • Page 28 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [IXo Voltage Drop] Default: Based on Drive Rating E C v2 Value of voltage drop across the leakage Min/Max: 0.0/Motor NP Volts inductance of the motor at rated motor current. Units: 0.1 VAC Used only when parameter 53 is set to “FVC...
  • Page 29 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Pos Torque Limit] Default: 200.0% E C v2 Defines the torque limit for the positive torque Min/Max: 0.0/800.0% reference value. The reference cannot exceed Units: 0.1% this value.
  • Page 30 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Motor NP Hertz] × 0.25 [Break Frequency] Default: Sets the [Break Voltage] output frequency of Min/Max: 0.0/[Maximum Freq] the drive. Units: 0.1 Hz Refer to parameter 083 [Overspeed Limit]. E C v2 [Motor Fdbk Type] Default:...

  • Page 31: Speed Command File (File C)

    Programming and Parameters Chapter 1 Speed Command File (file C) Parameter Name and Description Values page 14 for symbol descriptions Standard [Speed Mode] 121… Default: “Open Loop” Sets the method of speed regulation. Options: “Open Loop” “Slip Comp” “Process PI” [Feedback Select] Default: “Open Loop”...
  • Page 32 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Skip Frequency 1] Default: 0.0 Hz [Skip Frequency 2] Default: 0.0 Hz [Skip Frequency 3] Default: 0.0 Hz Sets a frequency where the drive does not Min/Max: ±500.0 Hz operate.
  • Page 33 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Speed Ref A Sel] Default: “Analog In 2” 091… Selects the source of the speed reference to the Options: “Analog In 1” drive unless [Speed Ref B Sel] or [Preset Speed “Analog In 2”...
  • Page 34 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [TB Man Ref Sel] Default: “Analog In 1” Sets the manual speed reference source when a Options: “Analog In 1” digital input (parameter 361…366) is “Analog In 2”...
  • Page 35 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions Standard 361… [Jog Speed] Default: 10.0 Hz Sets the output frequency when a jog Min/Max: ±[Maximum Speed] command is issued. Units: 0.1 Hz [Jog Speed 1] Default: 10.0 Hz Sets the output frequency when Jog Speed 1 is...
  • Page 36 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Trim Out Select] Specifies the speed references to be trimmed. To apply negative trim, P190 [Direction Mode] must be set to 1 “Bipolar.” 1 =Trimmed 0 =Not Trimmed x =Reserved Nibble 4...
  • Page 37 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [PI Control] 361… Controls the PI regulator. 1 =Enabled 0 =Disabled x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit # Factory Default Bit Values [PI Reference Sel] Default: “PI Setpoint”...
  • Page 38 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions 124… [PI Upper Limit] Default: +[Maximum Freq] 100% Sets the upper limit of the PI output. Min/Max: ±400.0 Hz ±800.0% Units: 0.1 Hz 0.1% [PI Preload] Default: 0.0 Hz 124…...
  • Page 39 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [PI Reference Hi] Default: 100.0% Scales the upper value of [PI Reference Sel] of Min/Max: ±100.0% the source. Units: 0.1% [PI Reference Lo] Default: –100.0% Scales the lower value of [PI Reference Sel] Min/Max: ±100.0%...
  • Page 40 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Speed Desired BW] Default: 0.0 Radians/Sec E C v2 Sets the speed loop bandwidth and determines Min/Max: 0.0/250.0 Radians/Sec the dynamic behavior of the speed loop. As Units: 0.1 Radians/Sec bandwidth increases, the speed loop becomes...

  • Page 41: Dynamic Control File (File D)

    Programming and Parameters Chapter 1 Dynamic Control File (file D) Parameter Name and Description Values page 14 for symbol descriptions [Accel Time 1] Default: 10.0 Secs [Accel Time 2] 10.0 Secs Sets the rate of accel for all speed increases. Min/Max: 0.0/3600.0 Secs Max Speed...
  • Page 42 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Droop RPM @ FLA] Default: 0.0 rpm E C v2 Selects amount of droop that the speed Min/Max: 0.0/200.0 rpm reference is reduced when at full load torque. Units: 0.1 rpm Zero disables the droop function.
  • Page 43 Units: function is created by a PWM algorithm and can fail to generate the smooth holding force needed for some applications. Refer to the PowerFlex 70 and 700 Adjustable Frequency AC Drive Reference Manual, publication PFLEX- RM001. Important: Frame E drives can be limited to less than 150% depending on the setting of parameter 151 [PWM Frequency].
  • Page 44 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Bus Reg Mode A] Default: “Adjust Freq” [Bus Reg Mode B] “Both-Frq 1st” Active bus regulation mode. Choices are Options: “Disabled” dynamic brake, frequency adjust or both. “Adjust Freq”...
  • Page 45 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Flux Braking] Default: “Disabled” E C v2 Set to use an increase in the motor flux current Options: “Disabled” to increase the motor losses, and enables a “Enabled”...
  • Page 46 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Flying Start En] Default: “Disabled” Enables/disables the function that reconnects to Options: “Disabled” a spinning motor at actual rpm when a start “Enabled” command is issued. [Flying StartGain] Default: 4000...
  • Page 47 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions 179… [Sleep Wake Mode] Default: “Disabled” E C v2 Enables/disables the Sleep/Wake function. Options: “Disabled” Important: When enabled, the following “Direct” (Enabled) conditions must be met: “Invert”...
  • Page 48 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Sleep Wake Ref] Default: “Analog In 2” E C v2 Selects the source of the input controlling the Options: “Analog In 1” Sleep-Wake function. “Analog In 2” 320…...

  • Page 49: Utility File (File E)

    Programming and Parameters Chapter 1 Utility File (file E) Parameter Name and Description Values page 14 for symbol descriptions [Direction Mode] 320… Default: “Unipolar” Selects the method for changing drive Options: “Unipolar” 361… direction. “Bipolar” “Reverse Dis” Mode Direction Change Unipolar Drive Logic Bipolar...
  • Page 50 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Save MOP Ref] Enables/disables the feature that saves the present MOP frequency reference at power down or at stop. 361… 1 = Save 0 = Do Not Save x = Reserved Nibble 4 Nibble 3...
  • Page 51 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Language] Default: “Not Selected” Options: “Not Selected” Selects the display language when you are “English” using an LCD HIM. This parameter is not “Français” functional with an LED HIM. “Español”...
  • Page 52 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Dyn UserSet Actv] Read Only E C v2 Indicates the active user set and if the operation is dynamic or normal. 361… 1 =Condition True 0 =Condition False x = Reserved Nibble 4...
  • Page 53 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Drive Alarm 1] Read Only Alarm conditions that currently exist in the drive. Chapter 2 for information on Type 1 alarms. 1 =Condition True 0 =Condition False x =Reserved Nibble 4 Nibble 3...
  • Page 54 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Speed Ref Source] Default: Read Only Displays the source of the speed reference to Options: “PI Output” the drive. “Analog In 1” “Analog In 2” Displays after Start is pressed.
  • Page 55 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions 361… [Dig In Status] Read Only Status of the digital inputs. 1 =Input Present 0 =Input Not Present x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit # Enhanced firmware 2.001 &...
  • Page 56 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Drive Status 3] Read Only E C v3 Present operating condition of the drive. Manual Mode - See “Manual” Speed Sources on page 117. Fast Braking - Fast Braking is active, see [Stop/Brk Mode A] [Stop/Brk Mode B] on page 1 = Condition True...
  • Page 57 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Status 2 @ Fault] Read Only 224… Captures and displays [Drive Status 2] bit pattern at the time of the last fault. 1 = Condition True 0 = Condition False x = Reserved Nibble 4...
  • Page 58 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Testpoint 1 Sel] Default: [Testpoint 2 Sel] Min/Max: 0/999 Selects the function whose value is displayed 0/65535 value in [Testpoint x Data]. Units: These are internal values that are not accessible through parameters.
  • Page 59 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Fault 1 Code] Default: Read Only [Fault 2 Code] Min/Max: 0/9999 [Fault 3 Code] 0/65535 [Fault 4 Code] Units: A code that represents the fault that tripped the drive.

  • Page 60: Communication File (File H)

    Chapter 1 Programming and Parameters Communication File (file H) Parameter Name and Description Values page 14 for symbol descriptions [DPI Data Rate] Default: “125 kbps” Sets the baud rate for attached drive peripherals. Options: “125 kbps” When changing this value the drive must be reset for “500 kbps”...
  • Page 61 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [DPI Port Select] Default: “Not Used” Selects the port reference value that appears in [DPI Options: “Not Used” Port Value]. “DPI Port 1” “DPI Port 2” “DPI Port 3”...
  • Page 62 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions 288… [MOP Mask] See P276 [Logic Mask]. Controls the adapters that can issue MOP commands to the drive. [Local Mask] See P276 [Logic Mask]. 288… Controls the adapters that take exclusive control of drive logic commands (except stop).
  • Page 63 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions 276… [Local Owner] See P288 [Stop Owner]. Adapter that has requested exclusive control of all drive logic functions. If an adapter is in local lockout, all other functions (except stop) on all other adapters are locked out and non-functional.
  • Page 64 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Port Mask Act] E C v2 Active status for port communication. 1 =Not Masked 0 =Masked x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit # Factory Default Bit Values [Write Mask Cfg]...

  • Page 65: Inputs And Outputs File (File J)

    Programming and Parameters Chapter 1 Inputs and Outputs File (file J) Parameter Name and Description Values page 14 for symbol descriptions [Anlg In Config] Selects the mode for the analog inputs. 1 =Current 0 =Voltage x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit #...
  • Page 66 Chapter 1 Programming and Parameters Parameter Name and Description Values page 14 for symbol descriptions [Anlg Out Config] Selects the mode for the analog outputs. 1 =Current 0 =Voltage x =Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1 Bit # Factory Default Bit Values [Anlg Out Absolut] Selects whether the signed value or absolute value of a parameter is used before being scaled...
  • Page 67 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions [Analog Out1 Hi] Default: 10.00 Volts Sets the analog output value when the source Min/Max: 0.00/10.00 Volts value is at maximum. 0.00/20.00 mA Units: 0.01 Volt 0.01 mA [Analog Out1 Lo] Default:...
  • Page 68 “Jog 2” A dedicated hardware enable input is available via a “PI Invert” jumper selection. Refer to I/O Wiring Examples in the 36…40 “Reserved” PowerFlex 70 Adjustable Frequency AC Drive 41, 42 “UserSet Sel1-2” Installation Instructions, publication 20A-IN009. (5)(12) “Run Level”...
  • Page 69 Programming and Parameters Chapter 1 Parameter Name and Description Values page 14 for symbol descriptions Typical 3-Wire Inputs - Requires that only 3-wire functions are chosen. Including 2-wire selections causes a type 2 alarm. (10) Typical 2-Wire Inputs - Requires that only 2-wire functions are chosen. Including 3-wire selections causes a type 2 alarm.
  • Page 70 “At Speed” is removed. Refer to I/O Wiring Examples in the “At Freq” PowerFlex 70 Adjustable Frequency AC Drive Installation “At Current” Instructions, publication 20A-IN009. “At Torque” Activation level is defined in [Dig Outx Level] below.
  • Page 71 Programming and Parameters Chapter 1 Selected Option Definitions – [Analog Outx Sel], [Digital Inx Sel], and [Digital Outx Sel] Option Description Related At Speed Relay changes state when drive has reached commanded speed. Excl Link Links digital input to a digital output if the output is set to “Input 1-6 Link.” Input 1…6 Link When Digital Output 1 is set to of these (for example, Input 3 Link) in conjunction with Digital Input 3 set to “Excl Link,”...

  • Page 72: Applications File (File K)

    Chapter 1 Programming and Parameters Applications File (file K) Parameter Name and Description Values page 14 for symbol descriptions [Fiber Control] E C v3 Controls the Sync and Traverse functions. 1 = Enabled 0 = Disabled x = Reserved Nibble 4 Nibble 3 Nibble 2 Nibble 1...

  • Page 73: Parameter Cross Reference - By Name

    Programming and Parameters Chapter 1 Parameter Cross Parameter Name Number Group Page Parameter Name Number Group Page DC Brake Lvl Sel Stop/Brake Reference – by Name Accel Mask Masks and Modes Owners DC Brake Time Stop/Brake Accel Owner Masks and Modes Owners DC Bus Memory...
  • Page 74 Chapter 1 Programming and Parameters Parameter Name Number Group Page Parameter Name Number Group Page Fault Frequency Diagnostics MOP Rate MOP Config Fault X Code 243…249 Faults Motor Cntl Sel Torq Attributes Fault X Time 244…250 Faults Motor Fdbk Type Speed Feedback Fdbk Filter Sel...
  • Page 75 Programming and Parameters Chapter 1 Parameter Name Number Group Page Parameter Name Number Group Page Ramped Speed Metering Status 3 @ Fault Diagnostics Rated Amps Drive Data Stop/Brk Mode X 155, 156 Stop/Brake Modes Rated kW Drive Data Stop Owner Masks and Rated Volts Drive Data...
  • Page 76 Chapter 1 Programming and Parameters Notes: Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 77: Faults And Alarms

    Chapter Troubleshooting This chapter provides information for troubleshooting the PowerFlex 70 drive. It includes a list and descriptions of drive faults (with possible solutions, when applicable) and alarms. Topic Page Faults and Alarms Drive Status Clearing Alarms Testpoint Codes and Functions Common Symptoms and Corrective Actions A fault is a condition that stops the drive.
  • Page 78 Chapter 2 Troubleshooting HIM Indication The LCD and LED HIMs also provide visual notification of a fault or alarm condition. Condition Display Drive is indicating a fault. LCD HIM The LCD HIM immediately reports the fault condition by displaying the following information: ·...
  • Page 79 Locate and remove the enable enable jumper is removed. jumper on the main control board. Refer to DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and PowerFlex 70 AC Drives, publication PFLEX-UM003, for instructions and location. Safe-Off board has failed. Replace Safe-Off board.
  • Page 80 Chapter 2 Troubleshooting Table 1 - Fault Types, Descriptions and Actions (Continued) Fault Description Action Fatal Faults 900… 2 Diagnostic code indicating a drive malfunction. 1. Cycle power. 2. Replace Main Control Board. 3. Contact Tech Support. Flt QueueCleared No fault displayed. Used as a marker in the Fault Queue indicating that the clear queue function was performed.
  • Page 81 Troubleshooting Chapter 2 Table 1 - Fault Types, Descriptions and Actions (Continued) Fault Description Action Overspeed Limit 1 Functions such as Slip Compensation or Bus Remove excessive load or Regulation have attempted to add an output overhauling conditions or increase frequency adjustment greater than that [Overspeed Limit].

  • Page 82: Clearing Alarms

    Chapter 2 Troubleshooting Table 1 - Fault Types, Descriptions and Actions (Continued) Fault Description Action SW OverCurrent 1 Drive output current has exceeded the 1ms Check for excess load, improper DC current rating. This rating is greater than the boost setting. DC brake volts set 3-second current rating and less than the too high.
  • Page 83 Troubleshooting Chapter 2 Alarm Descriptions Table 3 provides a list of alarm messages and descriptions of the cause of the alarm. Table 3 - Alarm Descriptions and Actions Alarm Description Analog in Loss 5 1 An analog input is configured for “Alarm” on signal loss and signal loss has occurred. Bipolar 20 2 Parameter 190 [Direction Mode] is set to “Bipolar”...
  • Page 84 Chapter 2 Troubleshooting Table 3 - Alarm Descriptions and Actions (Continued) Alarm Description IR Volts Range 25 2 The drive auto tuning default is “Calculate” and the value calculated for IR Drop Volts is not in the range of acceptable values. This alarm clears when all motor nameplate data is properly entered.

  • Page 85: Testpoint Codes And Functions

    Troubleshooting Chapter 2 Table 4 - Alarm Cross Reference Alarm Alarm Alarm Precharge Active Motor Thermistor MaxFreq Conflict UnderVoltage In Phase Loss VHz Neg Slope Power Loss Load Loss IR Volts Range Start At PowerUp Ground Warn FluxAmpsRef Rang Analog in Loss Dig In ConflictA Speed Ref Cflct IntDBRes OvrHeat...

  • Page 86: Common Symptoms And Corrective Actions

    3. Set [Fault Clear] to 1 (see page 58). 4. “Clear Faults” on the HIM Diagnostic menu. Incorrect input wiring. Refer to PowerFlex 70 None Wire inputs correctly and/or install jumper. Adjustable Frequency AC Drive Installation Instructions, publication 20A-IN009, for wiring examples.
  • Page 87 A bipolar analog speed command input is None 1. Use meter to check that an analog input voltage incorrectly wired or signal is absent. is present. 2. Check wiring. Refer to PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions, publication 20A-IN009. Positive voltage commands forward direction.
  • Page 88 Chapter 2 Troubleshooting Notes: Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 89: Certifications And Specifications

    Appendix Supplemental Drive Information This appendix provides certification, specification, and communication information. Topic Page Certifications and Specifications Communication Configurations Output Devices Certifications and Table 13 through Table 17 provide certification and technical specifications. Table 13 - Certifications Specifications Certifications Description Frames A…E A…E...
  • Page 90 Appendix A Supplemental Drive Information Table 13 - Certifications (continued) Certifications Description Frames A…E A…E 240…480V 600V TÜV TÜV Rheinland Certificate T72041027 01 tested to EN 50178 TÜV Rheinland Certificate of a Competent Body AV 72061059 0001 for compliance with EMC Directive (89/336/EEC) TÜV Rheinland Certificate 968/EZ 166.01/06 Safe Off Option satisfies requirements for Category 3 safety function...
  • Page 91 Supplemental Drive Information Appendix A Table 15 - Pollution Degree Ratings According to EN 61800-5-1 Pollution Description Degree No pollution or only dry non-conductive pollution occurs. The pollution has no influence. Normally only non-conductive pollution occurs. Occasionally a temporary conductivity, caused by condensation, is expected when the drive is out of operation.
  • Page 92 Appendix A Supplemental Drive Information Table 16 - Specifications (continued) Category Specification Control Speed control - speed regulation without feedback (Vector Control mode) (continued) 0.1% of base speed across 120:1 speed range 120:1 operating range 30 rad/sec bandwidth with feedback (Vector Control mode) 0.001% of base speed across 120:1 speed range 1000:1 operating range...
  • Page 93 Supplemental Drive Information Appendix A Table 17 - IP20, NEMA/UL Type 1 Watts Loss (Rated Load, Speed, and PWM) Voltage ND Hp External Watts Internal Watts Total Watts Loss 208V 12.2 19.2 31.4 30.7 20.5 51.2 44.6 22.6 67.2 67.3 25.4 92.7 141.3...
  • Page 94 Appendix A Supplemental Drive Information Table 17 - IP20, NEMA/UL Type 1 Watts Loss (Rated Load, Speed, and PWM) (continued) Voltage ND Hp External Watts Internal Watts Total Watts Loss 600V 11.5 17.9 29.4 27.8 19.5 47.3 43.6 21.6 65.2 64.6 88.6 99.5...

  • Page 95: Communication Configurations

    Supplemental Drive Information Appendix A Communication Typical Programmable Controller Configurations Configurations This section provides information for programmable controller configurations and bit settings for logic command word and logic status word. If block transfers are programmed to continuously write information to the IMPORTANT drive, be sure to properly format the block transfer.
  • Page 96 Appendix A Supplemental Drive Information Logic Command Word/ Logic Status Word Table 18 Table 19 provide bit settings for logic command word and logic status word. Table 18 - Logic Command Word Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description x Stop 0 = Not Stop...

  • Page 97: Output Devices

    Supplemental Drive Information Appendix A Table 19 - Logic Status Word Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status Description x Ready 0 = Not Ready 1 = Ready Active 0 = Not Active 1 = Active...
  • Page 98 Appendix A Supplemental Drive Information Notes: Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 99: External And Internal Connections

    External and Internal Connections LCD Display Elements ALT Functions Removing the HIM Menu Structure Viewing and Editing Parameters The PowerFlex 70 drive provides a number of cable connection points External and Internal (B frame shown). Connections SK-M9-SCB1 Optional Service Connection Board...
  • Page 100 Appendix B HIM Overview Using the HIM With a 20-HIM-B1 Bezel Kit The 20-HIM-B1 bezel kit enables remote HIM or Wireless Interface Module (WIM) operation and provides an additional remote DPI port for accessories. Use the bezel cradle connection to mount the NEMA/UL 1 HIM or NEMA/UL 1 WIM (port 3).

  • Page 101: Lcd Display Elements

    LCD and LED not the last controlling device and does not have Manual control of the drive. Enables value to be entered as an exponent. (Not available on PowerFlex 70.) Param # Enables entry of a parameter number for viewing/ +/–...

  • Page 102: Menu Structure

    Status Info Drive Status 1 Device Items Clear Faults Drive Status 2 Clr Fault Queue Device Version Drive Alarm 1 PowerFlex 70 EC HIM Version Reset Device Product Data Drive Alarm 2 Speed Ref Source Main Control Board Power Unit Board...

  • Page 103: Viewing And Editing Parameters

    Return all the options for the user display to factory default values. Viewing and Editing The PowerFlex 70 drive is initially set to the basic parameter view. Parameter 196 [Param Access Lvl] controls the parameter views that you can see. The list below...
  • Page 104 Appendix B HIM Overview LCD HIM Step Keys Example Displays 1. In the Main Menu, press the up arrow or down arrow to scroll to “Parameter.” 2. Press Enter. “FGP File” appears on the top line FGP: File and the first three files appear below it. Monitor Motor Control Speed Command...
  • Page 105 Appendix Application Notes This appendix provides operational application notes. Topic Page External Brake Resistor Skip Frequency Stop Modes Motor Overload Motor Overload Memory Retention Per 2005 NEC Start At Powerup Overspeed Speed Reference Control Auto/Manual Examples Process PI for Standard Control Voltage Tolerance Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 106: External Brake Resistor

    Appendix C Application Notes External Brake Resistor Figure 1 shows the external brake resistor circuitry. Figure 1 - External Brake Resistor Circuitry Three-Phase AC Input (Input Contactor) M R (L1) S (L2) T (L3) Power Off Power On Power Source DB Resistor Thermostat Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...

  • Page 107: Skip Frequency

    Application Notes Appendix C Skip Frequency Figure 2 shows the skip frequency band parameters. Figure 2 - Skip Frequency Frequency Command Frequency Drive Output Frequency Skip + 1/2 Band 35 Hz Skip Frequency 30 Hz Skip – 1/2 Band 25 Hz Time Some machinery can have a resonant operating frequency that must be avoided to minimize the risk of equipment damage.
  • Page 108 Appendix C Application Notes Table 20 - Skip Frequency Examples Skip Frequency Examples The skip frequency has hysteresis so the Max. Frequency output does not toggle between high and low values. Three distinct bands can be programmed. If none of the skip bands Skip Band 1 touch or overlap, each band has its own Skip Frequency 1...

  • Page 109: Stop Modes

    Application Notes Appendix C Stop Modes Several methods are available for braking or stopping a load as described in the table below. Method Use When Application Requires . . . Braking Power Ramp • The fastest stopping time or fastest ramp time for speed changes (external Most, if an brake resistor or regenerative capability required for ramp times faster than external resistor...
  • Page 110 Appendix C Application Notes Configuration • [Stop/Brk Mode A], parameter 155 • [Stop/Brk Mode B], parameter 156 – 0 = Coast – 1 = Ramp – 2 = Ramp to Hold – 3 = DC Brake – 4 = Fast Brake •...
  • Page 111 Application Notes Appendix C Detailed Operation Mode Description Coast to Stop Bus Voltage Output Voltage Output Current Motor Speed Command Speed Time Coast Time is load dependent Stop Command Coast is selected by setting [Stop Mode A/B] to a value of “0.” When in Coast to Stop, the drive acknowledges the Stop command by shutting off the drive output and releasing control of the motor.
  • Page 112 Appendix C Application Notes Mode Description Ramp Bus Voltage Output Voltage Output Current Motor Speed Output Current Command Speed Output Voltage Brake Level Time DC Brake Time Stop Zero Command Command Speed This method uses drive output reduction to stop the load. Ramp is selected by setting [Stop Mode A/B] to a value of “1”.

  • Page 113: Motor Overload

    Application Notes Appendix C Mode Description Fast Brake Bus Voltage Output Voltage Output Current Motor Speed Command Speed Time Stop Command This method takes advantage of the characteristic of the induction motor whereby frequencies greater than zero (DC braking) can be applied to a spinning motor that provides more braking torque without causing the drive to regenerate.
  • Page 114 Appendix C Application Notes Operation below 100% current causes the temperature calculation to account for motor cooling. Motor Overload Curve 100000 Cold 10000 1000 Full Load Amps (%) [Motor OL Hertz] defines the frequency where motor overload capacity derate begins. The motor overload capacity is reduced when operating below [Motor OL Hertz].

  • Page 115: Motor Overload Memory Retention Per 2005 Nec

    Application Notes Appendix C Motor Overload Memory The PowerFlex 70 EC (firmware revision 3.002 or later) has the ability to retain the motor overload count at power down per the 2005 NEC motor overtemp Retention Per 2005 NEC requirement. A parameter has been added to provide this functionality. To enable/disable this feature, refer to the information below.

  • Page 116: Speed Reference Control

    Appendix C Application Notes The actual output frequency at maximum speed reference is the sum of the speed reference plus speed adder components from functions such as slip compensation. The Overspeed Limit is entered in Hertz and added to Maximum Speed and the sum of the two (Speed Limit) limit the output frequency.
  • Page 117 Application Notes Appendix C “Manual” Speed Sources The manual source for speed command to the drive is either the HIM requesting manual control (see ALT Functions on page 101) or the control terminal block (analog input 1, 2, or MOP based on P96 [TB Man Ref Sel]) if a digital input is programmed to “Auto/Manual”.

  • Page 118: Auto/Manual Examples

    Appendix C Application Notes Auto/Manual Examples PLC = Auto, HIM = Manual A process is run by a PLC when in Auto mode and requires manual control from the HIM during setup. The auto speed reference is issued by the PLC through a communications module installed in the drive.

  • Page 119: Process Pi For Standard Control

    Application Notes Appendix C Process PI for Standard The internal PI function of the PowerFlex 70 provides closed loop process control with proportional and integral control action. The function is designed Control for use in applications that require simple control of a process without external control devices.
  • Page 120 Appendix C Application Notes If a digital input has been configured to “PI Enable, ” two events are required to enable the loop: the digital input must be closed AND bit 0 of the PI Control parameter must be = 1. If no digital input is configured to “PI Enable, ”...

  • Page 121: Voltage Tolerance

    Application Notes Appendix C Voltage Tolerance This section describes voltage tolerances for the different drive ratings. Drive Rating Nominal Line Nominal Motor Drive Full Power Drive Operating Voltage Voltage Range Range 200…40 200† 200…264 180…264 208…264 230…264 380…400 380† 380…528 342…528 400…528 460…528...
  • Page 122 Appendix C Application Notes Notes: Rockwell Automation Publication 20A-UM001N-EN-P - July 2013...
  • Page 123 Index Anlg Out Absolut 66 Anlg Out Config 66 AC Input Line Circuit Breakers 89 Anlg Out1 Scale 67 AC Input Line Fuses 89 Anlg Out1 Setpt 67 Accel Mask 61 Applications File 72 Accel Owner 62 Auto Mode 116 Accel Time x 41 Auto Rstrt Delay 46 Access Level, Parameter 15...
  • Page 124 Index Conventions, Manual 8 Drive Logic Rslt 60 Cross Reference, Parameter 73 Drive Memory Group 50 Current Lmt Gain 41 Drive OL Count 55 Current Lmt Sel 41 Drive OL Level Alarm 83 Current Lmt Val 41 Drive OL Mode 41 Current Rate Lim 42 Drive OverLoad Fault 79 Drive Powerup Fault 79...
  • Page 125 Index Auxiliary Input 79 Frame Designations 89 Clearing 78 Frame Size, Drive 8 Decel Inhibit 79 Fuses Defined 78 Ratings 89 Drive OverLoad 79 Drive Powerup 79 Enable Hardware 79 Encoder Loss 79 Excessive Load 79 General Precautions 9 FluxAmpsRef Rang 80 Gnd Warn Level 48 Heatsink OvrTemp 80 Ground Warn Alarm 83...
  • Page 126 Index IR Volts Range Alarm 84 Monitor File 22 IR Volts Range Fault 80 MOP Config Group 50 IXo Voltage Drop 28 MOP Frequency 23 IXo VoltageRange Alarm 84 MOP Mask 62 IXo VoltageRange Fault 80 MOP Owner 62 MOP Rate 50 Motor Cntl Sel 25 Motor Control File 24 Jog Mask 61...
  • Page 127 Index Numbered List 15 Decel Owner 62 Organization 14 Decel Time x 41 Types 13 Dig In Status 55 Viewing 103 Dig Out Setpt 69 Viewing List Of Changed 101 Dig Out Status 55 Parameter Access Level 15 Dig Outx Level 70 Dig Outx OffTime 70 Parameter Chksum Fault 81 Dig Outx OnTime 70...
  • Page 128 Index Jog Speed 35 PI Reference Hi 39 Jog Speed 1 35 PI Reference Lo 39 Jog Speed 2 35 PI Reference Sel 37 Kf Speed Loop 39 PI Setpoint 37 Ki Speed Loop 39 PI Status 38 Kp Speed Loop 39 PI Upper Limit 38 Language 51 Port Mask Act 64...
  • Page 129 Index TB Man Ref Lo 34 Power Up Marker 58 TB Man Ref Sel 34 Powerup Delay 45 Testpoint x Data 58 Precautions, General 9 Testpoint x Sel 58 Precharge Active Alarm 84 Torq Current Ref 29 Preferences, Setting 103 Torque Current 22 Torque Estimate 23 Preset Speed x 35...
  • Page 130 Index Control 91 Torque Estimate 23 Drive Ratings 89 Torque Perf Mode 25 Electrical 91 Torque Ref x Hi 28 Encoder 92 Torque Ref x Lo 28 Environment 90 Torque Ref x Sel 28 Protection 90 Speed Command File 31 Torque Setpoint1 28 Speed Command Sources 116 Total Inertia 40...
  • Page 132 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. http://www.rockwellautomation.com/support you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

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