Page 1 Adjustable Frequency AC Drive Reference Manual www.abpowerﬂex.com...
Page 2 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.
Page 3: Table Of Contents
PowerFlex 70 Flange Mount Dimensions ........
Page 4 Table of Contents Motor Overload..............2-97 Motor Start/Stop Precautions .
Page 5: Chapter 1 Specifications & Dimensions
281VDC 324VDC 540VDC 648VDC 810VDC PowerFlex 700 AC Input Overvoltage Trip: AC Input Undervoltage Trip: See PowerFlex 70 above Bus Overvoltage Trip: Bus Undervoltage Trip: Adjustable Nominal Bus Voltage: See PowerFlex 70 above All Drives Heat Sink Thermistor: Monitored by microprocessor overtemp trip...
Page 6: Input/Output Ratings
Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high [Pulse Freq] readings. Input/Output Ratings Each PowerFlex Drive has normal and heavy duty torque capabilities. The listings can be found in Tables through 2.S.
Page 7: Derating Guidelines
Derating Guidelines Derating Guidelines PowerFlex 70 Ambient Temperature/Load PowerFlex70, A Frame 400V Class. Derating, Ambient Temperature and Load. Open, NEMA1, IP20. 10kHz 8kHz 6kHz 4kHz 2kHz % of Full Load, Amps PowerFlex70, B Frame 400V Class. Derating, Ambient Temperature and Load. Open, NEMA1, IP20...
Page 8 Derating Guidelines Altitude PowerFlex 70 Altitude Derating Factor - All Frames. 1000 2000 3000 4000 5000 6000 Altitude (m) Efﬁciency 1 HP 0.5 HP...
Page 9 PowerFlex 70 Dimensions PowerFlex 70 Figure 1.1 PowerFlex 70 Frames A-D Dimensions Dimensions are in millimeters and (inches) Frame Weight (see Table 1.A) 121.9 (4.80) 94.2 (3.71) 211.6 (8.33) 225.8 (8.89) 5.8 (0.23) 179.8 (7.08) 3.56 kg (7.85 lb) 171.2 (6.74) 122.7 (4.83) 220.2 (8.67) 234.6 (9.24) 5.8 (0.23) 179.8 (7.08) 4.49 kg (9.9 lb)
Page 10: Powerflex 70 Dimensions
PowerFlex 70 Dimensions Figure 1.2 PowerFlex 70 Bottom View Dimensions - Frame A 86.4 (3.40) 80.0 (3.15) ∅ 22.2 41.9 (1.65) (0.88) 35.6 (1.40) 99.3 137.4 (3.91) (5.41) Dimensions are in millimeters and (inches) Figure 1.3 PowerFlex 70 Bottom View Dimensions - Frame B 123.7...
Page 11 PowerFlex 70 Dimensions Figure 1.4 PowerFlex 70 Bottom View Dimensions - Frame C 96.5 (3.80) 65.5 ∅ 22.2 (2.58) (0.88) 34.5 (1.36) 96.0 118.3 140.5 (3.78) (4.65) (5.53) Number of fans will vary depending on drive size. Dimensions are in millimeters and (inches) Figure 1.5 PowerFlex 70 Bottom View Dimensions - Frame D...
Page 12: Powerflex 70 Flange Mount Dimensions
PowerFlex 70 Flange Mount Dimensions PowerFlex 70 Flange Mount Dimensions Figure Drive Catalog Number Knockout Dimensions Cutout Dimensions 20AB2P2F Figure 1.7 Figure 1.11 20AB4P2F 20AC1P3F / 20AD1P1F 20AC2P1F / 20AD2P1F 20AC3P5F / 20AD3P4F 20AE0P9F 20AE1P7F 20AE2P7F 20AB6P8F Figure 1.8 Figure 1.12...
Page 13 PowerFlex 70 Flange Mount Dimensions Figure 1.7 A Frame Knockout Dimensions 101.9 (4.01) 96.1 (3.78) 72.4 22.2 dia. (2.85) (0.87 dia.) 59.6 (2.35) 76.6 (3.02) 70.5 (2.78) 43.2 (1.70) Dimensions are in millimeters and (inches) Figure 1.8 B Frame Knockout Dimensions 140.6...
Page 14 1-10 PowerFlex 70 Flange Mount Dimensions Figure 1.9 C Frame Knockout Dimensions 111.2 (4.38) 92.2 (3.63) 73.0 (2.87) 53.1 22.2 dia. (2.09) (0.87 dia.) 68.7 (2.70) 40.6 (1.60) Dimensions are in millimeters and (inches) Figure 1.10 D Frame Knockout Dimensions 135.5...
Page 15 PowerFlex 70 Flange Mount Dimensions 1-11 Figure 1.11 A Frame Cutout Dimensions 156.0 (6.14) 140.7 (5.54) 70.4 (2.77) (0.27) 127.0 (5.00) 225.8 (8.89) 210.6 195.1 (8.29) (7.68) 105.3 (4.15) 8x 4.0 +0.13 -0.03 dia. 4x 3.0R (0.31) (0.16 +.005 -.001 dia.) (0.12R)
Page 16 1-12 PowerFlex 70 Flange Mount Dimensions Figure 1.12 B Frame Cutout Dimensions 205.2 (8.08) 190.0 (7.48) 95.0 (3.74) (0.27) 176.3 (6.94) 234.6 (9.24) 219.3 205.5 (8.64) (8.09) 109.7 (4.32) 8x 4.0 +0.13 -0.03 dia. 4x 3.0R (0.27) (0.16 +.005 -.001 dia.) (0.12R)
Page 17 PowerFlex 70 Flange Mount Dimensions 1-13 Figure 1.13 C Frame Cutout Dimensions 219.0 (8.62) 202.0 (7.95) 101.0 (3.98) (0.25) 300.0 189.4 (11.81) (7.46) 283.0 (11.14) 271.8 (10.70) 241.5 (9.51) 141.5 (5.57) 41.5 (1.63) 12x 4.0 ±0.13 dia. 4x 3.0R (0.16 ±.005 dia.) (0.12R)
Page 18 1-14 PowerFlex 70 Flange Mount Dimensions Figure 1.14 D Frame Cutout Dimensions 248.4 (9.78) 231.4 (9.11) 190.7 (7.51) 115.7 (4.56) 40.7 (1.60) (0.18) 350.0 222.4 (13.78) (8.75) 333.0 (13.11) 319.8 (12.59) 271.5 (10.69) 201.5 (7.93) 131.5 (5.18) 61.5 (2.42) 14x 4.0 ±0.13 dia.
Page 19 PowerFlex 70 Flange Mount Dimensions 1-15 Figure 1.15 Flange Mounting M4 x 8 x 25 (#10-24 x .75) Dimensions are in millimeters and (inches)
Page 20: Powerflex 700 Dimensions
1-16 PowerFlex 700 Dimensions PowerFlex 700 Figure 1.16 PowerFlex 700 Frames 0-3 (0 Frame Shown) Dimensions 15.0 (0.59) 5.5 (0.22) 5.8 (0.23) dia. CAUTION HOT surfaces can cause severe burns 5.5 (0.22) (0.31) Dimensions are in millimeters and (inches). Weight kg (lbs.)
Page 21 PowerFlex 700 Dimensions 1-17 Figure 1.17 PowerFlex 700 Bottom View Dimensions – Frame 0 96.0 (3.78) 75.0 (2.95) 55.0 (2.17) 35.0 (1.38) 22.2 (0.87) Dia. – 4 Places 30.2 (1.19) 187.5 185.0 (7.38) (7.28) 132.9 (5.23) 41.9 (1.65) 56.1 (2.21) 75.9 (2.99)
Page 22 1-18 PowerFlex 700 Dimensions Figure 1.19 PowerFlex 700 Bottom View Dimensions – Frame 2 167.5 (6.59) 156.9 (6.18) 28.7 (1.13) Dia. 3 Places 22.4 (0.88) Dia. 2 Places 184.8 (7.28) 157.5 (6.20) 150.9 (5.94) 112.1 (4.41) 39.3 (1.55) 57.2 (2.25) 72.7 (2.86)
Page 23: Chapter 2 Detailed Drive Operation
Accel Time bits are “1”, the default acceleration time is Accel Time 1 and the rate is determined as above. AC Supply Source PowerFlex 700 drives are suitable for use on a circuit capable of delivering Considerations up to a maximum of 200,000 rms symmetrical amperes, 600V.
Page 24: Alarms
Alarms Alarms Alarms are indications of situations that are occurring within the drive or application that should be annunciated to the user. These situations may affect the drive operation or application performance. Conditions such as Power Loss or Analog input signal loss can be detected and displayed to the user for drive or operator action.
Page 25 Application A process is being controlled by a PowerFlex drive. The speed reference to the drive is a 4 –20 mA analog signal from a sensor wired to Analog Input The input is conﬁgured for mA by setting the corresponding bit in [Anlg In Conﬁg] to “1”...
Page 26 Alarms By setting Speed Ref A Hi to 60 Hz and Speed ref A Lo to 0 Hz, the speed reference is scaled to the application needs. Because of the Input scaling and link to the speed reference, 4 mA represents minimum frequency (0 Hz.) and 20 mA represents Maximum Frequency (60 Hz.) Scale Block P322...
Page 27 5. The operator manually brings the process to a controlled stop until the signal loss is repaired. Alarm Queue (PowerFlex 700 Only) A queue of 8 parameters exists that capture the drive alarms as they occur. A sequential record of the alarm occurrences allows the user to view the history of the eight most recent events.
Page 28: Analog Inputs
Analog Inputs Analog Inputs Possible Uses of Analog Inputs The analog inputs provide data that can be used for the following purposes: • Provide a value to [Speed Ref A] or [Speed Ref B]. • Provide a trim signal to [Speed Ref A] or [Speed Ref B]. •...
Page 29 Analog In 1 Lo Input/Output Analog In 1 Hi Analog Input Volts or mA Parameter Cal Analog 1 1 Scale Analog In 2 Lo Processing Analog In 2 Hi Selection/Control Analog Input Volts or mA Cal Analog 2 2 Scale Speed Ref A Sel Speed Ref B Sel Trim In Select...
Page 30 Input/Output Parameter Processing Selection/Control Anlg In 1 Loss Anlg In Config Anlg In Sqr Root 0-10v Unipolar Loss Limit Cal 1 Detect 0-10V Analog 1 Voltage Cal Analog 1 Analog 1 Current Current Loss Limit 0-20mA Square Cal 1 Detect 4-20mA Root Analog In1 Value...
Page 31 Analog Inputs Scaling Blocks [Analog In Hi] [Analog In Lo] A scaling operation is performed on the value read from an analog input in order to convert it to units usable for some particular purpose. The user controls the scaling by setting parameters that associate a low and high point in the input range (i.e.
Page 32 2-10 Analog Inputs Conﬁguration #1: • [Speed Ref A Sel] = “Analog In 1” • [Minimum Speed] = 0 Hz • [Maximum Speed] = 60 Hz • [Analog In 1 Lo] = 0% • [Analog In 1 Hi] = 100% This is the default setting, where minimum input (0 volts) represents [Minimum Speed] of 0 Hz and maximum input (10 volts) represents [Maximum Speed] of 60 Hz.
Page 33 Analog Inputs 2-11 Config 2 Output Hertz Scaling Block [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Lo] [Minimum Speed] 0 Hz [Analog In 1 Hi] [Maximum Speed] 30 Hz Conﬁguration #3: • [Speed Ref A Sel] = “Ana In 1” •...
Page 34 2-12 Analog Inputs Conﬁguration #4: • [Minimum Speed] = 0 Hz. • [Maximum Speed] = 60 Hz. • [Analog In 1 Lo] = 100% • [Analog In 1 Hi] = 0% This conﬁguration is used to invert the operation of the input signal. Here, maximum input (100% of 10 Volts = 10 Volts) represents [Minimum Speed] of 0 Hz and minimum input (0% of 10 Volts = 0 Volts) represents [Maximum Speed] of 60 Hz.
Page 35 Analog Inputs 2-13 Config 5 Output Hertz Scaling Block [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Lo] [Minimum Speed] 0 Hz [Analog In 1 Hi] [Maximum Speed] 60Hz Square Root [Anlg In Sqr Root] For both analog inputs, the user can enable a square root function for an analog input through the use of [Analog In Sq Root].
Page 36 2-14 Analog Inputs Signal Loss [Analog In 1, 2 Loss] Signal loss detection can be enabled for each analog input. The [Analog In x Loss] parameters control whether signal loss detection is enabled for each input and deﬁnes what action the drive will take when loss of any analog input signal occurs.
Page 37 Analog Inputs 2-15 Value Display Parameters are available in the Monitoring Group to view the actual value of an analog input regardless of its use in the application. Whether it is a current limit adjustment, speed reference or trim function, the incoming value can be read via these parameters.
Page 38 Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity. Differential Isolation - External source must be less than 10V with respect to PE. Refer to the PowerFlex 70 User Manual for terminal designations and wiring examples.
Page 39 Analog Inputs 2-17 I/O Wiring Examples (PowerFlex 700 shown) Input/Output Connection Example Potentiometer Potentiometer Joystick 10k Ohm Pot. Recommended (2k Ohm Minimum) Joystick ±10V Input - 100k ohm input impedance. Analog Input Voltage - Bipolar Current - Unipolar ±10V Input - 100k ohm input –...
Page 40: Analog Outputs
Conﬁguration The PowerFlex 70 standard I/O analog output is permanently conﬁgured as a 0 -10 volt output. The output has 10 bits of resolution yielding 1024 steps. The analog output circuit has a maximum 1.3% gain error and a maximum 7 mV offset error.
Page 41 Analog Outputs 2-19 Table 2.B Analog Output Scaling Ranges [Analog Outx Lo] [Analog Outx Lo] Corresponds to: Corresponds to: [Analog Outx Hi] Quantity (Absolute Value Disabled) (Absolute Value Enabled) Corresponds to: Output Frequency -[Maximum Freq] 0 Hz [Maximum Freq] Commanded -[Maximum Freq] 0 Hz [Maximum Freq]...
Page 42 2-20 Analog Outputs [Analog Out1 Lo] Output Current vs. Analog Analog Output Voltage Output Voltage Marker Lines [Analog Out1 Hi] 200% Output Current Example 3 – Signed Output Quantity, Absolute Value Enabled • [Analog Out1 Sel] = “Output Torque Current” •...
Page 43 Analog Outputs 2-21 Table 2.C Software Filters Quantity Filter Output Frequency No extra ﬁltering Commanded Frequency No extra ﬁltering Output Current Filter A Output Torque Current Filter A Output Flux Current Filter A Output Power Filter A Output Voltage No extra ﬁltering DC Bus Voltage Filter A PI Reference...
Page 44: Auto / Manual
2-22 Auto / Manual Auto / Manual The intent of Auto/Manual is to allow the user to override the selected reference (referred to as the “auto” reference) by either toggling a button on the programming terminal (HIM), or continuously asserting a digital input that is conﬁgured for Auto/Manual.
Page 45 Auto / Manual 2-23 2. Manual control can only be granted to the TB or to a programming terminal (e.g. HIM) if Manual control is not already being exercised by the TB or another programming terminal at the time. 3. Manual control can only be granted to a terminal if no other device has Local control already asserted (i.e.
Page 46: Auto Restart (Reset/Run)
2-24 Auto Restart (Reset/Run) Auto Restart (Reset/ The Auto Restart feature provides the ability for the drive to automatically Run) perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset.
Page 47 Auto Restart (Reset/Run) 2-25 3. The drive will then issue an internal Start command to start the drive. 4. If another auto-resettable fault occurs the cycle will repeat itself up to the number of attempts set in [Auto Rstrt Tries]. 5.
Page 48: Bus Regulation
2-26 Bus Regulation Bus Regulation [Bus Reg Gain] [Bus Reg Mode A, B] Some applications, such as the hide tanning shown here, create an intermittent regeneration condition. When the hides are being lifted (on the left), motoring current exists. However, when the hides reach the top and fall onto a paddle, the motor regenerates power back to the drive, creating the potential for a nuisance overvoltage trip.
Page 49 Bus Regulation 2-27 The bus voltage regulation set point (Vreg) in the drive is ﬁxed for each voltage class of drive. The bus voltage regulation set points are identical to the internal dynamic brake regulation set points VDB's. Single Seq 2.50kS/s DB Bus Output Motor...
Page 50 2-28 Bus Regulation Figure 2.2 Bus Voltage Regulator, Current Limit and Frequency Ramp. Current Limit U Phase Motor Current Derivative Gain Magnitude W Phase Motor Current Block Calculator SW 3 Current Limit Level PI Gain Block I Limit, No Bus Reg Limit SW 1 No Limit...
Page 51 Bus Regulation 2-29 Bus voltage regulation is the highest priority of the three components of this controller because minimal drive current will result when limiting the bus voltage and therefore, current limit will not occur. 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.
Page 52: Cable, Control
“Disabled,” “Adjust Freq,” and “Dynamic brak.” The bus voltage regulator is never active with the internal dynamic braking function. The bus voltage regulation set point Vreg in PowerFlex 70 is ﬁxed for each voltage class of drive. The bus voltage regulation set points are identical to...
Page 53: Cable, Motor Lengths
The Reﬂected Wave phenomenon, also known as transmission line effect, produces very high peak voltages on the motor due to voltage reﬂection. While Allen-Bradley drives have patented software that limits the voltage peak to 2 times the DC bus voltage and reduce the number of occurrences, many motors have inadequate insulation systems to tolerate these peaks.
Page 54 2-32 Cable, Motor Lengths Figure 2.3 How to Measure Motor Cable Lengths Limited by Capacitance 15.2 (50) 91.4 (300) 152.4 (500) 167.6 (550) 182.9 (600) 91.4 (300) 15.2 (50) 15.2 (50) All examples represent motor cable length of 182.9 meters (600 feet).
Page 55: Cable, Power
Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller. Based on ﬁeld and internal testing, Rockwell Automation/Allen-Bradley has determined conductors manufactured with Poly Vinyl Chloride (PVC) wire insulation are subject to a variety of manufacturing inconsistencies which can lead to premature insulation degradation when used with IGBT drives that produce the reﬂected wave phenomena.
Page 56 2-34 Cable, Power Manufacturing Inconsistencies and their Effects on Cable Life Due to manufacturing inconsistencies, the following conditions can exist: • PVC insulation material may have a dielectric constant ranging between 4 and 8 depending on the manufacturer. The higher the dielectric constant, the lower the dielectric strength (and voltage withstand to transients).
Page 57 Cable, Power 2-35 Installation, Operation and Environmental Considerations • THHN jacket material has a relatively brittle nylon that lends itself to damage (i.e. nicks and cuts) when pulled through conduit on long wire runs. This issue is of even greater concern when the wire is being pulled through multiple 90 degree bends in the conduit.
Page 58: Cable, Standard I/O
2-36 Cable, Standard I/O Figure 2.5 Wire Selection Flowchart Selecting Wire to Withstand Reflected Wave Voltage for New and Existing Wire Installations in Conduit or Cable Trays Conductor Environment (Per NEC 7-31) (Per NEC code Table 7-31) XLPE (XHHW-2) Conductor Insulation for XLPE Insulation...
Page 59: Ce Conformity
• Use of line ﬁlters in ungrounded systems is not recommended. • PowerFlex drives may cause radio frequency interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the essential requirements for CE compliance listed below, if necessary.
Page 60 2-38 CE Conformity Table 2.G PowerFlex 70 – EN61800-3 First Environment Restricted Distribution Restrict Motor Restrict Motor Internal Comm Common Cable to Cable to Filter External Cable Mode Frame Drive Description 12 m (40 ft.) 40 m (131 ft.) Option...
Page 61: Copy Cat
2-39 Copy Cat Some PowerFlex drives have a feature called Copy Cat, which allows the user to upload a complete set of parameters to the LCD HIM. This information can then be used as backup or can be transferred to another drive by downloading the memory.
Page 62: Current Limit
2-40 Current Limit Current Limit [Current Lmt Sel] [Current Lmt Val] [Current Lmt Gain] There are 6 ways that the drive can protect itself from overcurrent or overload situations: • Instantaneous Overcurrent trip • Software Instantaneous Trip • Software Current Limit •...
Page 63 Current Limit 2-41 D. Overload Protection I2T - This is a software feature that monitors the output current over time and integrates per IT. The base protection is 110% for 1 minute or the equivalent I2T value (i.e. 150% for 3 seconds, etc.).
Page 64: Datalinks
2-42 Datalinks Datalinks A Datalink is one of the mechanisms used by PowerFlex drives to transfer data to and from a programmable controller. Datalinks allow a parameter value to be changed without using an Explicit Message or Block Transfer. Datalinks consist of a pair of parameters that can be used independently for 16 bit transfers or in conjunction for 32 bit transfers.
Page 65 Out. They cannot be separated or turned on individually. 2. Only one communications adapter can use each set of Datalink parameters in a PowerFlex drive. If more than one communications adapter is connected to a single drive, multiple adapters must not try to use the same Datalink.
Page 66: Dc Bus Voltage / Memory
2-44 DC Bus Voltage / Memory DC Bus Voltage / A measure of the instantaneous value or “nominal” bus voltage determined Memory by heavily ﬁltering bus voltage. Just after the pre-charge relay is closed during the initial power-up bus pre-charge, bus memory is set equal to bus voltage.
Page 67: Decel Time
Decel Time 2-45 Decel Time [Decel Time 1, 2] Sets the rate at which the drive ramps down its output frequency after a Stop command or during a decrease in command frequency (speed change). The rate established is the result of the programmed Decel Time and the Minimum and Maximum Frequency, as follows: Maximum Frequency –...
Page 68: Digital Inputs
2-17. There are 6 digital (discrete) inputs (numbered 1 through 6) available at the terminal block. PowerFlex 70 Each digital input has a maximum response/pass through/function execution time of 25ms. For example, no more than 25ms should elapse from the time the level changes at the Start input to the time voltage is applied to the motor.
Page 69 Digital Inputs 2-47 [Digital In1 Sel] Default: “Stop – CF” (CF = Clear Fault) [Digital In2 Sel] Default: “Start” [Digital In3 Sel] Default: “Jog” [Digital In4 Sel] Default: “Speed Sel 1” [Digital In5 Sel] Default: “Speed Sel 2” [Digital In6 Sel] Default: “Speed Sel 3”...
Page 70 Exclusive Link – digital input is routed through to digital output, no other use. Power Loss Level (PowerFlex 700 only) Selects between using ﬁxed value for power loss level and getting the level from a parameter Precharge Enable (PowerFlex 700 only) If common bus conﬁguration, denotes whether drive is disconnected from DC bus or not.
Page 71 Digital Inputs 2-49 If the “Clear Faults” input function is conﬁgured at the same time as “Stop - Clear Faults”, then it will not be possible to reset faults with the “Stop - Clear Faults” input. • Run Forward, Run Reverse An open to closed transition on one input or both inputs while drive is stopped will cause the drive to run unless the “Stop - Clear Faults”...
Page 72 2-50 Digital Inputs The purpose of this input function is to allow a 2-wire start while the direction is being controlled by some other means. The terminal block bit must be set in the [Start Mask] and [Logic Mask] parameters in order for the terminal block to start the drive using this input.
Page 73 Digital Inputs 2-51 direction “owner” before it can be used to control direction. If another device is currently the direction owner (as indicated by [Direction Owner]), it will not be possible to start the drive or change direction by using the terminal block digital inputs programmed for both Run and Direction control (i.e.
Page 74 2-52 Digital Inputs If one of these input functions is conﬁgured and the other one isn’t, the above description still applies, but the unconﬁgured input function should be considered permanently open. The drive will not jog while drive is running or while “Stop - Clear Faults”...
Page 75 Digital Inputs 2-53 The terminal block bit must be set in the [Reference Mask] and [Logic Mask] parameters in order for the reference selection to be controlled from the terminal block using the Speed Select inputs functions. Important: Reference Control is an “Exclusive Ownership” function (see Owners on page 2-104).
Page 76 2-54 Digital Inputs conﬁguration allows a single input to choose between [Speed Ref A Sel] and [Speed Ref B Sel]. Speed Select 1 Selected Parameter that determines Reference Open [Speed Ref A Sel] Closed [Speed Ref B Sel] As another example, describes what reference selections can be made if the “Speed Select 3”...
Page 77 Digital Inputs 2-55 There are two different schemes for using the Acc/Dec input functions. Each one will be described in its own section. • Accel 2, Decel 2 In the ﬁrst scheme, one input function (called “Accel 2”) selects between [Accel Time 1] and [Accel Time 2], and another input function (called “Decel 2”) selects between [Decel Time 1] and [Decel Time 2].
Page 78 2-56 Digital Inputs decremented by external devices. The MOP value will be retained through a power cycle. While the “MOP Increment” input is closed, MOP value will increase at rate contained in [MOP Rate]. Units for rate are Hz per second. While the “MOP Decrement”...
Page 79 Digital Inputs 2-57 If this input function is open, the integrator for the Process PI loop will be allowed to increase. See Process PI Loop on page 2-116. • PI Reset If this input function is closed, the integrator for the Process PI loop will be reset to 0.
Page 80 82% of nominal. If the input function is not conﬁgured, then the drive always uses the internal power loss level. This input function is used in PowerFlex 700 drives only. In PowerFlex 70 drives, the power loss level is always...
Page 81 If this input function is not conﬁgured, then the drive assumes that it is always connected to the DC bus, and no special precharge handling will be done. This input function is used in PowerFlex 700 drive only. In PowerFlex 70 drives, the drive assumes it is always connected to the DC bus.
Page 82 2-60 Digital Inputs The table below deﬁnes which pairs of input functions are in conﬂict. Combinations marked with a “ ” will cause an alarm. Important: There are combinations of input functions in Table 2.L that will produce other digital input conﬁguration alarms. “DigIn CﬂctA”...
Page 83 The bits are “1” when the input is closed and “0” when the input is open. Examples PowerFlex 70 Below is a typical digital input conﬁguration that includes “3-wire” start. The digital input conﬁguration parameters should be set up as follows: •...
Page 84 2-62 Digital Inputs Figure 2.6 Typical digital input conﬁguration with “3-wire” start Digital In1 Start Digital In2 Stop - CF Digital In3 Forward/Reverse Digital In4 Digital In5 Speed Select 2 Digital In6 Enable Common Figure 2.7 represents a typical digital input conﬁguration that includes “Run Fwd/Rev”...
Page 85: Digital Outputs
Each relay is a Form C (1 N.O. – 1 N.C. with shared common) device whose contacts and associated terminals are rated for a maximum of 250 VAC or 220 VDC. The table below shows speciﬁcations and limits for each relay / contact. PowerFlex 70 PowerFlex 700 Resistive Load Inductive Load...
Page 86 2-64 Digital Outputs The following drive conditions or status can be selected to cause the relay activation: Condition Description Fault A drive Fault has occurred and stopped the drive Alarm A Drive Type 1 or Type 2 Alarm condition exists Ready The drive is powered, Enabled and no Start Inhibits exist.
Page 87 Digital Outputs 2-65 chosen “driver” is Temperature, the drive assumes that the entered value for the limit [Dig Outx Level] is degrees C. No units will be reported to LCD HIM users, ofﬂine tools, devices communicating over a network, PLC’s, etc. The online and ofﬂine limits for the digital output threshold parameters will be the minimum and maximum threshold value required for any output condition.
Page 88 2-66 Digital Outputs The user can disable either timer by setting the corresponding delay time to Important: Note that whether a particular type of transition (FALSE to TRUE or TRUE TO FALSE) on an output condition results in an energized or de-energized output depends on the output condition.
Page 89: Direction Control
Direction Control 2-67 Direction Control Direction control of the drive is an exclusive ownership function. This means that only one device can be commanding / controlling direction at a time and that device can only command one direction or the other, not both. Direction is deﬁned as the forward or reverse, of the drive output, not he motor.
Page 90: Dpi
DPI adds a higher baud rate, brand speciﬁc enabling, Peer-to-Peer (P/P) communication, and Flash Memory programming support. PowerFlex drives support the existing SCANport and Drive Peripheral Interface (DPI) communication protocols. Multiple devices of each type (SCANport or DPI) can be attached to and communicate with the drive at the same time.
Page 91 DPI or SCANport devices are), so a proxy function is needed to create a DPI message to access information in an off-board peripheral. If an LCD HIM is attached to the PowerFlex 70 or 700 drive, it will be able to directly request off-board parameters using Peer-to-Peer messages (i.e. no proxy support needed in the drive).
Page 92 2-70 Table 2.N Timing speciﬁcations contained in DPI and SCANport Host status messages only go out to peripherals once they log in and at least every 125ms (to all attached peripherals). Peripherals time out if >250ms. Actual time dependent on number of peripherals attached. Minimum time goal of 5ms (may have to be dependent on Port Baud Rate).
Page 93: Drive Overload
Drive Overload 2-71 Drive Overload The drive thermal overload has two primary functions. The ﬁrst requirement is to make sure the drive is not damaged by abuse. The second is to perform the ﬁrst in a manor that does not degrade the performance, as long the drive temperature and current ratings are not exceeded.
Page 94 2-72 Drive Overload Figure 2.8 Normal Duty Boundary of Operation 1.80 1.70 1.60 1.50 1.40 1.30 1.20 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 1.00 10.00 100.00 1,000.00 Time (Seconds) The lower curve in Figure 2.9 shows the boundary of heavy duty operation.
Page 95 Drive Overload 2-73 Thermal Manager Protection The thermal manager protection assures that the thermal ratings of the power module are not exceeded. The operation of the thermal manager can be thought of as a function block with the inputs and outputs as shown below.
Page 96 2-74 Drive Overload When the calculated junction temperature reaches a maximum limit the drive will generate a fault. This fault can not be disabled. This maximum junction temperature is stored in EE on the power board along with other information to deﬁne the operation of the drive thermal overload function. These values are not user adjustable.
Page 97: Drive Ratings (Kw, Amps, Volts)
Drive Ratings (kW, Amps, Volts) 2-75 DTO Fault For all possible settings of [Drive OL Mode], the drive will always monitor the T and T and generate a fault when either temperature becomes Drive critical. If T is less than –20° C, a fault is generated. With these Drive provisions, a DTO fault is generated if the NTC ever malfunctions.
Page 98: Economizer
2-76 Economizer Economizer Auto-Economizer (also see Torque Performance Modes on page 2-162) Economize mode consists of the sensorless vector control voltage with an energy saving function (E-SVC). The output voltage is automatically adjusted, in steady state frequency operation only, as the load is increased or decreased such that minimum current is supplied to the motor and its efﬁciency is optimized.
Page 99: Fan Curve
Fan Curve 2-77 Fan Curve When torque performance is set to Fan Curve the relation ship between frequency and voltage is as shown in the following ﬁgure. The fan curve provides the option to generate voltage that is a function of the stator frequency squared up to the motor nameplate frequency.
Page 100: Faults
2-78 Faults Faults Faults are events or conditions within the drive which constitute user notiﬁcation and may warrant various responses. Some conditions are user conﬁgurable as to whether the drive will consider them a fault. Faults are indicated to the user via HIM fault codes and/or popup dialogs or status indications as well as a group of output parameters.
Page 101 Faults 2-79 new fault is logged into the queue each existing entry will be shifted up by one (i.e. previous entry #1 will move to entry #2, previous entry #2 will move to entry #3, etc.). If the queue is full when a fault occurs the oldest entry will be discarded.
Page 102 2-80 Faults 1. An off to on transition on a digital input conﬁgured for fault reset or stop/reset. 2. Setting [Fault Clear] to “1” 3. A DPI peripheral (several ways). 4. Performing a reset to factory defaults via parameter write. 5.
Page 103: Flying Start
Flying Start 2-81 Flying Start The Flying Start feature is used to start into a rotating motor, as quick as possible, and resume normal operation with a minimal impact on load or speed. When a drive is started in its normal mode it initially applies a frequency of 0 Hz and ramps to the desired frequency.
Page 104 2-82 Flying Start Cooling Tower Fans Draft/wind blows idle fans in reverse direction. Restart at zero damages fans, breaks belts. Flying start alleviates the problem...
Page 105: Fuses And Circuit Breakers
Fuses and Circuit Breakers 2-83 Fuses and Circuit Tables through provide drive ratings (including continuous, 1 Breakers minute and 3 second) and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 degree C and the U.S.
Page 106 2-84 Fuses and Circuit Breakers Table 2.O PF70 208/240 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 107 Fuses and Circuit Breakers 2-85 Table 2.R PF700 208/240 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 108: Grounding, General
2-86 Grounding, General Grounding, General The drive Safety Ground - PE must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked. Figure 2.11 Typical Grounding U (T1) R (L1)
Page 109 Grounding, General 2-87 Install as No. Description Needed Notes Programmable Controller Refer to publication 1770-4.1 for Programmable Controller Grounding Recommendations Motor ground PE (Safety) - ground bus PE to bus to building steel Nearest building structure steel Shield Additional shield (if required) Attach to motor frame Ground per local or national codes Analog signal...
Page 110: Him Memory
Selecting a Language See also Language on page 2-91. PowerFlex 700 drives support multiple languages. When you ﬁrst apply drive power, a language screen appears on the HIM. Use the Up or Down Arrow to scroll through the available languages. Press Enter to select the desired language. To switch to an alternate language, follow the steps below.
Page 111: Input Devices
Input Devices 2-89 Setting the User Display Step Key(s) Example Displays 1. Press the Up Arrow or Down Arrow to scroll Operator Intrfc: to Operator Intrfc. Press Enter. Change Password User Display 2. Press the Up Arrow or Down Arrow to scroll Parameters to User Display.
Page 112: Input Modes
Input Modes Input Modes The PowerFlex family of drives does not use a direct choice of 2-wire or 3-wire input modes, but allows full conﬁguration of the digital I/O. As a means of deﬁning the modes used, consider the following: •...
Page 113: Input Power Conditioning
3 phase power is recommended. Refer to Jog on page 2-51. Language PowerFlex drives are capable of communicating in 7 languages; English, Spanish, German, Italian, French, Portuguese and Dutch. All drive functions and information displayed on an LCD HIM are shown in the...
Page 114: Masks
2-92 Masks selected language. The desired language can be selected several different ways: • On initial drive power-up, a language choice screen appears. • The language choice screen can also be recalled at any time to change to a new language. This is accomplished by pressing the “Alt” key followed by the “Lang”...
Page 115 Masks 2-93 Example: A customer's process is normally controlled by a remote PLC, but the drive is mounted on the machine. The customer does not want anyone to walk up to the drive and reverse the motor because it would damage the process.
Page 116: Mop
2-94 The Motor Operated Pot (MOP) function is one of the sources for the frequency reference. The MOP function uses digital inputs to increment or decrement the Speed reference at a programmed rate. The MOP has three components: • [MOP Rate] parameter •...
Page 117 2-95 Important: The MOP reset only occurs on the stop edge and is not continuously cleared because the stop is asserted (this is always processed when a stop edge is seen, even if the drive is stopped). The reset only applies to the stop edge and not when a fault is detected.
Page 118: Motor Nameplate
2-96 Motor Nameplate Motor Nameplate [Motor NP Volts] The motor nameplate base voltage deﬁnes the output voltage, when operating at rated current, rated speed, and rated temperature. [Motor NP FLA] The motor nameplate deﬁnes the output amps, when operating at rated voltage, rated speed, and rated temperature.
Page 119: Motor Overload
Motor Overload 2-97 Motor Overload The motor thermal overload uses an IT algorithm to model the temperature of the motor. The curve is modeled after a Class 10 protection thermal overload relay that produces a theoretical trip at 600% motor current in ten (10) seconds and continuously operates at full motor current.
Page 120 2-98 Motor Overload During DC injection the motor current may exceed 70% of FLA, but this will cause the Motor Thermal Overload to trip sooner than when operating at base speed. At low frequencies, the limiting factor may be the Drive Thermal Overload.
Page 121 Motor Overload 2-99 Changing Overload Factor OL % = 1.20 OL % = 1.00 OL % = 0.80 90 100 % of Base Speed Duty Cycle for the Motor Thermal Overload When the motor is cold motor thermal overload will allow 3 minutes at 150%.
Page 122: Motor Start/Stop Precautions
2-100 Motor Start/Stop Precautions Motor Start/Stop Precautions 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 occasionally, an auxiliary contact on that device should also be wired to a digital input programmed as a “Stop”...
Page 123: Output Current
U, V, W. An auxiliary contact must be used to simultaneously disable the drive. Allen-Bradley Drives can be used with an output contactor between the drive and motor. This contactor can be opened under load without damage to the drive. It is recommended, however, that the drive have a programmed “Enable”...
Page 124: Output Frequency
2-102 Output Frequency By using an output reactor the effective motor voltage will be lower because of the voltage drop across the reactor - this may also mean a reduction of motor torque. Output Frequency [Output Frequency] This parameter displays the actual output frequency of the drive. The output frequency is created by a summation of commanded frequency and any active speed regulator such as slip compensation, PI Loop, bus regulator.
Page 125: Overspeed Limit
Overspeed Limit 2-103 Overspeed Limit The Overspeed Limit is a user programmable value that allows operation at maximum speed but also provides an “overspeed band” that will allow a speed regulator such as encoder feedback or slip compensation to increase the output frequency above maximum Speed in order to maintain maximum Motor Speed.
Page 126: Owners
2-104 Owners Owners An owner is a parameter that contains one bit for each of the possible adapters. The bits are set high (value of 1) when its adapter is currently issuing that command, and set low when its adapter is not issuing that command.
Page 127 Owners 2-105 Conversely, any number of adapters can simultaneously issue Stop Commands. Therefore, Stop Ownership is not exclusive. Example: The operator presses the Stop button on the Local HIM to stop the drive. When the operator attempts to restart the drive by pressing the HIM Start button, the drive does not restart.
Page 128: Parameter Access Level
2-106 Parameter Access Level Parameter Access The PowerFlex 70 allows the user to restrict the number of parameters that Level are viewable on the LCD or LED HIM. By limiting the parameter view to the most commonly adjusted set, additional features that may make the drive seem more complicated are hidden.
Page 129: Power Loss
Vmin. This is only a factor if [Power Loss Level] is set to a large value. PowerFlex 70 This is a ﬁxed value. WARNING: When using a value of Parameter #186 [Power Loss Level] larger than default, the customer must provide a minimum line impedance to limit inrush current when the power line recovers.
Page 130 2-108 Power Loss Line Loss Mode = Decel Line Loss Mode = Coast Recover Recover Close Close Trigger Trigger Open Open AC Input Volts AC Input Volts Table 2.U PF700 Bus Levels Class 200/240 VAC 400/480 VAC 600/690 VAC Vslew 1.2 VDC 2.4 VDC 3.0 VDC...
Page 131 Power Loss 2-109 Restart after Power Restoration If a power loss causes the drive to coast and power recovers the drive will return to powering the motor if it is in a “run permit” state. The drive is in a “run permit”...
Page 132 2-110 Power Loss If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over. The power loss alarm is cleared. If the drive is in a “run permit” state, the reconnect algorithm is run to match the speed of the motor.
Page 133 Power Loss 2-111 The inverter output is disabled and the motor coasts if the output frequency drops to zero or if the bus voltage drops below Vopen or if any of the “run permit” inputs are de-energized. The pre-charge relay opens if the bus voltage drops below Vopen. The pre-charge relay closes if the bus voltage rises above Vclose If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over.
Page 134 2-112 Power Loss the inverter output is disabled and the motor coasts. If the Not Stop or Run inputs are de-energized, the drive stops in the programmed manner. The pre-charge relay opens if the bus voltage drops below Vopen/Vmin and closes if the bus voltage rises above Vclose.
Page 135 Power Loss 2-113 The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Conﬁg 1] is set. The drive faults with a F003 – Power Loss fault if the power loss timer exceeds [Power Loss Time] and the Power Loss bit in [Fault Conﬁg 1] is set.
Page 136 2-114 Power Loss If power recovers while the drive is still in inertia ride through the power loss alarm is cleared and it then accelerates at the programmed rate to the set speed. Otherwise, if power recovers before power supply shutdown, the power loss alarm is cleared.
Page 137: Preset Frequency
Preset Frequency 2-115 Preset Frequency There are 7 Preset Frequency parameters that are used to store a discrete frequency value. This value can be used for a speed reference or PI Reference. When used as a speed reference, they are accessed via manipulation of the digital inputs or the DPI reference command.
Page 138: Process Pi Loop
2-116 Process PI Loop Process PI Loop [PI Conﬁg] [PI Control] [PI Reference Sel] [PI Setpoint] [PI Feedback Sel] [PI Integral Time] [PI Prop Gain] [PI Upper/Lower Limit] [PI Preload] [PI Status] [PI Ref Meter] [PI Feedback Meter] [PI Error Meter] [PI Output Meter] The internal PI function provides closed loop process control with proportional and integral control action.
Page 139 Process PI Loop 2-117 There are two ways the PI Controller can be conﬁgured to operate. • Process Trim - The PI Output can be added to the master speed reference • Process Control - PI can have exclusive control of the commanded speed.
Page 140 2-118 Process PI Loop When the PI is enabled, the output of the PI Controller is added to the ramped speed reference. Slip Comp Slip Adder Open Loop Linear RAmp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller Speed Control PI Fbk...
Page 141 Process PI Loop 2-119 Slip Comp Slip Adder Open Loop Linear RAmp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller PI Disabled Speed Control PI Fbk When the PI is enabled, the speed reference is disconnected and PI Output has exclusive control of the commanded speed, passing through the linear ramp and s-curve.
Page 142 2-120 Process PI Loop The option to invert the sign of PI Error is selected in the PI Conﬁguration parameter. PI_Config .Invert PI Ref Sel PI Error – PI_Config .Sqrt PI Fdbk Sel PI Fbk • Preload Integrator - This feature allows the PI Output to be stepped to a preload value for better dynamic response when the PI Output is enabled.
Page 143 Process PI Loop 2-121 Pre-load command may be used when the PI has exclusive control of the commanded speed. With the integrator preset to the commanded speed there is no disturbance in commanded speed when PI is enabled. After PI is enabled the PI output is regulated to the required level.
Page 144 2-122 Process PI Loop ≥0 +32K PI_Config .ZeroClamp Linear Spd Ref Spd Ramp Spd Cmd Ramp & S-Curve -32K +32K PI Output PI Ref Process PI -32K Controller PI Fbk • Feedback Square Root - This feature uses the square root of the feedback signal as the PI feedback.
Page 145 Process PI Loop 2-123 2. [PI Control] is a set of bits to dynamically enable and disable the operation of the process PI controller. When this parameter is interactively written to from a network it must be done through a data link so the values are not written to EEprom.
Page 146 Resetting the integrator eliminates this windup. NOTE: In the PowerFlex 70, once the drive has reached the programmable positive and negative PI limits, the integrator stops integrating and no further “windup” is possible.
Page 147 Process PI Loop 2-125 PF70 options include DPI adapter ports, MOP, preset speeds, analog inputs and PI setpoint parameter. In the PF700, options are expanded to also include additional analog inputs, pulse input, and encoder input. The value used for reference is displayed in PI Reference as a read only parameter.
Page 148 2-126 Process PI Loop If the application is Process Control, typically these limits would be set to the maximum allowable frequency setting. This allows the PI regulator to control over the entire required speed range. If the application is Process Trim, large trim corrections may not be desirable and the limits would be programmed for smaller values.
Page 149: Reﬂected Wave
Voltages in excess of twice the DC bus voltage,(650V DC nominal @ 480 V input) result at the motor and can cause motor winding failure. The patented reﬂected wave correction software in the PowerFlex 70 will reduce these over-voltage transients from a VFD to the motor. The correction software modiﬁes the PWM modulator to prevent PWM pulses...
Page 150 2-128 Reﬂected Wave over-voltage transient greater than 2 pu. The amplitude of the double pulsed motor over-voltage is determined by a number of variables. These include the damping characteristics of the cable, bus voltage, and the time between pulses, the carrier frequency, modulation technique, and duty cycle. The plot below shows the per unit motor over-voltage as a function of cable length.
Page 151: Reset Meters
Reset Meters 2-129 Reset Meters This section is under construction. If further information is required, please contact factory. Reset Run Refer to Auto Restart (Reset/Run) on page 2-24. RFI Filter Grounding RFI Filter Grounding on page 2-87...
Page 152: S Curve
2-130 S Curve S Curve The S Curve function of the PowerFlex family of drives allows control of the “jerk” component of acceleration and deceleration through user adjustment of the S Curve parameter. Jerk is the rate of change of acceleration and controls the transition from steady state speed to acceleration or deceleration and vice versa.
Page 153 S Curve 2-131 The acceleration and deceleration times are independent but the same S-curve percentage is applied to both of them. With S-curve set to 50%, acceleration time is extended by 0.5 seconds (1.0 * 50%), and deceleration time is extended by 1.0 seconds (2.0 * 50%). 70.0 60.0 50.0...
Page 154 2-132 S Curve The following graph shows an acceleration time of 1.0 second. After 0.75 seconds, the acceleration time is changed to 6.0 seconds. When the acceleration rate is changed, the commanded rate is reduced to match the requested rate based on the initial S-curve calculation. After reaching the new acceleration rate, the S-curve is then changed to be a function of the new acceleration rate.
Page 155: Scaling Blocks
Scaling Blocks 2-133 Scaling Blocks This section is under construction. If further information is required, please contact factory.
Page 156: Shear Pin Fault
2-134 Shear Pin Fault Shear Pin Fault This feature allows the user to select programming that will fault the drive if the drive output current exceeds the programmed current limit. As a default, exceeding the set current limit is not a fault condition. However, if the user wants to stop the process in the event of excess current, the Shear Pin feature can be activated.
Page 157: Skip Bands
Skip Bands 2-135 Skip Bands [Skip Freq 1-3] The skip band function provides three skip bands that the drive will ramp through but will not continuously run within. The user will be able to set the skip frequency (center frequency) for each band and the skip band centered on the skip frequency.
Page 158 2-136 Skip Bands If a skip band(s) extend beyond the max or min limits, the highest or lowest band values, respectively, will be clamped at the limit. The center frequency is recalculated based on the highest and lowest band values. If the band is outside the limits, the skip band is inactive.
Page 159: Sleep Mode
Sleep Mode 2-137 Sleep Mode The basic operation of this function is to start (wake) the drive when an analog signal is greater than or equal to the user speciﬁed [Wake Level], and stop the drive when an analog signal is less than or equal to the user speciﬁed [Sleep Level].
Page 160 2-138 Sleep Mode independent of any other functions that are also using the assigned analog input. Thus, using the same analog input for both speed reference and wake control is permitted. Also, [Analog In x Hi] and [Analog In x Lo] parameters have no affect on the function.
Page 161: Speed Control Speed Mode Speed Regulation
Speed Regulation speciﬁed regulation percentage. The [Speed Mode] parameter selects the speed regulation method for the drive, and can be set to one of 3 choices on the PowerFlex 70. Additional choices are available on the PowerFlex 700 (see page 2-142): •...
Page 162 2-140 Speed Control Speed Mode Speed Regulation Figure 2.16 Rotor Speed with/without Slip Compensation Slip Compensation Slip Compensation Slip Compensation Inactive Active Active 1.5 p.u. Load Load Load 1.0 p.u. Load Applied Applied 0.5 p.u. Load No Load 0.5 p.u. Load Load 1.0 p.u.
Page 163 With the Slip Compensation feature, the process will only require a new speed reference when the product is changed. The user will not have to tune the drive due to a different load characteristic. Dough Stress Cookie Line Relief CUTTERS OVEN 5/40 PowerFlex PowerFlex PowerFlex PowerFlex Drive Drive Drive Drive...
Page 164 2-142 Speed Control Speed Mode Speed Regulation Process PI – Process PI Loop on page 2-116 Encoder Feedback (PowerFlex 700 Only) This section is under construction. If further information is required, please contact factory. Droop (PowerFlex 700 Only) As the load on an induction motor increases, the rotor speed or shaft speed of the motor decreases, creating additional slip (and therefore torque) to drive the larger load.
Page 165 Speed Control Speed Mode Speed Regulation 2-143 TAKE UP Gear Gear PowerFlex PowerFlex Drive Drive To accomplish this, the PLC or other controller, will control the speed command being sent to the drives. Both drives can be programmed for droop operation. Or the lead drive may be used as the “speed regulator”...
Page 166: Speed Reference
The ﬁrst two references are programmable. The user can select which source they would like for each reference. If an analog input reference or pulse input reference (PowerFlex 700 Only) is chosen, two scale parameters are provide to scale the reference. The scale min/max are based on other parameter (uni/bipolar, analog in conﬁg, etc.).
Page 167 Speed Reference 2-145 Trim [Trim In Sel] Reference A and Reference B can be trimmed with a selectable source. The trim is an input signal value (+/-) which ia added to the reference. If an analog input is chosen as the trim source, two scale parameters are provide to scale the trim signal.
Page 168 2-146 Speed Reference Follower/Leader This section is under construction. If further information is required, please contact factory. HIM Speed Reference This section is under construction. If further information is required, please contact factory. Maximum frequency The maximum frequency deﬁnes the maximum reference frequency. The actual output frequency may be greater as a result of slip compensation and other types of regulation.
Page 169: Start Inhibits
Start Inhibits 2-147 Start Inhibits The [Start Inhibits] parameter indicates the inverted state of all start permissive conditions. If the bit is on (HI or 1), the corresponding permissive requirement has not been met and the drive is inhibited from starting.
Page 170: Start Permissives
2-148 Start Permissives Start Permissives Start permissives are conditions required to permit the drive to start in any mode – run, jog, auto-tune, etc. When all permissive conditions are met the drive is considered ready to start. The ready condition is available as the drive ready status.
Page 171: Start-Up
Start-Up Start-Up Routines PowerFlex drives offer a variety of Start Up routines to help the user commission the drive in the easiest manner and the quickest possible time. PowerFlex 70 Drives have the S.M.A.R.T Start routine and a Basic assisted routine for more complex setups.
Page 172 Basic Start Up (Top Level) Main Menu: <Diagnostics> Parameter Abort Device Select Memory Storage StartUp Preferences Startup PowerFlex 70 StartUp The drive must be stopped to Drive active? proceed. Press Esc to cancel. Any state 'Esc' key Stop Go to previous...
Page 173 Start-Up 2-151 Basic Start Up (Input Voltage) StartUp 1. Input Voltage This step should be done only when "alternate voltage" is needed (see user manual). It will reset all drive parameters with specific choice of Volts and Hz. Enter Backup Rated Volts Backup >300?
Page 174 2-152 Start-Up StartUp Basic Start Up (Motor Data/Ramp) 2. Motr Dat/Ramp Use motor name- plate data and required ramp times for the following steps. Enter StartUp 2. Motr Dat/Ramp Enter choice for Mtr NP Pwr Units Enter StartUp StartUp 2. Motr Dat/Ramp 2.
Page 175 Start-Up 2-153 Basic Start Up (Motor Tests) Startup 3. Motor Tests Enter This section optimizes torque performance and tests for proper Startup direction. Done Go to 0-1 (4) 3. Motor Tests Complete these steps in order: <A. Auto Tune> B. Directn Test C.
Page 176 2-154 Start-Up Basic Start Up (Speed Limits) StartUp 4. Speed Limits This section defines min/max speeds, and direction method Enter StartUp StartUp 4. Speed Limits 4. Speed Limits Disable reverse Enter choice for operation? Direction Method <Fwd/Rev Command> <No> +/- Speed Ref Enter Backup StartUp...
Page 177 Start-Up 2-155 Basic Start Up (Speed Control) StartUp 5. Speed Control Enter This section defines a source 5-13 from which to control speed. StartUp 5. Speed Control StartUp Enter choice for 5. Speed Control Input Signal Analog Input Enter choice for Analog Input 1 Speed Control Analog Input 2...
Page 178 2-156 Start-Up Basic Start Up (Start,Stop,I/O) StartUp StartUp 6. Strt,Stop,I/O 6. Strt,Stop,I/O This section Complete these D. Done Go to 0-1 (7) defines I/O fun- steps in order: Enter ctions including <A. Dig Inputs> B. Dig start and stop B. Dig Outputs Outputs Go to 6-24 from digital ins...
Page 179 Start-Up 2-157 Basic Start Up (Start,Stop,I/O [2]) 6-24 Go to 6-1 (C) StartUp B . Dig Outputs Done Make a selection <Digital Out 1> 6-29 Digital Out 2 StartUp Done C. Anlg Outpts Enter choice for Analog Out 1 Sel Digital Digital Out 1...
Page 180: Stop Modes
Coast Time is load dependent Stop Command 2. Dynamic Braking is explained in detail in the PowerFlex Dynamic Braking Selection Guide, presented in Appendix 3. Brake to Stop is selected by setting [Stop Mode A] to a value of “3.”...
Page 181 Stop Modes 2-159 4. Ramp To Stop is selected by setting [Stop Mode x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. The “normal” mode of machine operation can utilize [Decel Time 1].
Page 182 2-160 Stop Modes 5. Ramp To Hold is selected by setting [Stop Select x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. Once the drive reaches zero hertz, a DC Injection holding current is applied to the motor.
Page 183: Test Points
Test Points 2-161 Test Points [Testpoint 1 Sel] Default: [Testpoint 2 Sel] Min/Max: 0/999 Selects the function whose value is Display: displayed value in [Testpoint x Data]. These are internal values that are not accessible through parameters. See Testpoint Codes and Functions on page 4-10 for a listing of available codes and functions.
Page 184: Torque Performance Modes
2-162 Torque Performance Modes Torque Performance [Torque Perf Mode] Modes Current Resolver V/Hz Control V/Hz Voltage Inverter Current Motor Control Limit Flux Vector Control Voltage Feedback Slip Estimator V/Hz When torque performance is set to Custom V/Hz the following parameters are used to deﬁne the relationship between frequency and voltage.
Page 185 Torque Performance Modes 2-163 This curve is intended for applications such as fans and pumps where the load increases as the speed increases. This mode is intended to have a V/Hz proﬁle that more closely matches the developed torque to the load torque. Maximum Voltage Base Voltage (Nameplate)
Page 186 2-164 Torque Performance Modes Autotune [Autotune] The purpose of Autotune is to identify the motor ﬂux current and stator resistance for use in Sensorless Vector Control and Economizer modes. The result of the ﬂux current test procedure is stored in the parameter [Flux Current].
Page 187 AC induction motors require ﬂux to be established before controlled torque can be developed. To build ﬂux in these motors, voltage is applied to them. PowerFlex drives have two methods to ﬂux the motor. The ﬁrst method is a normal start. During a normal start, ﬂux is established as the output voltage and frequency are applied to the motor.
Page 188 2-166 Torque Performance Modes Figure 2.18 Accel Proﬁle during Normal Start - No Flux Up Frequency Reference Rated Flux Stator Rotor Oscillation due to flux being established Time The second method is Flux Up Mode. In this mode, DC current is applied to the motor at a level equal to the lesser of the current limit setting, drive rated current, and drive DC current rating.
Page 189 Torque Performance Modes 2-167 Torque Current This parameter displays only the torque producing component of output current. It displays the amount of current that is in phase with the output voltage. This current is real current and is used to produce torque in the motor.
Page 190: Troubleshooting
2-168 Troubleshooting Troubleshooting Power Up Marker Copy of factory “drive under power” timer at the last power-up of the drive. Used to provide relevance of Fault 'n' Time values with respect to the last power-up of the drive. This value will rollover to 0 after the drive has been powered on for more than the hours shown in the Range ﬁeld (approximately 47.667 years).
Page 191: Unbalanced Or Ungrounded Distribution Systems
Unbalanced or Ungrounded Distribution Systems 2-169 Unbalanced or Unbalanced Distribution Systems Ungrounded This drive is designed to operate on three-phase supply systems whose line Distribution Systems voltages are symmetrical. Surge suppression devices are included to protect the drive from lightning induced overvoltages between line and ground. Where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal), or where the supply ground is tied to another system or equipment that could cause the ground potential to vary with...
Page 192: User Sets
2-170 User Sets User Sets After a drive has been conﬁgured for a given application the user can store a copy of all of the parameter settings in a speciﬁc EEPROM area known as a “User Set.” Up to 3 User Sets can be stored in the drives memory to be used for backup, batch “switching”...
Page 193: Voltage Class
Voltage class 2-171 Voltage class PowerFlex drives are sometimes referred to by voltage “class.” This class identiﬁes the general input voltage to the drive. This general voltage includes a range of actual voltages. For example, a 400 Volt Class drive will have an input voltage range of 380-480VAC.
Page 194: Watts Loss
22.6 44.6 67.2 25.4 67.3 92.7 33.2 141.3 174.5 34.2 205.7 239.9 48.1 270.4 318.5 PowerFlex 700 For PowerFlex 700 drives, a ﬂange mount version is not offered - only total watts are shown (see Table 2.Y). (1) Includes HIM.
Page 195 Watts Loss 2-173 Table 2.Y 480V Watts Loss at Full Load/Speed, 4kHz Normal Duty HP Total 43.9 54.2 66.4 84.8 157.2 187.6 213.1 326.3 397.9 445.8 464.3 619.7 (1) Includes HIM and Standard I/O Board.
Page 196 2-174 Watts Loss...
Page 197: Appendix A Dynamic Brake Selection Guide
Appendix Dynamic Brake Selection Guide The Dynamic Braking Selection Guide provided on the following pages contains detailed information on selecting and using dynamic brakes. Dynamic Braking Selection Guide www.abpowerflex.com...
Page 198 Dynamic Brake Selection Guide...
Page 199 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.
Page 201 Table of Contents Section 1 What This Guide Contains ......1-1 How Dynamic Braking Works ......1-1 Dynamic Brake Components .
Page 202 Table of Contents Notes:...
Page 203: What This Guide Contains
Section What This Guide Contains This Selection Guide contains the information necessary to determine whether or not dynamic braking is required for your drive application and select the correct resistor rating. • Section 1 provides an overview of dynamic braking principles. •...
Page 204: Dynamic Brake Components
Dynamic Brake Components A Dynamic Brake consists of a Chopper (the chopper transistor and related control components are built into PowerFlex drives) and a Dynamic Brake Resistor. Figure 1.1 shows a simpliﬁed Dynamic Braking schematic. Figure 1.1 Simpliﬁed Dynamic Brake Schematic...
Page 205 Transistor. Resistor The Resistor dissipates the regenerated energy in the form of heat. The PowerFlex Family of Drives can use either the internal dynamic brake resistor option or an externally mounted dynamic brake resistor wired to the drive. The internal resistor kit for the drive may be used for the application if the required energy, deceleration time, and duty, all are small enough to be within the capabilities of the resistor.
Page 206 The algorithm runs as follows: • Opens the precharge relay if not already open. • Pulses the DB transistor on in a series of increasing width pulses. • Measures the resulting capacitor bank voltage drop during each pulse. • Veriﬁes the drop is within allowed limits (stored in the power board EEPROM).
Page 207: How To Determine Dynamic Brake Requirements
Section How to Determine Dynamic Brake Requirements When a drive is consistently operating in the regenerative mode of operation, serious consideration should be given to equipment that will transform the electrical energy back to the ﬁxed frequency utility grid. As a general rule, Dynamic Braking can be used when the need to dissipate regenerative energy is on an occasional or periodic basis.
Page 208 Gather the Following Information • Power rating from motor nameplate in watts, kilowatts, or horsepower • Speed rating from motor nameplate in rpm or rps (radians per second) • Motor inertia and load inertia in kg-m or lb.-ft. • Gear ratio (GR) if a gear is present between the motor and load •...
Page 209 Figure 2.1 Application Speed, Torque and Power Proﬁles ω(t) ω b ω o t 1 + t 4 T(t) t 1 + t 4 P(t) t 1 + t 4 -P b...
Page 210: Determine Values Of Equation Variables
Determine Values of Equation Variables Step 2 Total Inertia × = Total inertia reﬂected to the motor shaft (kg-m or lb.-ft. = Motor inertia (kg-m or lb.-ft. = Gear ratio for any gear between motor and load (dimensionless) = Load inertia (kg-m or lb.-ft.
Page 211 Step 3 Peak Braking Power ω ω ω – ---------------------------------------- – = Peak braking power (watts) 1.0 HP = 746 watts = Total inertia reﬂected to the motor shaft (kg-m 2πN ω = Rated angular rotational speed -------- - ----------- - ω...
Page 212 Step 4 Minimum Power Requirements for the Dynamic Brake Resistors It is assumed that the application exhibits a periodic function of acceleration and deceleration. If (t – t ) equals the time in seconds necessary for deceleration from rated speed to ω speed, and t is the time in seconds before the process repeats itself, then the average duty...
Page 213 Step 5 Percent Average Load of the Internal Dynamic Brake Resistor Skip this calculation if an external dynamic brake resistor will be used. × ------- - = Average load in percent of dynamic brake resistor = Average dynamic brake resistor dissipation calculated in Step 4 (watts) = Steady state power dissipation capacity of dynamic brake...
Page 214 Step 6 Percent Peak Load of the Internal Dynamic Brake Resistor Skip this calculation if an external dynamic brake resistor will be used. × ------- - = Peak load in percent of dynamic brake resistor = Peak braking power calculated in Step 2 (watts) = Steady state power dissipation capacity of dynamic brake resistors obtained from Table 2.A...
Page 215: Example Calculation
Example Calculation A 10 HP, 4 Pole, 480 Volt motor and drive is accelerating and decelerating as depicted in Figure 2.1. • Cycle period t is 40 seconds • Rated speed is 1785 RPM and is to be decelerated to 0 speed in 15.0 seconds •...
Page 216 2-10 750 Volts This was known because the drive is rated at 480 Volts rms. If the drive were rated 230 Volts rms, then V = 375 Volts. All of the preceding data and calculations were made from knowledge of the application under consideration.
Page 217 2-11 × Percent Peak Load ------- - 608.6 × ----------- - 1521% This is the result of the calculation outlined in Step 6. This point is plotted at zero seconds moving up vertically to this percentage. Figure 2.2 Resistor Power Curve 3000 2800 2600...
Page 218 2-12 Notes:...
Page 219: Evaluating The Capability Of The Internal Dynamic Brake Resistor
Evaluating the Capability of the Internal Dynamic Brake Resistor Record the values calculated in Section – t PowerFlex 70 Drives Find the correct Figure for your PowerFlex 70 drive rating. Drive Voltage Frame(s) Figure Number A and B A and B 1.
Page 220 Figure 3.1 PowerFlex 70 – 240 Volt, A and B Frames 3000 240A/B 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.2 PowerFlex 70 –...
Page 221 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.4 PowerFlex 70 – 480 Volt, A and B Frames 3000...
Page 222 Figure 3.5 PowerFlex 70 – 480 Volt, C Frame 3000 480C 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.6 PowerFlex 70 –...
Page 223: How To Select An External Dynamic Brake Resistor
Dynamic Brake Resistor. If this value is greater than the maximum imposed by the peak regenerative power of the drive, the drive can trip off due to transient DC bus overvoltage problems. Table 4.A Minimum Dynamic Brake Resistance for PowerFlex 70 Drives Drive Voltage Frame Minimum External Resistance (Ohms 10%) 32.9...
Page 224 Record the Values Calculated in Section 2 Calculate Maximum Dynamic Brake Resistance Value × ------------------------- - = Maximum allowable value for the dynamic brake resistor (ohms) = DC bus voltage the chopper module regulates to (375V DC or 750V DC) = Peak breaking power calculated in Section 2: Step 3 (watts)
Page 225 Select Resistor Select a resistor bank from Table 4.B or your resistor supplier that has: • a resistance value that is less than the value calculated (R in ohms) • a resistance value that is greater than the minimum resistance listed Table 4.A •...
Page 226 Table 4.B Resistor Selection for 240V AC Drives Catalog Catalog Ohms Watts Number Ohms Watts Number 222-1A 222-5A 222-1 222-5 225-1A 1378 225-5A 225-1 2056 220-5A 220-1A 2066 225-5 220-1 3125 220-5 222-2A 222-6A 222-2 1162 222-6 225-2A 1955 225-6A 225-2 2906 225-6...
Page 227 Table 4.C Resistor Selection for 480V AC Drives Catalog Catalog Ohms Watts Number Ohms Watts Number 442-1 442-6A 445-1A 1162 442-6 440-1A 1951 445-6A 445-1 2906 445-6 440-1 2912 440-6A 442-1A 4395 440-6 442-2A 4629 440-7A 442-2 6944 440-7 445-2A 4592 445-7 445-2...
Page 228 Notes:...
Page 230 Online: www.ab.com/support/abdrives Reach us now at www.rockwellautomation.com Wherever you need us, Rockwell Automation brings together leading brands in industrial automation including Allen-Bradley controls, Reliance Electric power transmission products, Dodge mechanical power transmission components, and Rockwell Software. Rockwell Automation's unique, flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners, distributors and system integrators around the world.
Page 231: Index
Index Carrier (PWM) Frequency, 2-36 AC Supply Source Considerations, Conformity, 2-37 Accel Mask, 2-92 Requirements, 2-37 Accel Owner, 2-104 Circuit Breakers, 2-83 Accel Time, Clear Fault Owner, 2-104 Accel Time 1, 2, 2-1, 2-45 Coast, 2-158 Agency Certiﬁcation, Common Mode Interference, 2-15 Alarm x Code, Compensation,...
Page 232 2-134 IR Drop Volts, 2-167 Faults, 2-78 IR Voltage Drop, 2-167 Filter, RFI, 2-87 Isolation Transformer, 2-91 Flange Mount, PowerFlex 70, Flux Current, 2-165, 2-167 Jog Mask, 2-92 Flux Current Ref, 2-167 Jog Owner, 2-104 Flux Up, 2-165 Flux Up Mode,...
Page 233 Index-3 Low Voltage Directive, 2-37 Decel Owner, 2-104 Dig Out1 Level, 2-64 Dig Out1 OffTime, 2-66 Dig Out1 OnTime, 2-66 Masks & Owners Group, 2-92 Dig Out2 Level, 2-64 Max Speed, 2-145 Dig Out2 OffTime, 2-66 Maximum frequency, 2-146 Dig Out2 OnTime, 2-66 MOP Mask, 2-92...
Page 234 Index-4 PI Preload, 2-116 Speed Pot, 2-17 PI Prop Gain, 2-116 Speed Ref A Sel, PI Ref Meter, 2-116 Speed Ref A, B Sel, 2-144 PI Reference Sel, 2-116 Speed Reference, 2-48, 2-52, 2-144 PI Setpoint, 2-116 Speed References Group, PI Status, 2-116 Start Inhibits,...
Page 235 Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201 Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444...

Allen-Bradley PowerFlex Reference Manual

Chapter 1 Specifications & Dimensions

Chapter 2 Detailed Drive Operation

Appendix A Dynamic Brake Selection Guide

What this Guide Contains

How to Determine Dynamic Brake Requirements

Evaluating the Capability of the Internal Dynamic Brake Resistor

How to Select an External Dynamic Brake Resistor

Index

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Related Manuals for Allen-Bradley PowerFlex

Summary of Contents for Allen-Bradley PowerFlex

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