Allen-Bradley PowerFlex 70 Reference Manual
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Allen-Bradley PowerFlex 70 Reference Manual

Adjustable frequency ac drives
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See also: Reference Manual , User Manual
Reference Manual
PowerFlex 70/700 Adjustable Frequency AC Drives
PowerFlex 70 Firmware Versions – Standard Control 2.001 and Below, Enhanced Control 2.xxx and Below
PowerFlex 700 Firmware Versions – Standard Control 3.001 and Below, Vector Control 3.002

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Summary of Contents for Allen-Bradley PowerFlex 70

  • Page 1 Reference Manual PowerFlex 70/700 Adjustable Frequency AC Drives PowerFlex 70 Firmware Versions – Standard Control 2.001 and Below, Enhanced Control 2.xxx and Below PowerFlex 700 Firmware Versions – Standard Control 3.001 and Below, Vector Control 3.002...

  • Page 2: Important User Information

    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: Summary Of Changes

    Summary of Changes The information below summarizes the changes to the PowerFlex 70/700 Reference Manual, publication PFLEX-RM001 since the last release. New and Updated Manual Updates Information Description of Changes Refer to: Removed the Specification and Dimension information (Chapter 1)
  • Page 4 Summary of Changes Notes: Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 5: Table Of Contents

    Table of Contents Important User Information ........2 Summary of Changes New and Updated Information .
  • Page 6 Table of Contents Flying Start ............. 105 Fuses and Circuit Breakers .
  • Page 7 Table of Contents Start Inhibits ............176 Start Permissives .
  • Page 8 Table of Contents Notes: Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 9: Preface

    This information only applies to PowerFlex 700 drives with the Vector Control option Vector Applies to PowerFlex 700 drives with [Motor Cntl Sel] set to “FVC Vector.” Vector Indicates that the information presented is specific to the PowerFlex 70 Enhanced Control Option. Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 10: Additional Resources

    Provides detailed information on: publication 20B-UM001 • Parameters and programming • Faults, alarms, and troubleshooting PowerFlex 70 AC Drive Technical Data, publication This publication provides detailed drive specifications, 20A-TD001 option specifications and input protection device ratings. PowerFlex 700 AC Drive Technical Data, publication...

  • Page 11: Detailed Drive Operation

    Chapter Detailed Drive Operation This chapter explains PowerFlex drive functions in detail. Explanations are organized alphabetically by topic. Refer to the Table of Contents for a listing of topics. Accel Time [Accel Time 1, 2] The Accel Time parameters set the rate at which the drive ramps up its output frequency after a Start command or during an increase in command frequency (speed change).

  • Page 12: Advanced Tuning

    Advanced Tuning Advanced Tuning Advanced Tuning Parameters – PF700 Vector Control Only ATTENTION: To guard against unstable or unpredictable operation, the following parameters must only be changed by qualified service personnel. The following parameters can only be viewed when “2, Unused” is selected in parameter 196, [Param Access Lvl].
  • Page 13 Advanced Tuning Parameter Name & Description Values 509 [Lo Freq Reg KpId] Default: This proportional gain adjusts the output voltage at very Min/Max: 0/32767 low frequency in response to the reactive, or d-axis, Units: motor current. A larger value increases the output voltage change.
  • Page 14 Advanced Tuning Parameter Name & Description Values 525 [Torq Adapt Speed] Default: 10.0% Selects the operating frequency/speed at which the Min/Max: 0.0/100.0% adaptive torque control regulators become active as a Units: 0.1% percent of motor nameplate frequency. 526 [Torq Reg Enable] Default: Enables or disables the torque regulator Min/Max:...

  • Page 15: 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 16 Alarms The configuration bits act as a mask to block or pass through the alarm condition to the active condition. An active alarm will be indicated on the LCD HIM and will cause the drive alarm status bit to go high (“1”) in the Drive Status word (Bit 6, parameter 209).
  • Page 17 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 18: Analog Inputs

    Analog Inputs While the process is normal and running from the analog input, everything proceeds normally. However, if the wire for the analog input should be severed or the sensor malfunction so that the 4-20mA signal is lost, the following sequence occurs: 1.
  • Page 19 Analog Inputs Analog Input Configuration [Anlg In Config] [Current Lmt Sel] allows an analog input to control the set point while [DC Brk Levl Sel] allows an analog input to define the DC hold level used when Ramp-to-Stop, Ramp-to-Hold, or Brake-to-Stop is active. To provide local adjustment of a master command signal or to provide improved resolution the input to analog channel 1 or 2 can be defined as a trim input.
  • Page 20 Analog Inputs Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 21 Analog Inputs Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 22 Analog Inputs Analog Scaling [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 23 Analog Inputs Output Hertz Analog Scaling [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 60 Hz [Analog In 1 Lo] [Speed Ref A Lo] 0 Hz Configuration #2: • [Anlg In Config], bit 0 = “0” (Voltage) •...
  • Page 24 Analog Inputs Configuration #3: • [Anlg In Config], bit 0 = “1” (Current) • [Speed Ref A Sel] = “Analog In 1” • [Speed Ref A Hi] = 60 Hz • [Speed Ref A Lo] = 0 Hz • [Analog In 1 Hi] = 20 mA •...
  • Page 25 Analog Inputs Output Hertz Analog Scaling [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 0 Hz [Analog In 1 Lo] [Speed Ref A Lo] 60 Hz Configuration #5: • [Anlg In Config], bit 0 = “0” (Voltage) •...
  • Page 26 Analog Inputs Configuration #6 – Torque Ref: Vector • [Anlg In Config], bit 0 = “0” (Voltage) • [Torque Ref A Sel] = “Analog In 1” • [Torque Ref A Hi] = 200% • [Torque Ref A Lo] = 0% •...
  • Page 27 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 28 Analog Inputs No signal loss detection is possible while an input is in bipolar voltage mode. The signal loss condition will never occur even if signal loss detection is enabled. 1.9V 1.6V Signal Loss End Signal Loss Condition Condition Trim An analog input can be used to trim the active speed reference (Speed Reference A/B).
  • Page 29 Analog Inputs Terminal Designations & Wiring Examples Refer to the appropriate PowerFlex User Manual or “Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, ” publication DRIVES-IN001 for I/O terminal designations and wiring examples. How [Analog Inx Hi/Lo] & [Speed Ref A Hi/Lo] Scales the Frequency Command Slope with [Minimum/Maximum Speed] Example 1: Consider the following setup:...
  • Page 30 Analog Inputs 3. Multiply by the Volts/Hertz ratio 15 Hz x 0.16667 Volts/Hz = 2.5 Volts Therefore the command frequency from 0 to 2.5 volts on the analog input will be 15 Hz. After 2.5 volts, the frequency will increase at a rate of 0.16667 volts per hertz to 7.5 volts.

  • Page 31: Analog Outputs

    Refer to Option Definitions in User Manual. 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 32 Analog Outputs Absolute (default) Certain quantities used to drive the analog output are signed, i.e. the quantity can be both positive and negative. The user has the option of having the absolute value (value without sign) of these quantities taken before the scaling occurs. Absolute value is enabled separately for each analog output via the bitmapped parameter [Anlg Out Absolut].
  • Page 33 Analog Outputs [Analog Out1 Lo] Output Current vs. Analog Analog Output Voltage Output Voltage Marker Lines [Analog Out1 Hi] 200% Output Current This example shows that you can have [Analog Out1 Lo] greater than [Analog Out1 Hi]. The result is a negative slope on the scaling from original quantity to analog output voltage.
  • Page 34 Analog Outputs Filtering Software filtering will be performed on the analog outputs for certain signal sources, as specified in Table 1. “Filter A” is one possible such filter, and it is described later in this section. Any software filtering is in addition to any hardware filtering and sampling delays.
  • Page 35 Analog Outputs [Anlg Out1 Scale] Default: Vector v3 [Anlg Out2 Scale] Vector v3 Min/Max: [Analog Out1 Sel] Sets the high value for the range of analog out scale. Units: 0.01 Entering 0.0 will disable this scale and max scale will be used.

  • Page 36: Auto/Manual

    Auto/Manual Parameter Controlled Analog Output Enables the analog outputs to be controlled by Datalinks to the drive. [Anlg1 Out Setpt] Default: 20.000 mA, 10.000 Volts Vector v3 [Anlg2 Out Setpt] Vector v3 Min/Max: 0.000/20.000mA Sets the analog output value from a communication –/+10.000V device.
  • Page 37 Auto/Manual gain exclusive control (Manual) of the reference. If granted control of the reference, the specific source for the reference is determined by the parameter TB manual reference select. The TB manual reference is selected in [TB Man Ref Sel]. The choices for this parameter are: –...

  • Page 38: Auto Restart (Reset/Run)

    Auto Restart (Reset/Run) 7. If a terminal has Manual control and clears its DPI reference mask (disallows reference ownership), then Manual control will be released. By extension, if the drive is configured such that the HIM can not select the reference (via reference mask setting), then the drive will not allow the terminal to acquire Manual control.
  • Page 39 Auto Restart (Reset/Run) The auto-reset/run feature provides 2 status bits in [Drive Status 2] – an active status, and a countdown status. 210 [Drive Status 2] Read Only Present operating condition of the drive. 1 =Condition True 0 =Condition False x =Reserved Bit # * Vector firmware 3.001 &...

  • Page 40: Autotune

    Autotune Aborting an Auto-Reset/Run Cycle During an auto-reset/run cycle the following actions/conditions will abort the reset/run attempt process. • Issuing a stop command from any source. (Note: Removal of a 2-wire run-fwd or run-rev command is considered a stop assertion). •...
  • Page 41 Autotune Inertia Test Vector [Total Inertia] is set by the inertia test. [Total Inertia] represents the time in seconds, for the motor coupled to a load to accelerate from zero to base speed at rated motor torque. During this test, the motor is accelerated to about 2/3 of base motor speed.
  • Page 42 Autotune • The second method calculates them from the user-entered motor nameplate data parameters. When [Autotune] is set to 3 “Calculate”, any changes made by the user to motor nameplate HP, Voltage, or Frequency activates a new calculation. This calculation is based on a typical motor with those nameplate values.
  • Page 43 Autotune Troubleshooting the Autotune Procedure If any errors are encountered during the Autotune process drive parameters are not changed, the appropriate fault code will be displayed in the fault queue, and the [Autotune] parameter is reset to 0. If the Autotune procedure is aborted by the user, the drive parameters are not changed and the [Autotune] parameter is reset to 0.

  • Page 44: Block Diagrams

    Block Diagrams Block Diagrams The following pages contain the block diagrams for the PowerFlex 700 Vector Control drive. Figure 1 PowerFlex 700VC Block Diagrams (1) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 45 Block Diagrams Figure 2 PowerFlex 700VC Block Diagrams (2) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 46 Block Diagrams Figure 3 PowerFlex 700VC Block Diagrams (3) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 47 Block Diagrams Figure 4 PowerFlex 700VC Block Diagrams (4) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 48 Block Diagrams Figure 5 PowerFlex 700VC Block Diagrams (5) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 49 Block Diagrams Figure 6 PowerFlex 700VC Block Diagrams (6) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 50 Block Diagrams Figure 7 PowerFlex 700VC Block Diagrams (7) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 51 Block Diagrams Figure 8 PowerFlex 700VC Block Diagrams (8) Save MOP Ref MOP Control (At Stop) Drive Logic Rslt (2.0 ms) (Stop) Clear Drive Logic Rslt (Mop Inc) Add Rate To MOP Output MOP Rate [3B2] [3D4] Ramp Drive Logic Rslt (Mop Dec) MOP Frequency Scale...
  • Page 52 Block Diagrams Figure 9 PowerFlex 700VC Block Diagrams (9) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 53 Block Diagrams Figure 10 PowerFlex 700VC Block Diagrams (10) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 54 Block Diagrams Figure 11 PowerFlex 700VC Block Diagrams (11) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...
  • Page 55 Block Diagrams Figure 12 PowerFlex 700VC Block Diagrams (12) Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 56: Bus Regulation

    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 57 Bus Regulation 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. DB Bus Motor Speed Output Frequency To avoid over-voltage faults, a bus voltage regulator is incorporated as part of the acceleration/deceleration control.
  • Page 58 Bus Regulation Figure 13 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 59 Note: These faults are not instantaneous and have shown test results that take between 2 and 12 seconds to occur. PowerFlex 70/700 The user selects the bus voltage regulator using the Bus Reg Mode parameters. The available modes include: •...
  • Page 60 Bus Regulation Table 3 Voltage Class DC Bus Memory DB On Setpoint DB Off Setpoint < 342V DC 375V DC On – 4V DC > 342V DC Memory + 33V DC < 685V DC 750V DC On – 8V DC >...

  • Page 61: Cable, Control

    Cable, Control If [Bus Reg Mode A], parameter 161 is set to “Both-DB 1st” Both regulators are enabled, and the operating point of the Dynamic Brake Regulator is lower than that of the Bus Voltage Regulator. The Bus Voltage Regulator setpoint follows the “DB Turn On” curve (Table 3).

  • Page 62: Carrier (Pwm) Frequency

    Carrier (PWM) Frequency Carrier (PWM) Frequency In general, the lowest possible switching frequency that is acceptable for any particular application is the one that should be used. There are several benefits to increasing the switching frequency. Refer to Figure 14 Figure 15.

  • Page 63: Ce Conformity

    CE Conformity CE Conformity EMC Instructions CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manuals.
  • Page 64 – Drive with any Comm Option – – – Drive with Remote I/O – – Table 6 PowerFlex 70 – EN61800-3 First Environment Restricted Distribution First Environment Restricted Distribution Restrict Motor Internal External Comm Cable Common Mode Drive Description Cable to:...

  • Page 65: Copy Cat

    Table 8 Recommended Filters Class Class Manufacturer Manufacturer Manufacturer Drive Type Frame Part Number (Meters) (Meters) Part Number (Meters) (Meters) Deltron PowerFlex 70 KMF306A – – – B w/o Filter KMF310A – – – B w/Filter KMF306A MIF306 – KMF318A –...

  • Page 66: Current Limit

    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 67: Datalinks

    Datalinks 4. Overload Protection I T - 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 I T value (i.e. 150% for 3 seconds, etc.). If the IT integrates to maximum, an F64 “Drive Overload”...
  • Page 68 Datalinks In the PLC data Table, the user enters Word 3 as a value of 100 (10.0 Secs) and word 4 as a value of 133 (13.3 seconds). On each I/O scan, the parameters in the PowerFlex drive are updated with the value from the data table: Accel Time P140 = 10.0 seconds (value from output image table Word 3) Decel Time P142 = 13.3 seconds (value from output image table Word 4).

  • Page 69: Dc Bus Voltage / Memory

    DC Bus Voltage / Memory Even if non-consecutive Datalinks are used (in the next example, Datalinks A1 and B2 would not be used), data is still returned in the same way. Datalink Most/Least Significant Word Parameter Data (decimal) 32573 32-bit data is stored in binary as follows: through 2 through 2 Example...

  • Page 70: Digital Inputs

    Selection for Digital Inputs. Wiring Examples Refer to the appropriate PowerFlex user manual for wiring diagrams. 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 71 Digital Inputs Digital Input Configuration Inputs are configured for the required function by setting a [Digital Inx Sel] parameter (one for each input). These parameters cannot be changed while the drive is running. PowerFlex 700 Digital Input Selection [Digital In1 Sel] Default: “Stop –...
  • Page 72 Digital Inputs PowerFlex 70 Digital Input Selection [Digital In1 Sel] Default: “Stop – CF” (CF = Clear Fault) [Digital In2 Sel] Default: “Start” [Digital In3 Sel] Default: “Auto/ Manual” [Digital In4 Sel] Default: “Speed Sel 1” [Digital In5 Sel] Default: “Speed Sel 2”...
  • Page 73 Digital Inputs Accel 2 Select acceleration rate 1 or 2. Decel 2 Select deceleration rate 1 or 2. Accel 2 & Decel 2 Select acceleration rate 1 and deceleration rate 1 or acceleration rate 2 and deceleration rate 2. MOP Increment Increment MOP (Motor Operated Pot Function Speed ref) MOP Decrement Decrement MOP (Motor Operated Pot Function Speed ref)
  • Page 74 Digital Inputs Open Closed Drive runs in reverse direction, terminal block takes direction ownership. Closed Open Drive runs in forward direction, terminal block takes direction ownership. Closed Closed Drive continues to run in current direction, but terminal block maintains direction ownership. 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.
  • Page 75 Digital Inputs causes a configuration alarm. See page 109 for typical 2 and 3-wire configurations. • Start An open to closed transition while the drive is stopped will cause the drive to run in the current direction, unless the “Stop – Clear Faults” input function is open.
  • Page 76 Digital Inputs The drive will not jog while running or while the “Stop - Clear Faults” input is open. Start has precedence. ATTENTION: If a normal drive start command is received while the drive is jogging, the drive will switch from jog mode to run mode. The drive will not stop, but may change speed and/or change direction.
  • Page 77 Digital Inputs and [Logic Mask] parameters, the terminal block becomes direction owner as soon as one (or both) of the “Jog Forward” or “Jog Reverse” input functions is closed. • Speed select 1, 2, and 3 One, two, or three digital input functions can be used to select the speed reference used by the drive, and they are called the Speed Select input functions.
  • Page 78 Digital Inputs The table below describes the various reference sources that can be selected using all three of the Speed Select input functions. Speed Select 3 Speed Select 2 Speed Select 1 Parameter that determines Reference Open Open Open [Speed Ref A Sel] Open Open Closed...
  • Page 79 Digital Inputs • Auto/Manual The Auto/Manual facility is essentially a higher priority reference select. It allows a single control device to assume exclusive control of reference select, irrespective of the reference select digital inputs, reference select DPI commands, the reference mask, and the reference owner. If the “Auto/Manual”...
  • Page 80 Digital Inputs by using the terminal block digital inputs, and the Speed Select Inputs will have no effect on which reference the drive is currently using. Because any combination of open / closed conditions (or unwired condition) commands a reference source, the terminal block seeks accel ownership as soon as the “Accel 2”...
  • Page 81 Digital Inputs • Stop Mode B This digital input function selects between two different drive stop modes. See also Stop Modes on page 197. If the input is open, then [Stop Mode A] selects which stop mode to use. If the input is closed, then [Stop Mode B] selects which stop mode to use.
  • Page 82 Digital Inputs • Local Control The “Local Control” input function allows exclusive control of all drive logic functions from the terminal block. If this input function is closed, the terminal block has exclusive control (disabling all the DPI devices) of drive logic, including start, reference selection, acceleration rate selection, etc.
  • Page 83 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 internal and not selectable. • Precharge Enable (PowerFlex 700 only) This input function is used to manage disconnection from a common DC bus.
  • Page 84 Digital Inputs Examples of configurations that cause an alarm are: • User tries to configure both the “Start” input function and the “Run Forward” input function at the same time. “Start” is only used in “3-wire” start mode, and “Run Forward” is only used in “2-wire” run mode, so they should never be configured at the same time •...
  • Page 85 Digital Inputs Table 11 Input function combinations that produce “DigIn CflctB” alarm Fwd/ Start Stop–CF Run Fwd Run Rev Jog Fwd Jog Rev Start Stop–CF Run Fwd Run Rev Jog Fwd Jog Rev Fwd / Rev “Digin CflctC” indicates that more than one physical input has been configured to the same input function, and this kind of multiple configuration isn’t allowed for that function.
  • Page 86 The bits are “1” when the input is closed and “0” when the input is open. Digital In Examples PowerFlex 70 Figure 16 shows a typical digital input configuration that includes “3-wire” start. The digital input configuration parameters should be set as shown.

  • Page 87: 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 250V AC or 220V DC. The table below shows specifications and limits for each relay/contact. PowerFlex 70 PowerFlex 700 Resistive Load Inductive Load...
  • Page 88 Digital Outputs PowerFlex 70 Digital Output Selection [Digital Out1 Sel] Default: “Fault” [Digital Out2 Sel] “Run” Selects the drive status that will energize a (CRx) Options: “Fault” output relay. “Alarm” “Ready” “Run” Contacts shown in the Installation Instructions “Forward Run”...
  • Page 89 Digital Outputs 2. The relay changes state because a particular value in the drive has exceeded a preset limit. The following drive values can be selected to cause the relay activation: Condition Description At Speed The drive Output Frequency has equalled the commanded frequency The balance of these functions require that the user set a limit for the specified value.
  • Page 90 Digital Outputs An Output can be “linked” directly to an Digital Input so that the output “tracks” the input. When the input is closed, the Output will be energized, and when the input is open, the output will be de-energized. This “tracking will occur if two conditions exist: –...

  • Page 91: Direction Control

    3. Control Word bit manipulation from a DPI device such as a communications interface. Bits 4 & 5 control direction. Refer to the Logic Command Word information in Appendix A of the PowerFlex 70 or 700 User Manual. 4. The sign (+/-) of a bipolar analog input.

  • Page 92: Dpi

    Consumer messages are used for control and status information. DPI adds a higher baud rate, brand specific enabling, Peer-to-Peer (P/P) communication, and Flash Memory programming support. PowerFlex 70 & 700 support the existing SCANport and DPI communication protocols. Multiple devices of each type (SCANport or DPI) can be attached to and communicate with PowerFlex 70 &...
  • Page 93 Peer-to-Peer messaging allows two devices to communicate directly rather than through the master or host (i.e. drive). They are the same priority as C/S messages and will occur in the background. In the PowerFlex 70 drive, the only Peer-to-Peer functionality supports proxy operations for the LED HIM. Since the PowerFlex 700 drive does not support an LED HIM, it will not support Peer-to-Peer proxy operations.

  • Page 94: Drive Overload

    Drive Overload Table 12 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.
  • Page 95 Drive Overload If the drive is operated in a low ambient condition the drive may exceed rated levels of current before the monitored temperature becomes critical. To guard against this situation the drive thermal overload also includes an inverse time algorithm.
  • Page 96 Drive Overload The lower curve in Figure 19 shows the boundary of heavy duty operation. In heavy duty, the drive is rated to produce 150% of rated current for 60 seconds, 200% for three seconds, and 220% for 100 milliseconds. The maximum value for current limit is 200% so the limit of 220% for 100 milliseconds should never be crossed.
  • Page 97 Drive Overload 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. Figure 20 Thermal Manager Inputs/Outputs DTO Select DTO Fault...
  • Page 98 Drive Overload Current Limit Current Limit as selected by the user can be reduced by the thermal manager. The resulting active current limit may be displayed as a test point parameter. The active current limit will always be less than or equal to the value selected by the user, and will not be less than flux current.

  • Page 99: Drive Ratings (Kw, Amps, Volts)

    Drive Ratings (kW, Amps, Volts) torque load reducing the output frequency does not lower the current (load). Lowering current limit on a CT load will push the drive down to a region where the thermal issue becomes worse. In this situation the thermal manager will increase the calculated losses in the power module to track the worst case IGBT.

  • Page 100: Efficiency

    Efficiency Efficiency The following chart shows typical efficiency for PWM variable frequency drives, regardless of size. Drives are most efficient at full load and full speed. vs. Speed vs. Load % Speed/% Load Fan Curve When torque performance (see page 201) is set to Fan/Pump, the relationship between frequency and voltage is shown in the following figure.

  • Page 101: Faults

    Faults are also logged into a fault queue such that a history of the most recent fault events is retained. Each recorded event includes a fault code (with associated text) and a fault “time of occurrence.” The PowerFlex 70 drive has a four event queue and the PowerFlex 700 has an eight event queue.
  • Page 102 Faults The fault queue will be a first-in, first-out (FIFO) queue. Fault queue entry #1 will always be the most-recent entry (newest). Entry 4 (8) will always be the oldest. As a new fault is logged, 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.).

  • Page 103: Flux Braking

    Flux Braking Resetting faults will clear the faulted status indication. If any fault condition still exists, the fault will relatch and another entry made in the fault queue. Clearing the Fault Queue Performing a fault reset does not clear the fault queue. Clearing the fault queue is a separate action.

  • Page 104: Flux Up

    Flux Up limits. In general, the flux current is not increased when the motor is at or above rated speed. At higher speeds, field weakening is active and the motor flux current cannot be increased. As the speed decreases below base speed, the flux current increases until there is enough voltage margin to run rated motor current.

  • Page 105: Flying Start

    Flying Start Figure 22 Flux Up Current versus Flux Up Time Flux Up Current = Maximum DC Current Rated Flux Rated Motor Flux Current Motor Flux Flux Up Time [Flux Up Time] Once rated flux is reached in the motor, normal operation begins and the desired acceleration profile is achieved.

  • Page 106: Fuses And Circuit Breakers

    Draft/wind blows idle fans in reverse direction. Restart at zero damages fans, breaks belts. Flying start alleviates the problem Fuses and Circuit Breakers Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or PowerFlex 700 Technical Data (publication 20B-TD001) for fuse information. Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 107: Grounding, General

    Grounding, General Grounding, General Refer to “Wiring and Grounding Guidelines for PWM AC Drives, ” publication DRIVES-IN001. HIM Memory Copy Cat on page HIM Operations Selecting a Language See also Language on page 111. PowerFlex 700 drives support multiple languages. When you first apply drive power, a language screen appears on the HIM.

  • Page 108: Input Devices

    Input Devices The User Display The User Display is shown when module keys have been inactive for a predetermined amount of time. The display can be programmed to show pertinent information. Setting the User Display Step Key(s) Example Displays 1. Press the Up Arrow or Down Arrow to scroll to Operator Intrfc: Operator Intrfc.

  • Page 109: 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 110: Input Power Conditioning

    [Feedback Select] setting, no modifications (i.e. no PI adder, no slip adder, no trim adder, etc.) will be made to the reference. For PowerFlex 70 and PowerFlex 700 with Standard Control, the jog reference will always be a positive number limited between Minimum Speed and Maximum Speed.

  • Page 111: Language

    Language 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 selected language. The desired language can be selected several different ways: •...
  • Page 112 Linking Parameters Table 13 Linkable Parameters Number Parameter Number Parameter Maximum Voltage Bus Reg Ki Compensation Bus Reg Kp Flux Up Mode Bus Reg Kd Flux Up Time Flying StartGain SV Boost Filter Auto Rstrt Delay IR Voltage Drop Wake Level Flux Current Ref Wake Time Start/Acc Boost...

  • Page 113: Masks

    Masks Masks A mask is a parameter that contains one bit for each of the possible Adapters. Each bit acts like a valve for issued commands. Closing the valve (setting a bit's value to 0) stops the command from reaching the drive logic. Opening the valve (setting a bit's value to 1) allows the command to pass through the mask into the drive logic.

  • Page 114: Mop

    Direction Mask Adapter # This “masks out” the reverse function from all adapters except Adapter 2, making the local HIM (Adapter 1) REV button inoperable. Also see Owners on page 125. The Motor Operated Pot (MOP) function is one of the sources for the frequency reference.

  • Page 115: Motor Control

    Motor Control If the value is “SAVE MOP Ref ” when the drive power returns, the MOP reference is reloaded with the value from the non-volatile memory. When the bit is set to 0, the MOP reference defaults to zero when power is restored. The MOP save reference parameter and the MOP rate parameter can be changed while the drive is running.

  • Page 116: Motor Nameplate

    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 117: Motor Overload

    Motor Overload Motor Overload Also see Motor Overload Protection on page 119. 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 118 Motor Overload Changing Overload Factor OL % = 1.20 OL % = 1.00 OL % = 0.80 90 100 % of Base Speed 3. [Motor OL Hertz] is used to further protect motors with limited speed ranges. Since some motors may not have sufficient cooling ability at lower speeds, the Overload feature can be programmed to increase protection in the lower speed areas.

  • Page 119: Motor Overload Protection

    6320 5995 1794 1500 Motor Overload Protection PowerFlex 70 PowerFlex 70: Class 10 motor overload protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A)(2). UL 508C File E59272. PowerFlex 700 Frames 0…6 Standard Control:...

  • Page 120: Motor Start/Stop Precautions

    • Wiring AC line to drive output or control terminals. • Improper bypass or output circuits not approved by Allen-Bradley. • Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring.

  • Page 121: Notch Filter

    Notch Filter Notch Filter The 700 Vector has a notch filter in the torque reference loop used Vector to eliminate mechanical resonance created by a gear train. [Notch Filter Freq] sets the center frequency for the 2 pole notch filter, and [Notch Filter K] sets the gain.
  • Page 122 Notch Filter Figure 26 Resonance The insert shows the resonant frequency in detail. Figure 27 shows the same mechanical gear train as Figure 26. [Notch Filter Freq] is set to 10. Figure 27 10 Hz Notch Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 123: Output Current

    Output Current Output Current [Output Current] This parameter displays the total output current of the drive. The current value displayed here is the vector sum of both torque producing and flux producing current components. Output Devices Drive Output Contactor ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood.

  • Page 124: Output Frequency

    Output Frequency resulting from high dv/dt. When using motor line reactors, it is recommended that the drive PWM frequency be set to its lowest value to minimize losses in the reactors. 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.

  • Page 125: Owners

    Owners Figure 28 Typical V/Hz Curve for Full Custom (with Speed/Frequency Limits Allowable Output Frequency Range - Bus Regulation or Current Limit Allowable Output Frequency Range - Normal Operation (lower limit on this range can be 0 depending on the value of Speed Adder) Allowable Speed Reference Range Maximum Voltage...
  • Page 126 Owners Non Exclusive Multiple adapters can simultaneously issue the same command and multiple bits may be high. 288 [Stop Owner] Read Only thru Adapters presently issuing a valid stop command. 1 =Issuing Command 0 =No Command x =Reserved Bit # 289 [Start Owner] See [Stop Owner] thru...

  • Page 127: Parameter Access Level

    Permissives. Parameter Access Level The PowerFlex 70 allows the user to restrict the number of parameters that 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 128: Pet

    Vopen is normally 60V DC below Vtrigger (in a 480VAC drive). Both Vopen and Vtrigger are limited to a minimum of Vmin. This is only a factor if [Power Loss Level] is set to a large value. PowerFlex 70 This is a fixed value.
  • Page 129 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 15 PF700 Bus Levels Class 200/240V AC 400/480V AC 600/690V AC Vslew 1.2V DC 2.4V DC 3.0V DC Vrecover...
  • Page 130 Power Loss 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” state if: 3 wire mode –...
  • Page 131 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 132 Power Loss 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 133 Power Loss The pre-charge relay opens if the bus voltage drops below Vopen/Vmin and closes if the bus voltage rises above Vclose. The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts. The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Config 1] is set.
  • Page 134 Power Loss 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. The drive faults with a F004 – UnderVoltage fault if the bus voltage falls below Vmin and the UnderVoltage bit in [Fault Config 1] is set.

  • Page 135: Preset Frequency

    Preset Frequency 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 136 Process PI Loop The PI function can perform a combination of proportional and integral control. It does not perform derivative control, however, the accel / decel control of the drive can be considered as providing derivative control. There are two ways the PI Controller can be configured to modify the commanded speed.
  • Page 137 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 138 Process PI Loop Slip Comp Slip Adder Open Loop Linear Ramp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller Speed Control PI Fbk PI Disabled 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 139 Process PI Loop 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. Refer to diagram 2 below.
  • Page 140 Process PI Loop PI Enabled Start at Spd Cmd PI Output Spd Cmd Pre-load to Command Speed • Ramp Ref - The PI Ramp Reference feature is used to provide a smooth transition when the PI is enabled and the PI output is used as a speed trim (not exclusive control),.
  • Page 141 Process PI Loop • Feedback Square Root - This feature uses the square root of the feedback signal as the PI feedback. This is useful in processes that control pressure, since centrifugal fans and pumps vary pressure with the square of speed. The PI has the option to take the square root of the selected feedback signal.
  • Page 142 Process PI Loop When a digital input is configured as “PI Enable, ” the PI Enable bit of [PI Control] must be turned on for the PI loop to become enabled. If a digital input is not configured as “PI Enable” and the PI Enable bit in [PI Control] is turned on, then the PI loop may become enabled.
  • Page 143 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”...
  • Page 144 Process PI Loop Configuration Example: The PI reference meter and PI feedback meter should be displayed as positive and negative values. Feedback from our dancer comes into Analog Input 2 as a 0-10V DC signal. • [PI Reference Sel] = 0 “PI Setpoint” •...
  • Page 145 Process PI Loop The PI Integral Gain is entered in seconds. If the PI Integral Gain is set to 2.0 seconds and PI Error is 100.00% the PI output will integrate from 0 to 100.00% in 2.0 seconds. Positive and Negative Limits The PI has parameters to define the positive and negative limits of the output PI Positive Limit, and PI Negative Limit.
  • Page 146 Process PI Loop Figure 29 Process PI Block Diagram PI_Config .ZeroClamp PI_Config .Exclusive PI_Status .Enabled +32K Linear Ramp Spd Ref Spd Cmd Spd Ramp & S-Curve -32K PI Pos Limit +32K PI Neg Limit PI Kp -32K ≥0 PI ExcessErr ≥...
  • Page 147 Process PI Loop Figure 30 Vector Control Option Process PI Loop Overview PI Lower Limit PI Upper Limit PI Ref Hi PI Configuration PI Prop Gain Reference PI Ref PI Error Linear Hi/Lo PI Cmd Ramp PI BW Limit PI Status Filter Scale PI Configuration...
  • Page 148 Process PI Loop For example, winders using torque control rely on PD control not PI control. Also, [PI BW Filter] is useful in filtering out unwanted signal response in the PID loop. The filter is a Radians/Second low pass filter. Percent of Reference 124 [PI Configuration] thru...

  • Page 149: Reflected Wave

    Voltages in excess of twice the DC bus voltage (650V DC nominal at 480V input) will occur at the motor and can cause motor winding failure. The patented reflected wave correction software in the PowerFlex 70/700 will reduce these over-voltage transients from a VFD to the motor. The correction software modifies the PWM modulator to prevent PWM pulses less than a minimum time from being applied to the motor.
  • Page 150 Reflected Wave The above figure shows the inverter line-to-line output voltage (top trace) and the motor line-to-line voltage (bottom trace) for a 10 HP, 460V AC inverter, and an unloaded 10 HP AC induction motor at 60 Hz operation. 500 ft. of #12 AWG cable connects the drive to the motor.

  • Page 151: Regen Power Limit

    Regen Power Limit Regen Power Limit The [Regen Power Lim] is programmed as a percentage of the Vector rated power. The mechanical energy that is transformed into electrical power during a deceleration or overhauling load condition is clamped at this level. Without the proper limit, a bus overvoltage may occur.
  • Page 152 S Curve 80.0 60.0 40.0 20.0 -20.0 -40.0 -60.0 -80.0 Seconds S-Curve Selection S-curve is enabled by defining the time to extend the acceleration and deceleration. The time is entered as a percentage of acceleration and deceleration time. In this case acceleration time is 2.0 seconds. The line on the left has s-curve set to 0%.
  • Page 153 S Curve Time to Max Speed Note that S-curve time is defined for accelerating from 0 to maximum speed. With maximum speed = 60 Hz, Ta = 2.0 sec, and S-curve = 25%, acceleration time is extended by 0.5 seconds (2.0 * 25%). When accelerating to only 30 Hz the acceleration time is still extended by the same amount of time.

  • Page 154: Scale Blocks

    Scale Blocks Scale Blocks See also Analog Scaling on page 22 page Scale blocks are used to scale a parameter value. [Scalex In Value] is Vector linked to the parameter that you wish to scale. [Scalex In Hi] determines the high value for the input to the scale block.
  • Page 155 Scale Blocks Parameter Settings Parameter Value Description [Trim In Select] 11, Preset 1 Preset 1 becomes the trim speed [Scale1 In Hi] 10.0 V Hi value of Analog In 2 [Scale1 In Lo] Lo value of Analog In 2 [Scale1 Out Lo] 0 RPM Lo value of desired Trim [Scale2 In Hi]...
  • Page 156 Scale Blocks Parameter Links Destination Parameter Source Parameter Description [Scale1 In Value] [Encoder Speed] We are scaling Encoder Speed = Link Scale1 In Hi Analog Out1 Hi Encoder Speed Scale1 Out Analog Out1 Scale1 In Value Value Scale1 In Lo Analog Out1 Lo Example Configuration #3 In this configuration Analog In 2 is a –10V to +10V signal which corresponds to...

  • Page 157: Shear Pin Fault

    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 158: Skip Frequency

    Skip Frequency Skip Frequency Figure 31 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 may have a resonant operating frequency that must be avoided to minimize the risk of equipment damage.
  • Page 159 Skip Frequency Skip Frequency Examples The skip frequency will have hysteresis Max. Frequency so the output does not toggle between high and low values. Three distinct bands can be programmed. If none of Skip Band 1 Skip Frequency 1 the skip bands touch or overlap, each band has its own high/low limit.

  • Page 160: Sleep Mode

    Sleep Mode Sleep Mode Operation The basic operation of the Sleep-Wake function is to Start (wake) the drive when an analog signal is greater than or equal to the user specified [Wake Level], and Stop (sleep) the drive when an analog signal is less than or equal to the user specified [Sleep Level].
  • Page 161 Sleep Mode Timers Timers will determine the length of time required for Sleep/Wake levels to produce true functions. These timers will start counting when the Sleep/Wake levels are satisfied and will count in the opposite direction whenever the respective level is dissatisfied. If the timer counts all the way to the user specified time, it creates an edge to toggle the Sleep/Wake function to the respective condition (sleep or wake).

  • Page 162: Speed Control, Mode, Regulation & Vector Speed Feedback

    The [Speed Mode] parameter selects the speed regulation method for the drive, and can be set to one of 3 choices on the PowerFlex 70/700. The PowerFlex 700 Vector option has 5 choices. In addition, [Feedback Select] in the Vector option, chooses the feedback used for the speed regulator.
  • Page 163 Speed Control, Mode, Regulation & Vector Speed Feedback Open Loop 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. This decrease in motor speed may have adverse effects on the process. If the [Speed Mode] parameter is set to “Open Loop, ”...
  • Page 164 Speed Control, Mode, Regulation & Vector Speed Feedback original speed. Conversely, when the load is removed, the rotor speed increases momentarily until the slip compensation decays to zero. Motor nameplate data must be entered by the user in order for the drive to correctly calculate the proper amount of slip compensation.
  • Page 165 Speed Control, Mode, Regulation & Vector Speed Feedback Application Example - Baking Line The diagram below shows a typical application for the Slip Compensation feature. The PLC controls the frequency reference for all four of the drives. Drive #1 and Drive #3 control the speed of the belt conveyor. Slip compensation will be used to maintain the RPM independent of load changes caused by the cutter or dough feed.

  • Page 166: Speed Feedback Filter

    Speed Feedback Filter [Motor Fdbk Type] selects the type of encoder: • “Quadrature” – dual channel. • “Quad Check” – dual channel and detects loss of encoder signal when using differential inputs. • “Single Chan” – pulse type, single channel. •...

  • Page 167: Speed Reference

    Speed Reference Speed Reference Operation The output frequency of the drive is controlled, in part, by the speed command or speed reference given to it. This reference can come from a variety of sources including: • HIM (local or remote) •...
  • Page 168 CommandFreq SpeedRef = x 32767 [Maximum Freq] For example, to send out a command frequency of 60 Hz on a PowerFlex 70 or 700 with default settings we would calculate the following: 60 Hz SpeedRef = x 32767 = 15123...
  • Page 169 Speed Reference Using the above formula, calculate the Speed Reference sent from a network using a DPI adapter. For example, to send out a command frequency of 60 Hz with [Maximum Freq] = 70 Hz, we would calculate the following: 60 Hz SpeedRef = x 32767 = 28086...
  • Page 170 Speed Reference For example, if the following parameters are set: [Analog In x Hi] = 10 V [Analog In x Lo] = 0 V [Speed Ref A Hi] = 45 Hz [Speed Ref x Lo] = 5 Hz then the speed command for the drive will be linearly scaled between 45 Hz at maximum analog signal and 5 Hz at minimum analog signal.

  • Page 171: Speed Regulator

    Speed Regulator through. This is due to the positive and negative minimum speeds. If the reference is positive and less than the positive minimum, it is set to the positive minimum. If the reference is negative and greater than negative minimum, it is set to the negative minimum.

  • Page 172: Speed/Torque Select

    Speed/Torque Select value of zero. Units are (per unit torque) / (per unit speed). For example, when [Kp Speed Loop] is 20, the proportional gain block will output 20% motor rated torque for every 1% error of motor rated speed. Feed Forward Gain Vector The first section of the PI regulator is the feed forward block.
  • Page 173 Speed/Torque Select As shown, [Speed/Torque Mod] (parameter 88) is used to select the mode of operation. Zero torque current is allowed when set to “0.” When set to a “1, ” the drive/motor is operated in speed mode. The torque command changes as needed to maintain the desired speed.
  • Page 174 Speed/Torque Select Figure 38 Ref A Hi Scale Torque Ref A Sel Ref A Lo Torq Ref A Div Ref B Hi Scale Torque Ref B Sel Ref B Lo Torq Ref B Mult Torque Reference: [Torque Ref A Sel], parameter 427 is scaled by [Torque Ref A Hi] and [Torque Ref A Lo].
  • Page 175 Speed/Torque Select Figure 39 Internal Torque Command At Speed Relay Load Step (Decrease) Speed Feedback Sum Mode Configuring the drive in this mode allows an external torque input to be summed with the torque command generated by the speed regulator. The drive requires both a speed reference and a torque reference to be linked.

  • Page 176: Speed Units

    Speed Units Speed Units [Speed Units] selects the units to be used for all speed related Vector parameters. The options for [Speed Units] are: • “Hz” – converts status parameters only to Hz. • “RPM” – converts status parameters only to RPM. •...

  • Page 177: Start-Up

    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 178 Start-Up Figure 40 PowerFlex 70 & 700 Standard Control Option Startup 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.
  • Page 179 Start-Up Figure 41 PowerFlex 70 & 700 Standard Control Option Startup (1) 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...
  • Page 180 Start-Up Figure 42 PowerFlex 70 & 700 Standard Control Option Startup (2) Basic Start Up (Motor Data/Ramp) StartUp 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...
  • Page 181 Start-Up Figure 43 PowerFlex 70 & 700 Standard Control Option Startup (3) 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...
  • Page 182 Start-Up Figure 44 PowerFlex 70 & 700 Standard Control Option Startup (4) 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...
  • Page 183 Start-Up Figure 45 PowerFlex 70 & 700 Standard Control Option Startup (5) Basic Start Up (Speed Control) StartUp 5. Speed Control 5-13 Enter This section defines a source StartUp from which to control 5. Speed Control speed. StartUp Enter choice for 5.
  • Page 184 Start-Up Figure 46 PowerFlex 70 & 700 Standard Control Option Startup (6) 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.
  • Page 185 Start-Up Figure 47 PowerFlex 70 & 700 Standard Control Option Startup (7) 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.
  • Page 186 Start-Up Figure 48 PowerFlex 700 Vector Control Option Startup For first time powerup... Select: Flux Vector Start Up (Top Level) <English> Francais Espanol Deustch Italiano Main Menu: Abort <Diagnostics> (allow Start/Jog) Parameter Start-Up/Continue Device Select (disallow Start/Jog) Memory Storage Start-Up Preferences Any state (allow Start/Jog)
  • Page 187 Start-Up Figure 49 PowerFlex 700 Vector Control Option Startup (1) Flux Vector Start Up (Motor Control Select) Start-Up 1-31 V/Hz The Fan/Pump option selects a B = Basic mode predefined V/Hz curve. Start-Up The Custom/Std. Start-Up 1. Motor Control option allows 1.
  • Page 188 Start-Up Figure 50 PowerFlex 700 Vector Control Option Startup (2) Flux Vector Start Up (Motor Dat/Ramp) Start-Up 2. Motr Dat/Ramp Use motor name- plate data and required ramp times for the B = Basic mode following steps. Enter Start-Up 2. Motr Dat/Ramp Enter choice for 2-14 Power Units...
  • Page 189 Start-Up Figure 51 PowerFlex 700 Vector Control Option Startup (3) 3-22 Flux Vector Start Up (Motor Tests) Start-Up Start-Up 3-21 Start-Up 3. Motor Tests 3. Motor Tests C.Inertia Test This section Select source of V/Hz Control optimizes motor Start/Stop 3-25 does not require performance and <Digital Inputs>...
  • Page 190 Start-Up Figure 52 PowerFlex 700 Vector Control Option Startup (4) Flux Vector Start Up (Speed Limits) Start-Up 4. Speed Limits This section defines min/max speeds and direction method Start-Up 4. Speed Limits Enter value for Maximum Speed +60.00 Hz xxx.xx <> yyy.yy Start-Up 4.
  • Page 191 Start-Up Figure 53 PowerFlex 700 Vector Control Option Startup (5) Start-Up Flux Flux Vector Start Up (Speed/Torque Control) 5-34 5. Speed Control Start-Up Vector This section C. Anlg Inputs Mode? 5-13 selects the Enter choice for Torque Go to 6-49 speed/torque Reference:: Start-Up...
  • Page 192 Start-Up Figure 54 PowerFlex 700 Vector Control Option Startup (6) Flux Vector Start Up (Strt,Stop,I/O) Start-Up 6. Strt,Stop,I/O This section B = Basic mode defines I/O Start-Up Go to 6-27 B. Dig functions 6. Strt,Stop,I/O Outputs including Start Enter/ Complete these and Stop.
  • Page 193 Start-Up Figure 55 PowerFlex 700 Vector Control Option Startup (7) 6-27 Flux Vector Start Up (Start,Stop,I/O [2]) Start-Up Go to 6-1 (C.Anlg Done B. Dig Outputs Inputs) Make a selection <Digital Out 1> Digital Out 2 6-34 Digital Out 1 Digital Out 3 6-28 Digital Out 3...
  • Page 194 Start-Up Figure 56 PowerFlex 700 Vector Control Option Startup (8) Flux Vector Start Up (Application Functions) Start-Up 7.Appl. Features This allows programming of additional drive features. Start-Up Auto 7.Appl Features Restart Make a Selection Flying <Flying Start> Start Auto Restart Done Start-Up Start-Up...
  • Page 195 Start-Up Figure 57 PowerFlex 700 Vector Control Option Startup (9) Flux Vector Start Up (S.M.A.R.T.) Start-Up SMART Enter choice of Speed units: <Hz> Start-Up SMART Enter value for Digital In 2 Sel Start Start-Up 2. Motr Dat/Ramp Enter choice for Stop Mode A Coast <Ramp>...
  • Page 196 Start-Up Figure 58 PowerFlex 700 Vector Control Option Startup (10) Flux Vector Start Up (Motor Control Select) Start-Up Start-Up 1. Motor Control 1. Motor Control This section Enter choice of selects the type Control: of Motor Control <Speed> the drive will Torque use.

  • Page 197: Stop Modes

    Stop Modes Stop Modes [Stop Mode A, B] [DC Brake Lvl Sel] [DC Brake Level] [DC Brake Time] 1. Coast to Stop - When in Coast to Stop, the drive acknowledges the Stop command by shutting off the output transistors and releasing control of the motor.
  • Page 198 Stop Modes 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 199 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 200: Test Points

    Test Points Test Points [Testpoint 1 Sel] Default: [Testpoint 2 Sel] Min/Max: 0/999 Selects the function whose value is displayed value in Display: [Testpoint x Data]. These are internal values that are not accessible through parameters. See Testpoint Codes and Functions for a listing of available codes and functions.

  • Page 201: Torque Performance Modes

    Torque Performance Modes Torque Performance [Torque Perf Mode] or [Motor Cntl Sel] (Vector) selects the output mode of the drive. The choices are: Modes • Custom Volts/Hertz Used in multi-motor or synchronous motor applications. • Fan/Pump Volts/Hertz Used for centrifugal fan/pump (variable torque) installations for additional energy savings.
  • Page 202 Torque Performance Modes were started across the line. As seen in the diagram below, the volts/hertz ratio can be changed to provide increased torque performance when required. The shaping takes place by programming 5 distinct points on the curve: – Start Boost - Used to create additional torque for breakaway from zero speed and acceleration of heavy loads at lower speeds –...
  • Page 203 Torque Performance Modes The algorithms operate on the knowledge that motor current is the vector sum of the torque and flux producing components. Values can be entered to identify the motor values or an autotune routine can be run to interrogate and identify the motor values (see Autotune on page 40).

  • Page 204: Torque Reference

    Torque Reference Figure 59 Flux Vector High Bandwidth Current Regulator CURRENT FEEDBACK Flux V mag Reg. Current Speed Voltage SPEED REF. Inverter Motor Reg. Reg. Control TORQUE REF. V ang Encoder SLIP Adaptive Controller AUTOTUNE PARAMETERS SPEED FEEDBACK Torque Reference When the PowerFlex 700 Vector Control drive is operated in Vector Torque mode, an external signal is used for a Torque reference.

  • Page 205: Troubleshooting

    Troubleshooting PowerFlex 700 Firmware 3.001 (& later) Enhancements Extra selections have been added to [Torque Ref A Sel] and [Torque Ref B Sel] in firmware version 3.001 (and later) for the PowerFlex 700 Vector Control drive: • Scale Block Output available as a selection •...

  • Page 206: User Sets

    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 207: Voltage Class

    European motors (kW rated, 1500 RPM, etc.). Refer to Figure Voltage Tolerance Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or PowerFlex 700 Technical Data (publication 20B-TD001) for details. Watts Loss Refer to the Powerflex 70 Technical Data (publication 20A-TD001) or PowerFlex 700 Technical Data (publication 20B-TD001) for Watts Loss information.
  • Page 208 Watts Loss Notes: Rockwell Automation Publication PFLEX-RM001H-EN-P - June 2013...

  • Page 209: Index

    Index Circuit Breakers 106 Clear Fault Owner 126 Accel Mask 113 Coast 197 Accel Owner 126 Compensation 149 Accel Time 11 Conduit 61 Accel Time 1/2 11 Contactor, Output 123 Advanced Tuning 70 Contactors Alarm Queue 18 Bypass 120 Alarm x Code 18 Input 120 Alarms 15 Output 120...
  • Page 210 Index Directive 63 Language 111 EMC Instructions 63 Language Parameter 111 Encoder 165 Language Select, HIM 107 ESD, Static Discharge 10 Linking Parameters 111 Exclusive Ownership 125 Local Mask 113 Local Owner 126 Logic Mask 113 Low Voltage Directive 63 Fan Curve 100 Fault Clr Mask 113 Fault Configuration 103...
  • Page 211 Index Parameters PI Config 135 Accel Mask 113 PI Configuration 148 Accel Owner 126 PI Control 135 Alarm x Code 18 PI Deriv Time 147 Analog In Hi 22 PI Error Meter 135 Analog In Lo 22 PI Feedback Meter 135 Analog In1 Value 28 Analog In2 Value 28 PI Feedback Sel 135...
  • Page 212 Index Speed Units 176 Speed/Torque Select 172 Start Inhibits 176 Start Mask 113 Start Owner 126 Start Permissives 176 Start/Stop, Repeated 120 Start-Up 177 Static Discharge, ESD 10 Stop Mode A, B 197 Stop Modes 197 Stop Owner 126 Sum Mode 175 Terminal Designations 29 Test Points 200 Testpoint 1 Sel 200...
  • Page 214 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

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Powerflex 700

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