Allen-Bradley PowerFlex 70 User manual

Installation Instructions
PowerFlex®70 Adjustable Frequency
AC Drive
When reading this document, look for this symbol “ ” to guide
you through the 5 BASIC STEPS needed to install and perform a Basic
Start-Up of the PowerFlex 70. A Human Interface Module (HIM) is
required to perform the Basic Start-Up routine covered in this manual.
The information provided Does Not replace the User Manual and is
intended for qualified drive service personnel only.
For detailed PowerFlex 70 information including advanced start-up
routines, programming, application considerations and related
precautions refer to the following publications online at
www.rockwellautomation.com/literature:
To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
To find your local Rockwell Automation distributor, visit
www.rockwellautomation.com/locations
Allen-Bradley Drives Technical Support
Title Publication
PowerFlex 70 User Manual 20A-UM001
DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and
PowerFlex 70 AC Drives
20A-UM003
PowerFlex Comm Adapter Manuals 20COMM-UM
Dynamic Braking Resistor Calculator PFLEX-AT001
PowerFlex 70 and 700 Reference Manual - Volume 1 PFLEX-RM001
PowerFlex Reference Manual PFLEX-RM004
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM)
AC Drives
DRIVES-IN001
Online at… By Email at… By Telephone at…
www.ab.com/support/abdrives [e-mail] 262-512-8176
Step x

Publication 20A-IN009C-EN-P
2PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions
Installation Instructions in Other Languages
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Publication 20A-IN009C-EN-P
PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 3
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . .4
Step 1 Read the General Precautions . . . . . . . . . . . . . . . . . . . .4
Qualified Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Product Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Low Voltage Directive (2006/95/EC) . . . . . . . . . . . . . . . . . . .7
EMC Directive (89/336/EEC). . . . . . . . . . . . . . . . . . . . . . . . .7
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Essential Requirements for CE Compliance. . . . . . . . . . . . . .8
Step 2 Mount the Drive – Minimum Requirements . . . . . . . .9
Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . .9
Maximum Surrounding Air Temperature . . . . . . . . . . . . . . . .9
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Step 3 Wire the Drive – Wire Recommendations . . . . . . . . .11
Terminal Block Specifications . . . . . . . . . . . . . . . . . . . . . . .12
Power & Ground Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Drive, Fuse & Circuit Breaker Ratings. . . . . . . . . . . . . . . . .14
Disconnecting MOVs and Common Mode Capacitors. . . . .21
Step 4 I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
I/O Terminal Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
I/O Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Hardware Enable Circuitry (Enhanced Control Only) . . . . .31
Safe Off Board Option (Enhanced Control Only) . . . . . . . .32
Encoder Interface Option (Enhanced Control Only) . . . . . .33
Step 5 Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Prepare For Drive Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . .34
Information About Start-Up Motor Tests . . . . . . . . . . . . . . .35
Appendix
First Powerup Menu Structure . . . . . . . . . . . . . . . . . . . . . . .36
Human Interface Module (HIM) Overview . . . . . . . . . . . . .37
Drive Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Common I/O Programming Changes . . . . . . . . . . . . . . . . . .42
Troubleshooting – Abbreviated Fault & Alarm Listing . . . .43
Common Symptoms and Corrective Actions . . . . . . . . . . . .45
Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Table of Contents

Publication 20A-IN009C-EN-P
4PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions
Qualified Personnel
Catalog Number Explanation
Position Number
1-3 45-78 9 10111213141516
20A B 2P2 A 3 A Y Y N N C 0
abcdefghi jkl
a
Drive
Code Type
20A PowerFlex 70
b
Voltage Rating
Code Voltage Ph.
B 240V ac 3
C 400V ac 3
D 480V ac 3
E 600V ac 3
c
ND Output Rating for Voltage Rating
Examples:
Code Amps kW (Hp)
2P2 2.2 0.37 (0.5)
022 22 5.5 (7.5)
e
HIM
Code Interface Module
0 Blank Cover
3 Full Numeric LCD
5 Prog. Only LCD
8
Wireless Interface Module -
IP66, NEMA/UL Type 4X/12
Only
g
Brake IGBT
Code w/Brake IGBT
seYY
h
Internal Brake Resistor
Code w/Resistor
seYY
oNN
l
Feedback
Code Feedback
N NA - Standard Control
0No Feedback - Enhanced
Control
15V/12V Encoder w/Enhanced
Control
j
Comm Slot
Code Version
B BACnet
C ControlNet (Coax)
D DeviceNet
E EtherNet/IP
OIRR
S RS485 DF1
N None
d
Enclosure
Code Enclosure
APanel Mount - IP 20, NEMA/UL
Type 1
C
Wall/Machine Mount = IP66,
NEMA/UL Type 4X/12 for
indoor use only
F
Flange Mount - Front Chassis =
IP 20, NEMA/UL Type 1; Rear
Heatsink = IP66, NEMA/UL
Type 4X/12 for indoor/outdoor
use
GWall/Machine Mount - IP54,
NEMA/UL Type 12
LFlange Mount with Conformal
Coat
MPanel Mount with Conformal
Coat
Only available on Frame E.
f
Documentation
Code Type
A Manual
N No Manual
i
Emission Class
Code Rating
A
Filtered
A & B Frames (Optional)
C, D, & E Frames (Standard)
N
Not Filtered
A & B Frames (Optional)
C, D, & E Frames
600V Frames A through D available only
without filter (Cat. Code N). 600V Frame E
available only with filter (Cat. Code A).
Increases size to Frame B.
k
Control & I/O
Code Control Safe-Off
N Standard N/A
C Enhanced No
GEnhanced Yes
Not available as factory installed option for
600V ratings.
Step 1 Read the General Precautions
!
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.

Publication 20A-IN009C-EN-P
PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 5
Personal Safety
Product Safety
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing any
work on the drive. Measure the DC bus voltage at the +DC terminal of
the Power Terminal Block and the -DC test point (refer to page 13 for
location). The voltage must be zero.
!
ATTENTION: Risk of injury or equipment damage exists. DPI or
SCANport host products must not be directly connected together via
1202 cables. Unpredictable behavior can result if two or more devices
are connected in this manner.
!
ATTENTION: The drive start/stop/enable control circuitry includes
solid state components. If hazards due to accidental contact with
moving machinery or unintentional flow of liquid, gas or solids exist,
an additional hardwired stop circuit may be required to remove the AC
line to the drive. An auxiliary braking method may be required.
!
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
!
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference Guarding Against Electrostatic Damage, publication
8000-4.5.2 or any other applicable ESD protection handbook.
!
ATTENTION: Configuring an analog input for 0-20 mA operation
and driving it from a voltage source could cause component damage.
Verify proper configuration prior to applying input signals.
!
ATTENTION: A contactor or other device that routinely disconnects
and reapplies the AC line to the drive to start and stop the motor can
cause drive hardware damage. The drive is designed to use control input
signals that will start and stop the motor. If an input device is used,
operation must not exceed one cycle per minute or drive damage will
occur.

Publication 20A-IN009C-EN-P
6PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions
Output Contactor Precaution
!
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. It
forces the output frequency to be greater than commanded frequency
while the drive’s bus voltage is increasing towards levels that would
otherwise cause a fault; however, it can also cause either of the
following two conditions to occur.
1. Fast positive changes in input voltage (more than a 10% increase
within 6 minutes) can cause uncommanded positive speed changes;
however an “OverSpeed Limit” fault will occur if the speed reaches
[Max Speed] + [Overspeed Limit]. If this condition is unacceptable,
action should be taken to 1) limit supply voltages within the
specification of the drive and, 2) limit fast positive input voltage
changes to less than 10%. Without taking such actions, if this operation
is unacceptable, the “adjust freq” portion of the bus regulator function
must be disabled (see parameters 161 and 162).
2. Actual deceleration times can be longer than commanded
deceleration times; however, a “Decel Inhibit” fault is generated if the
drive stops decelerating altogether. If this condition is unacceptable, the
“adjust freq” portion of the bus regulator must be disabled (see
parameters 161 and 162). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.
Note: These faults are not instantaneous and have shown test results
that take between 2 and 12 seconds to occur.
!
ATTENTION: To guard against drive damage when using output
contactors, the following information must be read and understood.
One or more output contactors may be installed between the drive and
motor(s) for the purpose of disconnecting or isolating certain motors/
loads. If a contactor is opened while the drive is operating, power will
be removed from the respective motor, but the drive will continue to
produce voltage at the output terminals. In addition, reconnecting a
motor to an active drive (by closing the contactor) could produce
excessive current that may cause the drive to fault. If any of these
conditions are determined to be undesirable or unsafe, an auxiliary
contact on the output contactor should be wired to a drive digital input
that is programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is opened.

Publication 20A-IN009C-EN-P
PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 7
CE Conformity(1)
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.
CE Declarations of Conformity are available online at:
www.ab.com/certification/ce/docs
Low Voltage Directive (2006/95/EC)
•EN50178 Electronic equipment for use in power installations.
EMC Directive (89/336/EEC)
•EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
•Some drives are equipped with an adhesive label on the top of the
drive. If the adhesive label is removed from the top of the drive, the
drive must be installed in an enclosure with side openings less than
12.5 mm (0.5 in) and top openings less than 1.0 mm (0.04 in) to
maintain compliance with the LV Directive.
•The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
•Use of line filters in ungrounded systems is not recommended.
•PowerFlex drives may cause radio interference if used in a
residential or domestic environment. The installer is required to take
measures to prevent interference, in addition to the essential
requirements for CE compliance listed below, if necessary.
•Conformity of the drive with CE EMC requirements does not
guarantee an entire machine or installation complies with CE EMC
requirements. Many factors can influence total machine/installation
compliance.
•PowerFlex drives can generate conducted low frequency
disturbances (harmonic emissions) on the AC supply system. More
information regarding harmonic emissions can be found in the
PowerFlex Reference Manual, publication PFLEX-RM004.
EMC Instructions
(1) CE Certification testing has not been completed for 600 Volt class drives.

Publication 20A-IN009C-EN-P
8PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions
Essential Requirements for CE Compliance
Conditions 1…6 listed below must be satisfied for PowerFlex drives to
meet the requirements of EN61800-3.
1. Standard PowerFlex 70 CE compatible Drive.
2. Review important precautions/attention statements throughout this
manual before installing drive.
3. Grounding as described in Chapter 1 of the User Manual, publication
20A-UM001.
4. Output power, control (I/O) and signal wiring must be braided,
shielded cable with a coverage of 75% or better, metal conduit or
equivalent attenuation.
5. All shielded cables should terminate with the proper shielded
connector.
6. Conditions in Table A.
Table A PowerFlex 70 EN61800-3 EMC Compatibility
Frame(s)
Drive Description
Second Environment
First Environment
Restricted
Distribution
Restrict Motor
Cable to
40 m (131 ft)
Internal
Filter
Option
External
Filter
Input
Ferrite (1)
ADrive Only ✔✔
See PowerFlex
Reference Manual
with any Comm Option ✔✔
with Remote I/O ✔✔✔
BDrive Only ✔✔
with any Comm Option ✔✔
with Remote I/O ✔✔ ✔
C,
D,
E
Drive Only ✔
with any Comm Option ✔
with Remote I/O ✔✔
(1) Input cables through a Ferrite Core (Frames A, B and C Fair-Rite #2643102002 or equivalent,
Frames D and E Fair-Rite #2643251002 or equivalent).

Publication 20A-IN009C-EN-P
PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions 9
Minimum Mounting Clearances
Specified vertical clearance requirements are
intended to be from drive to drive. Other objects
can occupy this space; however, airflow must not
be reduced and inlet air temperature must not
exceed the product specification.
Maximum Surrounding Air Temperature
Important: Some drives are equipped with an adhesive label on the top
of the chassis. Removing the adhesive label from the drive
changes the NEMA/UL enclosure rating from Type 1
Enclosed to Open Type.
Step 2 Mount the Drive – Minimum Requirements
Enclosure Rating Temperature Range
Open Type, IP 20, NEMA/UL Type 1 & Flange Mount 0…50 °C (32…22 °F)
IP54, IP 66 & NEMA/UL Type 4X/12 0…40 °C (32…104 °F)
76.2 mm
(3.0 in) 76.2 mm (3.0 in)

Publication 20A-IN009C-EN-P
10 PowerFlex® 70 Adjustable Frequency AC Drive Installation Instructions
Table B PowerFlex 70 Frames
Dimensions
Output Power Frame Size
kW
ND (HD)
HP
ND (HD)
208…240V AC Input 400…480V AC Input 600V AC Input
Not (1)
Filtered
(2)
Filtered
IP66
(4X/12)
Not (1)
Filtered
(2)
Filtered
IP66
(4X/12)
Not (1)
Filtered
(2)
Filtered
IP66
(4X/12)
0.37 (0.25) 0.5 (0.33) A B B A B B A – B
0.75 (0.55) 1 (0.75) A B B A B B A – B
1.5(1.1)2(1.5)BBBABBA–B
2.2(1.5)3(2)BBBBBBB–B
4(3)5(3)–CDBBBB–B
5.5 (4) 7.5 (5) – D D – C D C – D
7.5 (5.5) 10 (7.5) – D D – C D C – D
11 (7.5) 15 (10) – D D – D D D – D
15 (11) 20 (15) – E E – D D D – D
18.5 (15) 25 (20) – E E – D D D – D
22 (18.5) 30 (25) – – – – D D D – D
30 (22) 40 (30) – – – – E E – E E
37 (30) 50 (40) – – – – E E – E E
(1) Not Filtered indicated if Position 13 of the Catalog Number = N.
(2) Filtered indicated if Position 13 of the Catalog Number = A.
A
E
B
D
F
C
B
AC
D E
IP20/66 (NEMA/UL Type 1/4X/12) Flange Mount
Frame
Dimension Dimensions are in millimeters and (inches) Weight (1)
kg (lb)ABCDEF
IP20 / NEMA Type 1
A 122.4 (4.82) 225.7 (8.89) 179.8 (7.08) 94.2 (3.71) 211.6 (8.33) 5.8 (0.23) 2.71 (6.0)
B 171.7 (6.76) 234.6 (9.24) 179.8 (7.08) 122.7 (4.83) 220.2 (8.67) 5.8 (0.23) 3.60 (7.9)
C 185.0 (7.28) 300.0 (11.81) 179.8 (7.08) 137.6 (5.42) 285.6 (11.25) 5.8 (0.23) 6.89 (15.2)
D 219.9 (8.66) 350.0 (13.78) 179.8 (7.08) 169.0 (6.65) 335.6 (13.21) 5.8 (0.23) 9.25 (20.4)
E 280.3 (11.04) 555.8 (21.88) 207.1 (8.15) 200.0 (7.87) 491.0 (19.33) 6.9 (0.27) 18.60 (41.0)
IP66 / NEMA Type 4X/12
B 171.7 (6.76) 239.8 (9.44) 203.3 (8.00) 122.7 (4.83) 220.2 (8.67) 5.8 (0.23) 3.61 (8.0)
D 219.9 (8.66) 350.0 (13.78) 210.7 (8.29) 169.0 (6.65) 335.6 (13.21) 5.8 (0.23) 9.13 (20.1)
E 280.3 (11.04) 555.8 (21.88) 219.8 (8.65) 200.0 (7.87) 491.0 (19.33) 6.9 (0.27) 18.60 (41.0)
Flange Mount
A 156.0 (6.14) 225.8 (8.89) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 2.71 (6.0)
B 205.2 (8.08) 234.6 (9.24) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 3.60 (7.9)
C 219.0 (8.62) 300.0 (11.81) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 6.89 (15.2)
D 248.4 (9.78) 350.0 (13.78) 178.6 (7.03) 123.0 (4.84) 55.6 (2.19) – 9.25 (20.4)
E 280.3 (11.04) 555.8 (21.88) 207.1 (8.15) 117.2 (4.61) 89.9 (3.54) – 18.60 (41.0)
(1) Weights include Human Interface Module (HIM).