Allen-Bradley PowerFlex 70 User manual

User Manual
PowerFlex 70 Adjustable Frequency AC Drives
Standard Control Firmware, Revision 2.xxx
Enhanced Control Firmware, Revision 2.xxx…4.xxx

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
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.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 3
Summary of Changes
The information below summarizes the changes to this PowerFlex® 70 Adjustable
Frequency AC Drives User Manual since the May 2009 release.
Parameter Updates The following parameters have been added or updated.
Additional Manual Updates The following information has been added, removed, or updated.
Description of New or Updated Parameters Page
Parameter 007 [Output Power] 22
Parameter 054 [Maximum Voltage] 25
Parameter 427 [Torque Ref A Sel] 28
Parameter 090 [Speed Ref A Sel] 33
Parameter 096 [TB Man Ref Sel] 34
Parameter 175 [Auto Rstrt Delay] 46
Parameter 213 [Speed Ref Source] 54
Parameter 238 [Fault Config 1] 58
Parameters 361…366 [Digital InxSel] 68
Description of New or Updated Information Page
Removed Chapter 1, Installation/Wiring.All installation and wiring information is now in
the PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions, publication
20A-IN009.
–
Removed Chapter 2, Startup Information. All startup information is now in the PowerFlex
70 Adjustable Frequency AC Drive Installation Instructions, publication 20A-IN009. –
Updated the Catalog Number Explanation options 11
Updates and additions to fault descriptions:
Cntl Bd Overtemp (55) 79
DB Resistance (69) 79
Encoder Quad Err (90) 79
Hardware Fault (93) 79
Fatal Faults (900…930) 80
Ground Fault (13) 80
Heatsink LowTemp (10) 80
Output PhaseLoss (21) 80
Power Down Csum (112) 81
Power Unit (70) 81
Fault Cross Reference 82
Updated EPRI/SEMIF 47 certification 89
Added information for Korean KC Registration certification 89
Added information for Drive to motor power ratio 91
Updated information for Motor overload protection 92
Added footnote 2 for information regarding watts loss with certain drives 93
Removed dimensions and fuse/breaker information. All dimensions and fuse/breaker
information is now in the PowerFlex 70 Adjustable Frequency AC Drive Installation
Instructions, publication 20A-IN009.
–

4Rockwell Automation Publication 20A-UM001N-EN-P - July 2013
Summary of Changes
Notes:

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 5
Table of Contents
Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Catalog Number Explanation (continued) . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Monitor File (file A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor Control File (file B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Speed Command File (file C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Dynamic Control File (file D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Utility File (file E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Communication File (file H). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Inputs and Outputs File (file J). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Applications File (file K). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Chapter 2
Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Testpoint Codes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . 86
Appendix A
Supplemental Drive Information
Certifications and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Appendix B
HIM Overview
External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removing the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Viewing and Editing Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6Rockwell Automation Publication 20A-UM001N-EN-P - July 2013
Table of Contents
Appendix C
Application Notes
External Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Skip Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Motor Overload Memory Retention Per 2005 NEC. . . . . . . . . . . . . . . . 115
Start At Powerup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Speed Reference Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Auto/Manual Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Process PI for Standard Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Voltage Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 7
Preface
The purpose of this manual is to provide you with the basic information needed
to program and troubleshoot the PowerFlex 70 Adjustable Frequency AC Drive.
About This Publication This manual is intended for qualified pJulyersonnel. You must be able to program
and operate Adjustable Frequency AC Drive devices. In addition, you must have
an understanding of the parameter settings and functions.
What Is Not in This
Publication
This manual provides basic start-up, programming, and troubleshooting
information; it does not include information for mounting, wiring, and installing
the drive. For installation instructions, refer to the PowerFlex 70 Adjustable
Frequency AC Drive Installation Instructions, publication 20A-IN009. For
detailed drive information, refer to the PowerFlex Reference Manuals,
publications PFLEX-RM001 and PFLEX-RM004.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Topic Page
About This Publication 7
What Is Not in This Publication 7
Additional Resources 7
Manual Conventions 8
Drive Frame Sizes 8
General Precautions 9
Catalog Number Explanation 11
Catalog Number Explanation (continued) 12
Resource Description
PowerFlex 70 Adjustable Frequency AC Drive Installation
Instructions, publication 20A-IN009 Provides the five basic steps needed to install and
perform a basic startup of the PowerFlex 70 drive.
PowerFlex 70 and 700 Reference Manual - Vol. 1,
publication PFLEX-RM001 Provides detailed information for specifications and dimensions, operation, and dynamic brake selection for
the drive.
PowerFlex 70 Enhanced Control and 700 Vector Control
Reference Manual, publication PFLEX-RM004 Provides detailed drive information including operation, parameter descriptions, and programming.
DriveGuard Safe-Off Option (Series B) for PowerFlex 40P and
PowerFlex 70 AC Drives, publication PFLEX-UM003 Provides information for the installation and operation
of the DriveGuard Safe Torque Off option.
PowerFlex Comm Adapter Manuals, publication
20COMM-UM Provides information for the installation and operation of the various communication protocol adapters
available for the drive.
PowerFlex Dynamic Braking Resistor Calculator Application
Technique, publication PFLEX-AT001 Provided information for determining dynamic braking
requirements and evaluating resistors for dynamic
braking.
Wiringand GroundingGuidelines forPulse WidthModulated
(PWM) AC Drives, publication DRIVES-IN001 Provides the basic information needed to properly wire and ground Pulse Width Modulated (PWM) AC drives.

8Rockwell Automation Publication 20A-UM001N-EN-P - July 2013
Preface
You can view or download publications at
http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
For Allen-Bradley® drives technical support, see Rockwell Automation Support
on the back cover of this manual.
Manual Conventions In this manual we refer to the PowerFlex 70 Adjustable Frequency AC Drive as;
drive, PowerFlex 70 or PowerFlex 70 Drive.
To help differentiate parameter names and Liquid Crystal Display (LCD) text
from other text, the following conventions are used:
•Parameter Names appear in [brackets].
For example: [DC Bus Voltage].
•Display Text appears in “quotes.” For example: “Enabled.”
Drive Frame Sizes Similar PowerFlex 70 drive sizes are grouped into frame sizes to simplify spare
parts ordering, dimensioning, and so on. A cross reference of drive catalog
numbers and their respective frame size is provided in Appendix A.
Industry Installation Guidelines for Pulse Width Modulated
(PWM) AC Drives Application Technique,
publication DRIVES-AT003
Provides basic information for enclosure systems and
environmental/location considerations (to help protect
against environmental contaminants), and power and
grounding considerations needed to properly install AC
drives.
Preventive Maintenance of Industrial Control and Drive
System Equipment, publication DRIVES-TD001 Provides a checklist to use as a guide for performing
preventive maintenance on industrial control and drive
systems.
Safety Guidelines for the Application, Installation and
Maintenance of Solid State Controls, publication SGI-1.1 Describes some important differences between
solid-state equipment and hard-wired
electromechanical devices
A Global Reference Guide for Reading Schematic Diagrams,
publication 100-2.10 Provides a simple cross-reference of common
schematic/wiring diagram symbols that are used in
various parts of the world.
Guarding Against Electrostatic Damage,
publication 8000-4.5.2 This data sheet explains the causes of electrostatic damage (ESD), and how you can guard against its
effects.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
other certification details.
Resource Description

Rockwell Automation Publication 20A-UM001N-EN-P - July 2013 9
Preface
General Precautions Qualified Personnel
Personal Safety
Product Safety
ATTENTION: Allow only qualified personnel familiar with adjustable frequency
AC drives and associated machinery to plan or implement the installation,
start-up and subsequent maintenance of the system. Failure to comply can
result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the
bus capacitors has discharged before performing any work on the drive.
Measure the DC bus voltage at the +DC terminal of the Power Terminal Block
and the -DC test point (refer to PowerFlex 70 Adjustable Frequency AC Drive
Installation Instructions, publication 20A-IN009 for locations). 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 can 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 can result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference A-B publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” 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 to start and
stop the motor. If an input device is used, operation must not exceed one cycle
per minute or drive damage can occur.

10 Rockwell Automation Publication 20A-UM001N-EN-P - July 2013
Preface
Output Contactor Precaution
ATTENTION: Nuisance tripping can occur in Standard Control firmware revision
1.011 and earlier due to unstable currents. When using a motor that is
connected for a voltage that is different from the drive (for example, by using a
230V connected motor with a 460V drive) the following adjustment must be
made to “Stability Gain” by using DriveExplorer software and a personal
computer.
Any adjustment made to “Stability Gain” must be manually restored if the drive
is reset to defaults or is replaced.
If unstable currents are still present after making the adjustment, contact the
factory for assistance.
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 can cause a fault; however, it can also
cause either of the following two conditions to occur.
•Fast positive changes in input voltage (more than a 10% increase within 6
minutes) can cause uncommanded positive speed changes; however an F25
“OverSpeed Limit” fault occurs if the speed reaches P82 [Max Speed] + P83
[Overspeed Limit]. If this condition is unacceptable. Take action 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 [Bus Reg Mode A] and 162 [Bus
Reg Mode B]).
•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 [Bus Reg Mode A] and 162 [Bus
Reg Mode B]). In addition, installing a properly sized dynamic brake resistor
provides 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 can 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 is removed from the respective motor, but the drive
continues 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 can cause the drive to fault. If any of these conditions are
determined to be undesirable or unsafe, wire an auxiliary contact on the output
contactor to a drive digital input that is programmed as “Enable.” This causes the
drive to execute a coast-to-stop (cease output) whenever an output contactor is
opened.
Motor Nameplate Voltage
Drive Rated Voltage
---------------------------------------------------------------128×