Allen-Bradley PowerFlex 70 User manual

Adjustable
Frequency AC
Drive
User Manual
www.abpowerflex.com

Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “ Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls ” (Publication SGI-1.1 available from
your local Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi )
describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also
because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each intended
application of this equipment is acceptable.
In no event will the Allen-Bradley Company be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
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, the Allen-Bradley Company cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
!
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss.
Shock Hazard labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the drive to alert
people that surfaces may be at dangerous temperatures.

Summary of Changes
The information below summarizes the changes to the PowerFlex 70
User Manual since the last release.
Description of New or Updated Information See Page(s)
Speed Reference Selection Chart clarified. 1-15
Drive, Fuse & Circuit Breaker Ratings information updated A-1 – A-4

soc-2

Table of Contents
Preface
Overview
Who Should Use this Manual? . . . . . . . . . P-1
What Is Not in this Manual . . . . . . . . . . . . P-1
Reference Materials. . . . . . . . . . . . . . . . . . P-2
Manual Conventions . . . . . . . . . . . . . . . . . P-2
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-3
General Precautions. . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-5
Chapter 1
Installation/Wiring
Opening the Cover. . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . 1-3
General Grounding Requirements. . . . . . . 1-4
Fuses and Circuit Breakers . . . . . . . . . . . . 1-5
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . 1-6
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Speed Reference Control. . . . . . . . . . . . . 1-15
Auto/Manual Examples. . . . . . . . . . . . . . 1-16
Disconnecting MOVs and
Common Mode Capacitors . . . . . . . . . . . 1-18
EMC Instructions . . . . . . . . . . . . . . . . . . 1-19
Chapter 2
Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Status Indicators . . . . . . . . . . . . . . . . . . . . 2-2
Start-Up Routines . . . . . . . . . . . . . . . . . . . 2-3
Running S.M.A.R.T. Start . . . . . . . . . . . . . 2-4
Running an Assisted Start Up . . . . . . . . . . 2-4
Chapter 3
Programming
and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
How Parameters are Organized . . . . . . . . . 3-3
Monitor File (File A) . . . . . . . . . . . . . . . . . 3-8
Motor Control File (File B) . . . . . . . . . . . . 3-9
Speed Command File (File C). . . . . . . . . 3-12
Dynamic Control File (File D) . . . . . . . . 3-17
Utility File (File E) . . . . . . . . . . . . . . . . . 3-21
Communication File (File H) . . . . . . . . . 3-29
Inputs & Outputs File (File J) . . . . . . . . . 3-33
Parameter Cross Reference – by Name. . 3-37
Parameter Cross Reference – by Number 3-39
Chapter 4
Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . 4-1
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Manually Clearing Faults . . . . . . . . . . . . . 4-3
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Clearing Alarms. . . . . . . . . . . . . . . . . . . . . 4-7
Alarm Descriptions . . . . . . . . . . . . . . . . . . 4-7
Testpoint Codes and Functions . . . . . . . . 4-10
Common Symptoms . . . . . . . . . . . . . . . . 4-10
Appendix A
Supplemental Drive Information
Output Devices . . . . . . . . . . . . . . . . . . . . . A-1
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Appendix B
HIM Overview
External and Internal Connections . . . . . . B-1
LCD Display Elements . . . . . . . . . . . . . . . B-2
ALT Functions. . . . . . . . . . . . . . . . . . . . . . B-2
Menu Structure . . . . . . . . . . . . . . . . . . . . . B-3
Viewing and Editing Parameters . . . . . . . . B-5
Removing the HIM . . . . . . . . . . . . . . . . . . B-7
Index

ii

Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 70 Adjustable
Frequency AC Drive.
This manual is intended for qualified personnel. 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.
Since this User Manual is designed to provide only basic start-up
information, the following topics have not been included:
• Specifications
• Mounting Dimensions
• Spare Parts Information
Please refer to the PowerFlex Reference Manual for detailed drive
information. The reference manual is included on the CD supplied with
your drive or is also available online at http://www.ab.com/manuals .
For information on… See page…
Who Should Use this Manual? P-1
What Is Not in this Manual P-1
Reference Materials P-2
Manual Conventions P-2
Drive Frame Sizes P-3
General Precautions P-3
Catalog Number Explanation P-5
Who Should Use this Manual?
What Is Not in this Manual

P-2 Overview
The following manuals are recommended for general drive information:
For detailed PowerFlex 70 information including mounting dimensions
and specifications:
• 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 display text from other
text, the following conventions will be used:
– Parameter Names will appear in [brackets].
For example: [DC Bus Voltage].
– Display Text will appear in “quotes.” For example: “Enabled.”
• The following words are used throughout the manual to describe an
action:
Reference Materials
Title Publication Available Online at …
Industrial Automation Wiring
and Grounding Guidelines
1770-4.1
(1)
(1)
Not available online, contact your local Allen-Bradley Sales Office.
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-SB001A-EN-E
www.ab.com/manuals/dr
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
www.ab.com/manuals/gi
A Global Reference Guide for
Reading Schematic Diagrams
0100-2.10
(1)
Guarding Against Electrostatic
Damage
8000-4.5.2
www.ab.com/manuals/gi
Title Publication Available …
PowerFlex Reference
Manual
PFLEX-RM001A-EN-E on the CD supplied with the drive
or at
www.ab.com/manuals/dr
Manual Conventions
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Shall Required and necessary
Should Recommended
Should Not Not Recommended

Overview P-3
Similar PowerFlex 70 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame size is provided in
Appendix A.
Drive Frame Sizes
General Precautions
!
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 A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
!
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: 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.
!
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 Figure 1.3 on
page 1-9 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: A risk of injury or equipment damage exists in
firmware version 1.011 and earlier. When there is a combination of long
shielded motor cables, high source impedance, low speed, light motor
load and parameter 190 [Direction Mode] is set to “Unipolar” or
“Bipolar,” an unexpected change in motor direction may occur. If these
conditions exist, choose one of the following corrective actions:
• Set parameter 190 to “Reverse Dis”
• Set parameters 161 and 162 to “Disabled”
• Install a properly sized Dynamic Brake resistor

P-4 Overview
!
ATTENTION: Nuisance tripping may occur in firmware version
1.011 and earlier due to unstable currents. When using a motor that is
connected for a voltage that is different from the drive (e.g., using a
230V connected motor with a 460V drive) the following adjustment
must be made to “Stability Gain” 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 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.
Motor Nameplate Voltage
Drive Rated Voltage
---------------------------------------------------------------128×