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×

Overview
P-5
Catalog Number Explanation
Code Voltage Ph. Type
A 240V AC 1 SA
B 240V AC 3 SA
C 400V AC 3 SA
D 480V AC 3 SA
E 600V AC 3 SA
Code Version
C ControlNet (Coax)
D DeviceNet
F ControlNet (Fiber)
H RS485 HVAC
I Interbus
L LonWorks
P Profibus DPV1
R RIO
S RS485 DF-1
N N/A
Code Interface Module
0 Blank HIM
1 Digital LED HIM
2 Digital LCD HIM
3 Full Numeric LCD HIM
4 Analog LCD HIM
5 Prog. Only LCD HIM
Code w/Brake Resistor
YYes
NNo
Code Enclosure
A Panel Mount - IP 20 (NEMA Type 1)
F Flange Mount - IP 20 (NEMA Type 1) Chassis, IP66 (NEMA Type 4x/12) Heatsink
Code w/Brake IGBT
YYes
20A B 2P1 A 1 A Y Y N N N N
Drive Voltage Rating Rating Enclosure HIM Documentation Brake IGBT Brake Resistor Emission Class Comm Slot
Output Current @ 480V 60Hz Input
Code Amps kW (HP)
1P1 1.1 0.37 (0.5)
2P1 2.1 0.75 (1.0)
3P4 3.4 1.5 (2.0)
5P0 5.0 2.2 (3.0)
8P0 8.0 3.7 (5.0)
011 11 5.5 (7.5)
014 14 7.5 (10)
022 22 11 (15)
027 27 15 (20)
Code Type
A User Manual
N No Manual
Code Rating
A Filtered
A(1) & B Frames (Optional)
C & D Frames (Standard)
N Not Filtered
A & B Frames (Optional)
C & D Frames NA (Code A only)
(1)Increases A Frame size to B
Output Current @ 240V 60Hz Input
Code Amps kW (HP)
2P2 2.2 0.37 (0.5)
4P2 4.2 0.75 (1.0)
6P8 6.8 1.5 (2.0)
9P6 9.6 2.2 (3.0)
015 15.3 4.0 (5.0)
022 22 5.5 (7.5)
028 28 7.5 (10)
Output Current @ 400V 50Hz Input
Code Amps kW (HP)
1P3 1.3 0.37 (0.5)
2P1 2.1 0.75 (1.0)
3P5 3.5 1.5 (2.0)
5P0 5.0 2.2 (3.0)
8P7 8.7 4.0 (5.0)
011 11.5 5.5 (7.5)
015 15.4 7.5 (10)
022 22 11 (15)
030 30 15 (20)
Output Current @ 208V 60Hz Input
Code Amps kW (HP)
2P2 2.5 0.37 (0.5)
4P2 4.8 0.75 (1.0)
6P8 7.8 1.5 (2.0)
9P6 11 2.2 (3.0)
015 17.5 4.0 (5.0)
022 25.3 5.5 (7.5)
028 32.2 7.5 (10)
Output Current @ 600V 60Hz Input
Code Amps kW (HP)
0P9 0.9 0.37 (0.5)
1P7 1.7 0.75 (1.0)
2P7 2.7 1.5 (2.0)
3P9 3.9 2.2 (3.0)
6P1 6.1 4.0 (5.0)
9P0 9.0 5.5 (7.5)
011 11 7.5 (10)
017 17 11 (15)
022 22 15 (20)
Code Type
20A 70
20B 700

P-6 Overview
Notes:

Chapter
1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 70 Drive.
Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
IP 20 (NEMA Type 1)
For information on… See page For information on… See page
Opening the Cover 1-1 Power Wiring 1-6
Mounting Considerations 1-2 I/O Wiring 1-10
AC Supply Source Considerations 1-3 Speed Reference Control 1-15
General Grounding Requirements 1-4 Disconnecting MOVs and
Common Mode Capacitors
1-18
Fuses and Circuit Breakers 1-5 EMC Instructions 1-19
!
ATTENTION: The following information is merely a guide for proper
installation. The Allen-Bradley Company cannot assume responsibility
for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.
Opening the Cover
1. Loosen cover screw. 2. Pull cover straight off chassis to
avoid damaging connector pins.

1-2 Installation/Wiring
Ambient Operating Temperatures
PowerFlex 70 drives are designed to operate at 0° to 50°C ambient.
Important: Removing the adhesive label from the drive changes the
enclosure rating from Type 1 Enclosed to Open Type.
Minimum Mounting Clearances
(1)
(1)
Minimum mounting clearances apply to both panel mount and flange mount
enclosures.
Mounting Considerations
152.4 mm
(6.0 in.)
152.4 mm
(6.0 in.)
38.1 mm
(1.5 in.)
19.0 mm
(0.75 in.)
Refer to the PowerFlex Reference
Manual for detailed dimension
information.

Installation/Wiring 1-3
PowerFlex 70 drives are suitable for use on a circuit capable of
delivering up to a maximum of 200,000 rms symmetrical amperes, and a
maximum of 600 volts.
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Unbalanced or Ungrounded Distribution Systems
If phase to ground voltage will exceed 125% of normal line to line
voltage or the supply system is ungrounded, refer to the PowerFlex
Reference Manual .
Input Power Conditioning
If any of the following conditions exist, refer to the PowerFlex Reference
Manual .
• Frequent power outages
• Ungrounded AC supply source
• Facility has power factor correction capacitors
• Input voltage variations that:
– Exceed drive operating specifications
– Cause rapid increases in drive bus voltage (See also Attention
statement on page Preface-4.)
AC Supply Source Considerations
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in Appendix A.
!
ATTENTION: PowerFlex 70 drives contain protective MOVs and
common mode capacitors that are referenced to ground. These devices
should be disconnected if the drive is installed on an ungrounded
distribution system. See page 1-18 for jumper locations.

1-4 Installation/Wiring
If the supply system is grounded, the drive Safety Ground - PE must be
connected to system ground. Ground impedance must conform to the
requirements of national and local industrial safety regulations and/or
electrical codes. The integrity of all ground connections should be
periodically checked.
For installations within a cabinet, a single safety ground point or ground
bus bar connected directly to building steel should be used. All circuits
including the AC input ground conductor should be grounded
independently and directly to this point/bar.
Figure 1.1 Typical Grounding
Safety Ground - PE
This is the safety ground for the drive that is required by code. This point
must be connected to adjacent building steel (girder, joist), a floor
ground rod or bus bar (see above). Grounding points must comply with
national and local industrial safety regulations and/or electrical codes.
Shield Termination - SHLD
The SHLD terminal located on the Cable Entry Plate provides a
grounding point for the motor cable shield. Refer to Figure 1.2 on
page 1-8 for location. The motor cable shield connected to this terminal
on the Cable Entry Plate (drive end) should also be connected to the
motor frame (motor end). Use a shield terminating or EMI clamp to
connect shield to this terminal.
When shielded cable is used for control and signal wiring , the shield
should be grounded at the source end only, not at the drive end.
General Grounding Requirements
U (T1)
V (T2)
W (T3)
R (L1)
S (L2)
T (L3)
PE
SHLD

Installation/Wiring 1-5
RFI Filter Grounding
Using an optional external RFI filter may result in relatively high ground
leakage currents. Therefore, the filter must only be used in
installations with grounded AC supply systems and be permanently
installed and solidly grounded (bonded) to the building power
distribution ground. Ensure that the incoming supply neutral is solidly
connected (bonded) to the same building power distribution ground.
Grounding must not rely on flexible cables and should not include any
form of plug or socket that would permit inadvertent disconnection.
Some local codes may require redundant ground connections. The
integrity of all connections should be periodically checked. Refer to the
instructions supplied with the filter
.
The PowerFlex 70 can be installed with either input fuses or an input
circuit breaker. National and local industrial safety regulations and/or
electrical codes may determine additional requirements for these
installations. Refer to Appendix A for recommended fuses/circuit
breakers.
Fuses and Circuit Breakers
!
ATTENTION: The PowerFlex 70 does not provide branch short
circuit protection. Specifications for the recommended fuse or circuit
breaker to provide protection against short circuits are provided in
Appendix A.

1-6 Installation/Wiring
Cable Types Acceptable for 200-600 Volt Installations
General
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than or equal to 15 mils (0.4 mm/0.015 in.).
UL installations in 50°C ambient must use 600V, 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas . Any wire chosen must have a minimum insulation thickness of 15
Mils and should not have large variations in insulation concentricity.
Shielded
Power Wiring
!
ATTENTION: National Codes and standards (NEC, VDE, BSI etc.)
and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
Location Rating/Type Description
Standard
(Option 1)
600V, 90°C (194°F)
RHH/RHW-2
Belden 29501-29507 or
equivalent
• Four tinned copper conductors with XLPE insulation
• Foil shield and tinned copper drain wire with 85% braid
coverage
• PVC jacket
Standard
(Option 2)
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
Shawflex 2ACD/3ACD or
equivalent
• Three tinned copper conductors with XLPE insulation
• 5 mil single helical copper tape (25% overlap min.)
with three bare copper grounds in contact with shield
• PVC jacket
Class I & II;
Division I & II
Tray rated 600V, 90°C
(194°F) RHH/RHW-2
• Three bare copper conductors with XLPE insulation
with impervious corrugated continuously welded
aluminum armor
• Black sunlight resistant PVC jacket overall
• Three copper grounds on #10 AWG and smaller

Installation/Wiring 1-7
EMC Compliance
Refer to EMC Instructions on page 1-19 for details.
Cable Trays and Conduit
If cable trays or large conduits are to be used, refer to guidelines
presented in the PowerFlex Reference Manual .
Motor Cable Lengths
Typically, motor lead lengths less than 30 meters (approximately 100
feet) are acceptable. However, if your application dictates longer lengths,
refer to the PowerFlex Reference Manual for details.
!
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” motor leads.

1-8 Installation/Wiring
Power Terminal Block
Figure 1.2 Typical Power Terminal Block Location (B Frame Shown)
Table 1.A Power Terminal Block Specifications
Table 1.B Wire Routing Recommendations
No. Name Description Frame
Wire Size Range
(1)
(1)
Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Torque Maximum Minimum
➊
Power Terminal
Block
Input power and
motor connections
A, B,
& C
3.5 mm
2
(12 AWG)
0.3 mm
2
(22 AWG)
0.6 N-m
(5 lb.-in.)
D 8.4 mm
2
(8 AWG)
0.8 mm
2
(18 AWG)
1.4 N-m
(12 lb.-in.)
➋
SHLD terminal Terminating point
for wiring shields
All ——1.6 N-m
(14 lb.-in.)
No. Description
➌
Suggested entry for incoming line wiring.
➍
Suggested entry for motor wiring.
➊
➋
➌➍