Allen-Bradley powerflex 700 User manual

PowerFlex 700 AC Drives – Frames 0…10
Vector Control Firmware 4.001 and Up
User Manual

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 can 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 can also be on or inside the equipment to provide specific precautions.
Allen-Bradley, DPI, DriveExplorer, DriveExecutive, Force Technology, PLC, PowerFlex, SCANport, 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 can 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 can be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage can be present.
BURN HAZARD: Labels can be on or inside the equipment, for example, a drive or motor, to alert people that surfaces can
reach dangerous temperatures.
ARC FLASH HAZARD: Labels can 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 20B-UM002G-EN-P - July 2014 3
Summary of Changes
The information below summarizes the changes to the PowerFlex 700 User
Manual, publication 20B-UM002 since the last release.
New and Updated
Information
Manual Updates
Description of New or Updated Information Page
Removed the product certifications and specifications from Appendix A. All certification and specification
information is located in the PowerFlex 700 Adjustable Frequency AC Drive Technical Data, publication 20B-
TD001.
N/A

4Rockwell Automation Publication 20B-UM002G-EN-P - July 2014
Summary of Changes
Notes:

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 5
Table of Contents
Preface Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ATEX Approved Drives & Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Numbered List View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Monitor File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor Control File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Speed Command File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Utility File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inputs & Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Applications File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pos/Spd Profile File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Parameter Cross Reference – by Number. . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Chapter 2
Troubleshooting
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Front Panel LED Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Precharge Board LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
HIM Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Fault Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Common Symptoms/Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Testpoint C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . odes and Functions 96
Appendix A
Supplemental Drive Information
Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Typical Programmable Controller Configurations . . . . . . . . . . . . . . 97

6Rockwell Automation Publication 20B-UM002G-EN-P - July 2014
Table of Contents
Appendix B
HIM Overview
External & Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removing/Installing the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Disconnecting the HIM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Reconnecting the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Parameter Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Device Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Memory Storage Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Start Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Preferences Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Viewing and Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
LCD HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Linking Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Establishing A Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Appendix C
Application Notes
Adjustable Voltage Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Enabling Adjustable Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
External Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Hand-Off-Auto (HOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Lifting/Torque Proving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TorqProve Manual Start Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Drive Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Installation/Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Lifting/Torque Proving Application Programming . . . . . . . . . . . . . 116
Limit Switches for Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Minimum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Motor Control Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Torque Producers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Torque Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Speed Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Motor DC Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Motor Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Motor Overload Memory Retention Per 2005 NEC. . . . . . . . . . . . . . . . 123
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Position Indexer/Speed Profiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Common Guidelines for all Step Types . . . . . . . . . . . . . . . . . . . . . . . . 124
Position Loop Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Profile Command Control Word . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Velocity Regulated Step Types and Parameters . . . . . . . . . . . . . . . . . 126
Position Regulated Step Types and Parameters . . . . . . . . . . . . . . . . . 127
Homing Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Example 1: Five Step Velocity Profile (Time-Based and Encoder-
Based) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Example 2: Six Step Velocity Profile (Digital Input-Based) . . . . . . 131

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 7
Table of Contents
Example 3: Five Step Positioner with Incremental Encoder . . . . . 132
Power Loss Ride Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Process PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
PI Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Reverse Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Sleep Wake Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Start At PowerUp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Stop Dwell Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Voltage Tolerance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Appendix D
Instructionsfor ATEXApprovedDrives
in Group II Category (2) G D
Applications with ATEX Approved
Motors
Motor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Drive Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Start-Up & Periodic Drive Testing Requirement . . . . . . . . . . . . . . . . . . 150
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Index

8Rockwell Automation Publication 20B-UM002G-EN-P - July 2014
Table of Contents

Rockwell Automation Publication 20B-UM002G-EN-P - July 2014 9
Preface
The purpose of this manual is to provide you with the basic information needed
to program and troubleshoot the PowerFlex 700 Adjustable Frequency AC Drive
with Vector Control.
Who Should Use this Manual? 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.
What Is Not in this Manual The PowerFlex 700 Series B User Manual provides programming and
troubleshooting information for the Vector Control drive, Frames 0…10.
Drive installation and wiring information is not in this manual, but can be found
in the Installation Instructions for your drive:
Frames 0…6 – publication 20B-IN019
Frames 7…10 – publication 20B-IN014
Literature is available online at http://www.rockwellautomation.com/literature.
Manual Conventions •In this manual we refer to the PowerFlex 700 Adjustable Frequency AC
Drive as; drive, PowerFlex 700 or PowerFlex 700 Drive.
•To help differentiate parameter names and LCD 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:
Topic Page
Who Should Use this Manual? 9
What Is Not in this Manual 9
Manual Conventions 9
Additional Resources 10
ATEX Approved Drives & Motors 10
Drive Frame Sizes 10
General Precautions 11
Catalog Number Explanation 13
Word Meaning Word Meaning
Can Possible, able to do something Shall Required and necessary
Cannot Not possible, not able to do something Should Recommended
May Permitted, allowed Should Not Not recommended
Must Unavoidable, you must do this

10 Rockwell Automation Publication 20B-UM002G-EN-P - July 2014
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
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.
ATEX Approved Drives &
Motors
For detailed information on using ATEX approved drives and motors, refer to
Appendix D.
Drive Frame Sizes Similar PowerFlex 700 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 the Catalog Number Explanation on
page 13.
Resource Description
PowerFlex 700 Standard Control User Manual, publication
20B-UM001
Provides detailed information on:
•Parameters and programming
•Faults, alarms, and troubleshooting
PowerFlex 700 AC Drive Technical Data, publication
20B-TD001
This publication provides detailed drive specifications,
option specifications and input protection device ratings.
PowerFlex Comm Adapter Manuals, publication
20COMM-UM…
These publications provide information on configuring,
using, and troubleshooting PowerFlex communication
adapters.
PowerFlex 70 and PowerFlex 700 Reference Manual,
publication PFLEX-RM001
These publications provide detailed application specific
information for programming and configuring the
PowerFlex 700 drive.
PowerFlex 70 Enhanced Control and PowerFlex 700 Vector
Control Reference Manual, publication PFLEX-RM004
Wiring and Grounding Guidelines for Pulse Width
Modulated (PWM) AC Drives, publication DRIVES-IN001
Provides basic information needed to properly wire and
ground PWM AC drives.
Safety Guidelines for the Application, Installation and
Maintenance of Solid State Control, publication SGI-1.1
Provides general guidelines for the application,
installation, and maintenance of solid-state control.
Guarding Against Electrostatic Damage, publication
8000-4.5.2
Provides practices for guarding against Electrostatic
damage (ESD)
Product Certifications website, http://ab.com Provides declarations of conformity, certificates, and
other certification details.