Rockwell Automation Allen-Bradley PowerFlex 700 B Series User manual

Adjustable Frequency AC Drive
Series B
Firmware Versions
4.001
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 Rockwell Automation sales office or www.rockwellautomation.com/literature)
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 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.
Important: Identifies information that is critical for successful application and
understanding of the product.
DriveExplorer, DriveExecutive, Force Technology and SCANport are trademarks of Rockwell Automation, Inc.
PowerFlex and PLC are registered trademarks of Rockwell Automation, Inc.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
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 the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.

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-4
Chapter 1 Installation/Wiring Opening the Cover . . . . . . . . . . . . . . . . . . 1-1
Mounting Considerations . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . 1-2
General Grounding Requirements . . . . . . 1-4
Fuses and Circuit Breakers . . . . . . . . . . . . 1-5
Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-5
Using Input/Output Contactors . . . . . . . . 1-12
Disconnecting MOVs and CM Capacitors 1-13
I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Reference Control . . . . . . . . . . . . . . . . . . 1-21
Auto/Manual Examples. . . . . . . . . . . . . . 1-22
Lifting/Torque Proving . . . . . . . . . . . . . . 1-23
Common Bus/Precharge Notes . . . . . . . . 1-23
EMC Instructions . . . . . . . . . . . . . . . . . . 1-24
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 . . . . . . . . . . . . . . . . . . . . . . . 3-7
Motor Control File . . . . . . . . . . . . . . . . . . 3-9
Speed Command File . . . . . . . . . . . . . . . 3-16
Dynamic Control File . . . . . . . . . . . . . . . 3-26
Utility File . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Communication File . . . . . . . . . . . . . . . . 3-46
Inputs & Outputs File . . . . . . . . . . . . . . . 3-51
Applications File . . . . . . . . . . . . . . . . . . . 3-59
Pos/Spd Profile File. . . . . . . . . . . . . . . . . 3-65
Parameter Cross Reference – by Name. . 3-72
Parameter Cross Reference – by Number 3-75
Chapter 4 Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . 4-1
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Manually Clearing Faults . . . . . . . . . . . . . 4-4
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-4
Clearing Alarms . . . . . . . . . . . . . . . . . . . . 4-9
Alarm Descriptions . . . . . . . . . . . . . . . . . 4-10
Common Symptoms/Corrective Actions 4-13
Testpoint Codes and Functions . . . . . . . . 4-16
Appendices See Next Page

ii Table of Contents
Appendix A Supplemental
Drive Information
Specifications. . . . . . . . . . . . . . . . . . . . . . . A-1
Communication Configurations . . . . . . . . A-5
Output Devices . . . . . . . . . . . . . . . . . . . . . A-8
Drive, Fuse & Circuit Breaker Ratings . . . A-8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . A-17
Frame Cross Reference . . . . . . . . . . . . . . A-27
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
Linking Parameters . . . . . . . . . . . . . . . . . . B-6
Removing/Installing the HIM . . . . . . . . . . B-8
Appendix C Application Notes Adjustable Voltage Operation . . . . . . . . . . C-1
External Brake Resistor . . . . . . . . . . . . . . . C-3
Lifting/Torque Proving . . . . . . . . . . . . . . . C-4
Limit Switches for Digital Inputs . . . . . . C-11
Minimum Speed . . . . . . . . . . . . . . . . . . . C-12
Motor Control Technology . . . . . . . . . . . C-12
Motor Overload . . . . . . . . . . . . . . . . . . . . C-14
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . C-16
Position Indexer/Speed Profiler. . . . . . . . C-17
Power Loss Ride Through . . . . . . . . . . . . C-27
Process PID . . . . . . . . . . . . . . . . . . . . . . . C-28
Reverse Speed Limit . . . . . . . . . . . . . . . . C-32
Skip Frequency . . . . . . . . . . . . . . . . . . . . C-33
Sleep Wake Mode . . . . . . . . . . . . . . . . . . C-35
Start At PowerUp. . . . . . . . . . . . . . . . . . . C-37
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . C-38
Voltage Tolerance . . . . . . . . . . . . . . . . . . C-42

Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 700
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.
The PowerFlex 700 User Manual is designed to provide only basic
start-up information. For detailed drive information, please refer to the
PowerFlex Reference Manual. The reference manual is included on the
CD supplied with your drive or is also available online at
http://www.rockwellautomation.com/literature.
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-4
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 700 information:
For Allen-Bradley Drives Technical Support:
•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:
Reference Materials
Title Publication Available Online at . . .
Wiring and Grounding Guidelines
for PWM AC Drives
DRIVES-IN001…
www.rockwellautomation.com/
literature
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-TD001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
100-2.10
Guarding Against Electrostatic
Damage
8000-4.5.2
Title Publication Available . . .
PowerFlex
Reference Manual
PFLEX-RM001… on the CD supplied with the drive or at
www.rockwellautomation.com/literature
Title Online at . . .
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives
Manual Conventions
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended

Overview P-3
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
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 & –DC
terminals of the Power Terminal Block (refer to Chapter 1 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: An incorrectly applied or installed bypass system can
result in component damage or reduction in product life. The most
common causes are:
•Wiring AC line to drive output or control terminals.
•Improper bypass or output circuits not approved by Allen-Bradley.
•Output circuits which do not connect directly to the motor.
Contact Allen-Bradley for assistance with application or wiring.

P-4 Overview
The PowerFlex 700 catalog numbering scheme is shown on page P-5.
!
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.
Important: These faults are not instantaneous. Test results have
shown that they can take between 2-12 seconds to
occur.
!
ATTENTION: Loss of control in suspended load applications can
cause personal injury and/or equipment damage. Loads must always be
controlled by the drive or a mechanical brake. Parameters 600-611 are
designed for lifting/torque proving applications. It is the responsibility
of the engineer and/or end user to configure drive parameters, test any
lifting functionality and meet safety requirements in accordance with all
applicable codes and standards.
Catalog Number Explanation

Overview P-5
Code Control I/O Volts
CVector
➎24V DC/AC
DVector
➎115V AC
Code Version
C ControlNet (Coax)
DDeviceNet
E EtherNet/IP
RRIO
SRS-485
NNone
Code Operator Interface
0 Blank Cover
2 Digital LCD
3 Full Numeric LCD
4 Analog LCD
5 Prog. Only LCD Code w/Resistor
YYes
➊
NNo
Code CE FilterCM Choke
AYesYes
BYesNo
Code Type
0 None
1 Encoder, 12V
Code Enclosure
A Panel Mount - IP 20 (NEMA Type 1)
F Flange Mount - Front = Open Style,
Back = IP 54 (NEMA Type 12)
G Panel Mount (Stand-Aone) - IP 54 (NEMA Type 12)
Code w/Brake IGBT➋
YYes
NNo
➊Not available for Frame 3 drives or larger.
➋Brake IGBT is standard on Frames 0-3 and optional on Frames 4-6.
➌Note: CE Certification testing has not been performed on 600V class drives.
➍Frames 5 & 6 Only.
➎DPI Only.
➏Must be used with option C or D (position 15). Positions 17-20 are only required
when custom firmware is supplied.
➐Positions 16-20 of the catalog number are not applicable for Canada. These
options (positions 16-20) are only available as User Installed in Canada
Code Type
A User Manual
N No Manual
Code Type
20B 700
400V 60Hz Input
400V
Code Amps kW
1P3 1.3 0.37
2P1 2.1 0.75
3P5 3.5 1.5
5P0 5.0 2.2
8P7 8.7 4.0
011 11.5 5.5
015 15.4 7.5
022 22 11
030 30 15
037 37 18.5
043 43 22
056 56 30
072 72 37
085 85 45
105 105 55
125 125 55
140 140 75
170 170 90
205 205 110
260 260 132
600V 60Hz Input➌
600V
Code Amps HP
1P7 1.7 1.0
2P7 2.7 2.0
3P9 3.9 3.0
6P1 6.1 5.0
9P0 9.0 7.5
011 11 10
017 17 15
022 22 20
027 27 25
032 32 30
041 41 40
052 52 50
062 62 60
077 77 75
099 99 100
125 125 125
144 144 150
208/240V 60Hz Input
208V 240V
Code Amps Amps HP
2P2 2.5 2.2 0.5
4P2 4.8 4.2 1.0
6P8 7.8 6.8 2.0
9P6 11 9.6 3.0
015 17.5 15.3 5.0
022 25.3 22 7.5
028 32.2 28 10
042 48.3 42 15
052 56 52 20
070 78.2 70 25
080 92 80 30
104 120 104 40
130 130 130 50
154 177 154 60
192 221 192 75
260 260 260 100
690V 60Hz Input
690V
Code Amps kW
052 52 45
060 60 55
082 82 75
098 98 90
119 119 110
142 142 132
480V 60Hz Input
480V
Code Amps HP)
1P1 1.1 0.5
2P1 2.1 1.0
3P4 3.4 2.0
5P0 5.0 3.0
8P0 8.0 5.0
011 11 7.5
014 14 10
022 22 15
027 27 20
034 34 25
040 40 30
052 52 40
065 65 50
077 77 60
096 96 75
125 125 100
156 156 125
180 180 150
248 248 200
Code Type
AD➏60Hz Maximum
Position
1-3 4 5-7 8 9 10 11 12 13 14 15 16➐17-18➐19-20➐
20B D 2P1 A 3 A Y N A R C 0 NN AD
Drive Voltage Rating Rating Enclosure HIM Documentation Brake Brake Resistor Emission Comm Slot I/O Feedback Future
Use
Custom
Firmware
Code Vol ta ge Ph. Prechg.
B240VAC3–
C400VAC3–
D480VAC3–
E600VAC
➌3–
F690VAC
➍3–
H540VDC
➍–N
J650VDC
➍–N
N325VDC
➍–Y
P540VDC
➍–Y
R650VDC
➍–Y
T810VDC
➍–Y
W932VDC
➍–Y

P-6 Overview
Notes: