Rockwell Automation Allen-Bradley PowerFlex 700 Series User manual

Migration Guide
PowerFlex 700 Drives to PowerFlex 750-Series Drives
Catalog Numbers XXX XXX XXXX XXX XXX XXX
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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 online at http://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.
Allen-Bradley, ControlNet, DeviceLogix, DeviceNet, PowerFlex, Rockwell Automation, Rockwell Software, RSLogix, 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
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010 3
Table of Contents
Preface Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive Selection Considerations Available Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hardware Drive Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PowerFlex Drive Conversion Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Terminal Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PowerFlex 700 Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PowerFlex 750-Series Drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control Terminal Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Input/Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
PowerFlex 700 Drives I/O Cassette Terminals. . . . . . . . . . . . . . . . . . 39
PowerFlex 753 Drives Main Control Board I/O . . . . . . . . . . . . . . . . 42
PowerFlex 755 Drives Main Control Board I/O . . . . . . . . . . . . . . . . 43
PowerFlex 750-Series Option Module. . . . . . . . . . . . . . . . . . . . . . . . . . 44
PowerFlex Drive Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Analog Speed Follower and
Preset Speed
Drive Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Analog Speed Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Three-wire Control with Analog Speed Reference. . . . . . . . . . . . . . . 51
Three-wire Control Parameter Comparison . . . . . . . . . . . . . . . . . . . . .53
Two-wire Control with Analog Input Speed Reference . . . . . . . . . . 55
Two-wire Control Parameter Comparison . . . . . . . . . . . . . . . . . . . . . .57
Two-wire Control with Preset Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Two-wire Control Parameter Comparison . . . . . . . . . . . . . . . . . . . . . .60
Preset Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Network Communications Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
20-COMM Carrier Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PowerFlex 750-Series Communication Options. . . . . . . . . . . . . . . . . 64
PowerFlex 755 Embedded EtherNet/IP Adapter. . . . . . . . . . . . . . . . 65
Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Velocity Reference/Feedback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Using the I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
16 Bit-based Processors (PLC5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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Table of Contents
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Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010 5
Preface
Overview
The purpose of this publication is to assist in migrating a PowerFlex 700 drive to a
PowerFlex 750-Series drive. This publication is broken into three chapters:
•Chapter 1: Drive Selection Considerations
Compares the features of the PowerFlex 750-Series drives to the PowerFlex
700 drive.
•Chapter 2: Analog Speed Follower and Preset Speed
The control wiring and parameters of the PowerFlex 700 drive analog
speed follower are compared to the PowerFlex 753 drive (with main
control board I/O) and the PowerFlex 755 drive (with optional I/O
module).
•Chapter 3: Network Communications
What PowerFlex 700 20-COMM network options can be migrated to the
PowerFlex 750-Series drives are addressed, as well as the dedicated
communications in the PowerFlex 750-Series drives.
Additional Resources
These documents contain additional information concerning related Rockwell
Automation products.
You can view or download publications at http://www.rockwellautomation.com/
literature/. To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
Resource Description
PowerFlex 700 AC Drives Vector Control Firmware 4.001 & Up,
Frames 0…10 User Manual, publication 20B-UM002 Provides information on how to install, start-up and troubleshoot the PowerFlex 700
adjustable frequency AC drives with vector control.
PowerFlex 750-Series AC Drives Technical Data, publication
750-TD001 Provides technical data regarding the PowerFlex 750-Series adjustable frequency AC drives for a variety of industrial applications.
PowerFlex 750-Series AC Drives Installation Instructions,
publication 750-IN001 Provides information on how to install, start-up, and troubleshoot PowerFlex 750-Series adjustable frequency AC drives.
PowerFlex 750-Series AC Drives Programming Manual,
publication 750-PM001 Provides information on how to program the PowerFlex 750-Series adjustable frequency AC drives.
PowerFlex 755 Drive Embedded EtherNet/IP Adaptor User
Manual, publication 750COM-UM001 Provides network communication information for the EtherNet/IP adaptor embedded
on the main control board in PowerFlex 755 drives.
PowerFlex 750-Series Drive DeviceNet Option Module User
Manual, publication 750COM-UM002 Provides network communication information for the optional 20-750-DNET module
that can be installed in a PowerFlex 750-Series drive.
PowerFlex 20-750-CNETC Coaxial ControlNet Option Module
User Manual, publication 750COM-UM003 Provides network communication information for the optional 20-750-CNETC module that can be installed in a PowerFlex 750-Series drive.
20-Comm-E EtherNet/IP Adaptor User Manual, publication
20COMM_UM010 Provides network communication information for the optional 20-Comm-E EtherNet/IP
adaptor that can be installed in a PowerFlex 750-Series drive.
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1 Provides general guidelines for installing an Allen-Bradley industrial automation
system.
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6Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010
Preface
Notes:
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Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010 7
Chapter 1
Drive Selection Considerations
The differences between a PowerFlex 753 drive and PowerFlex 755 drive must be
considered when selecting a PowerFlex 750-Series drive as a replacement in a
PowerFlex 700 drive application.
Available Slots
The PowerFlex 750-Series drives are designed with a slot-based architecture
allowing customization with available option cards. The PowerFlex 753 drive is
equipped with three slots and the PowerFlex 755 drive has five slots.
Factory Installed Options
No options can be factory installed on the PowerFlex 750-Series drives. All
optional accessories must be installed by the user.
Hardware Drive Enable
Digital input (DI) 6 on the PowerFlex 700 drive can be programmed for any
available digital input functions including Enable. The PowerFlex 700VC has a
hardware enable jumper on the main control board that can be removed to force
DI 6 to act as hardware enabled with no software interpretation.
Digital Input 0 on the PowerFlex 750-Series drives can be programmed for any
available digital input functions including DI Enable. A hardware enable jumper
on the main control board can be removed to force DI 0 to act as hardware enabled
with no software interpretation.
The following figure shows the hardware enable jumper locations.
Figure 1 - Hardware Enable Jumper Locations on PowerFlex 750-Series Drives
PowerFlex 753 Drives (All Frames) PowerFlex 755 Drives (Frames 2…7) PowerFlex 755 Drive (Frame 8)
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8Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010
Chapter 1 Drive Selection Considerations
Specifications and
Features
Selecting a PowerFlex 750-Series drive to replace a PowerFlex 700 drive
application must consider the features and differences between the PowerFlex
753 and PowerFlex 755 drives.
Table 1 - PowerFlex Drive Comparisons
PowerFlex Drive
700 Standard Cassette 700 Vector Cassette Series B 753 755
Input Power
Ratings:
200-240V 0.37-45 kW (0.5-75 Hp) 0.37-66 kW (0.5-100 Hp) N/A N/A
400-480V 0.37-132 kW (0.5-200 Hp) 0.37-500 kW (0.5-700 Hp) 0.75-250 kW (1-350 Hp) 0.75-450 kW (1-700 Hp)
500-600V 0.37-132 kW (0.5-150 Hp) 0.37-132 kW (0.5-150 Hp) N/A N/A
690V 45-135 kW (60-150 Hp) 45-132 kW (60-150 Hp) N/A N/A
Single phase Yes, 50% derate Yes, 50% derate Yes, 50% derate Yes, 50% derate
Input inductor DC bus DC bus
Logic ride-through 0.5 seconds minimum,
2 seconds typical 0.5 seconds minimum, 2 seconds typical 0.5 seconds minimum, 2 seconds typical 0.5 seconds minimum, 2 seconds typical
Power ride-through 15 milliseconds 15 milliseconds 15 milliseconds 15 milliseconds
Transient protection MOV MOV MOV MOV
DC input terminals Yes Yes Frames 2…4 standard,
Frames 5…7 optional Frames 2…4 standard, Frames 5…8 optional
Output Power
Carrier frequency All frames: 2-10 kHz All frames: 2-10 kHz Frames 2…6: 2, 4, 8 and
12 kHz
Frame 7: 2, 4 and 8 kHz
Frames 2…6: 2, 4, 8 and
12 kHz
Frame 7: 2, 4 and 8 kHz
Frame 8: 2 and 4 kHz
Output frequency range 0-400 Hz 0-420 Hz 0-650 Hz 0-650 Hz
Efficiency 97.5% typical 97.5% typical 97.5% typical 97.5% typical
Power factor 0.98 0.98 0.98 0.98
Overload capability:
Light duty N/A N/A N/A 110%-60 s, 120%-3 s (1)
Normal duty 110%-60 s, 150%-3 s 110%-60 s, 150%-3 s 110%-60 s, 150%-3 s 110%-60 s, 150%-3 s
Heavy duty 150%-60 s, 200%-3 s 150%-60 s, 200%-3 s 150%-60 s, 180%-3 s 150%-60 s, 180%-3 s
(1) Frame 8 only.
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Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010 9
Drive Selection Considerations Chapter 1
Table 2 - PowerFlex Drive Comparisons (continued)
PowerFlex Drive
700 Standard Cassette 700 Vector Cassette Series B 753 755
Environmental Ratings
Enclosure types and ambient temperature range:
IP20, NEMA/UL Type Open 0 to 50 °C (32 to 122 °F) (1)
0 to 40 °C (32 to 104 °F) (2)
0 to 65 °C (32 to 149 °F) (3)
0 to 50 °C (32 to 122 °F) (1)
0 to 40 °C (32 to 104 °F) (2)
0 to 65 °C (32 to 149 °F) (3)
0 to 50 °C (32 to 122 °F) (5) 0 to 50 °C (32 to 122 °F) (5)
IP00, NEMA/UL Type Open N/A N/A 0 to 50 °C (32 to 122 °F) (6) 0 to 50 °C (32 to 122 °F) (6)
IP20, NEMA/UL Type 1 (w/hood) N/A N/A 0 to 40 °C (32 to 104 °F) (5) 0 to 40 °C (32 to 104 °F) (5)
IP20, NEMA/UL Type 1 (w/label) N/A N/A 0 to 40 °C (32 to 104 °F) (6) 0 to 40 °C (32 to 104 °F) (6)
IP20, NEMA/UL Type 1
(MCC cabinet) N/A N/A N/A 0 to 40 °C (32 to 104 °F) (9)
Flange enclosure types and ambient temperature range:
Front
IP20, NEMA/UL, Type Open
IP00, NEMA/UL, Type Open N/A N/A N/A N/A 0 to 50 °C (32 to 122 °F) (5)
0 to 40 °C (32 to 104 °F) (6) 0 to 50 °C (32 to 122 °F) (5) 0 to 40 °C (32 to 104 °F) (6)
Back/heatsink
IP20, NEMA/UL, Type Open
IP66, NEMA/UL, Type 4X 0 to 40 °C (32 to 104 °F) (2) N/A 0 to 40 °C (32 to 104 °F) (2) N/A N/A 0 to 40 °C (32 to 104 °F) (7) N/A 0 to 40 °C (32 to 104 °F) (7)
Stand-alone/wall mount
IP54, NEMA/UL Type 12 N/A N/A 0 to 40 °C (32 to 104 °F) (7) 0 to 40 °C (32 to 104 °F) (7)
Storage temperature range -40 to 70 °C (-40 to 158 °F) -40 to 70 °C (-40 to 158 °F) -40 to 70 °C (-40 to 158 °F) -40 to 70 °C (-40 to 158 °F)
Standards and Certifications
UL YesYesYesYes
CE YesYesYesYes
CSA YesYesYesYes
C-Tick YesYesYesYes
ATEX Yes Yes N/A N/A
RINA Yes Yes (1) N/A N/A
TUV-FS No No Yes Yes
ROHS No No Yes Yes
Protection
Motor overload Standard Standard Standard Standard
Output short circuit Standard Standard Standard Standard
Output ground fault Standard Standard Standard Standard
Under and over voltage Standard Standard Standard Standard
Dynamic braking Internal chopper (4) Internal chopper (4) Internal chopper (8) Internal chopper (8)
Common mode choke Internal (standard) Internal (standard) (1) External (optional) External (optional)
(1) Frames 0…6 only.
(2) Frames 7…10 only; applies to chassis (heatsink).
(3) Frames 7…10 only; applies to control (front of backplane).
(4) Standard on Frames 0…3 and optional on Frames 4…6.
(5) Frames 2…5 only.
(6) Frames 6 and 7 only.
(7) Frames 2…7 only.
(8) Standard on Frames 2…5 and optional on Frames 6…7.
(9) Frame 8 only.
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10 Rockwell Automation Publication PFLEX-AP005A-EN-P - October 2010
Chapter 1 Drive Selection Considerations
Table 3 - PowerFlex Drive Comparisons (continued)
PowerFlex Drive
700 Standard Cassette 700 Vector Cassette Series B 753 755
Protection (continued)
Common mode capacitors Standard Standard (1) Standard Standard
Safety input:
Torque-off card N/A N/A Standard Standard
Speed monitor N/A N/A Optional Optional
Hardware enable Standard Standard Standard Standard
EMC filters (internal) Standard Standard (1) Standard Standard
Drive Control Performance and Features
Motor control type:
Induction V/Hz Standard Standard Standard Standard
Induction sensorless vector
(SVC) Standard Standard Standard Standard
Induction flux vector (FVC) N/A Standard with
FORCE Technology Standard with FORCE Technology Standard with FORCE Technology
Synchronous reluctance V/Hz Standard Standard Standard Standard
Synchronous reluctance SV N/A N/A Standard Standard
Adjustable voltage mode N/A Standard N/A Standard
Operating speed range 120:1 1,000:1 (2)
120:1 (3) 1,000:1 (2) 120:1 (3) 1,000:1 (2) 120:1 (3)
Speed control regulation
(% of base speed across
operating speed range)
0.5% across 80:1 0.001% across 120:1 (2)
0.1% across 120:1 (3) 0.001% across 100:1 (2) 0.1% across 120:1 (3) 0.001% across 100:1 (2) 0.1% across 120:1 (3)
Speed control bandwidth
(radians per second) 20 250 (2) 50 (3) 190 (2) 50 (3) 190 (2) 50 (3)
Slip compensation Standard Standard Standard Standard
Droop N/A Standard Standard Standard
Inertia adaption N/A N/A N/A Standard
Phase lock loop N/A N/A N/A Standard
Torque regulation N/A ± 2%, 2500 rad/sec (2)
± 5%, 600 rad/sec (3) ± 2%, 2500 rad/sec (2) ± 5%, 600 rad/sec (3) ± 2%, 2500 rad/sec (2) ± 5%, 600 rad/sec (3)
Features
Flying start Standard Standard (4) Standard (5) Standard (5)
Bus regulator Standard (4) Standard (4) Standard (4) Standard (4)
S-curve Standard Standard Standard Standard
Drive overload protection Standard (4) Standard (4) Standard (4) Standard (4)
Advanced diagnostics Standard Standard Standard Standard
(1) Frames 0…6 only.
(2) With encoder.
(3) Without encoder.
(4) Advanced.
(5) Advanced and non-advanced.
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