Rockwell Automation Allen-Bradley PowerFlex 700 User manual

User Manual
PowerFlex 700 AC Drives – Series A, Frames 0…6
Standard Control Firmware 3.001 and Below
Vector Control Firmware 3.002 and Below
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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 may 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 may also be on or inside the equipment to provide specific precautions.
PowerFlex, DriveExplorer, DriveExecutive, PLC, Force Technology, DPI, and SCANport are either trademarks or 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 a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the
product.
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.
ARC FLASH HAZARD: Labels may 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).
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Summary of Changes
The information below summarizes the changes to the PowerFlex 700
User Manual, publication 20B-UM001 since the last release.
Manual Updates
Description of New or Updated Information Page
Removed the Installation/Wiring information (Chapter 1), Start Up information
(Chapter 2), dimension, specification and fuse/breaker information (Appendix
A). This information can now be found in the Installation Instructions:
PowerFlex 700 Adjustable Frequency AC Drive – Frames 0…6,
publication 20B-IN0019
–
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soc-ii Summary of Changes
Notes:
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Table of Contents
Important User Information . . . . . . . . . . . 1-2
Preface Overview Who Should Use this Manual? . . . . . . . . . P-1
What Is Not in this Manual . . . . . . . . . . . . P-1
Additional Resources . . . . . . . . . . . . . . . . P-2
Manual Conventions . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . P-3
Catalog Number Explanation . . . . . . . . . . P-5
Chapter 1 Programming
and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 1-1
How Parameters are Organized. . . . . . . . . 1-3
Monitor File . . . . . . . . . . . . . . . . . . . . . . 1-12
Motor Control File . . . . . . . . . . . . . . . . . 1-14
Speed Command File . . . . . . . . . . . . . . . 1-21
Dynamic Control File . . . . . . . . . . . . . . . 1-31
Utility File . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Communication File . . . . . . . . . . . . . . . . 1-50
Inputs & Outputs File . . . . . . . . . . . . . . . 1-54
Applications File . . . . . . . . . . . . . . . . . . . 1-60
Parameter Cross Reference – by Name. . 1-61
Parameter Cross Reference – by Number 1-64
Chapter 2 Troubleshooting Faults and Alarms . . . . . . . . . . . . . . . . . . . 2-1
Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 2-2
Manually Clearing Faults . . . . . . . . . . . . . 2-3
Fault Descriptions . . . . . . . . . . . . . . . . . . . 2-4
Clearing Alarms . . . . . . . . . . . . . . . . . . . . 2-9
Alarm Descriptions . . . . . . . . . . . . . . . . . 2-10
Common Symptoms/Corrective Actions 2-13
Testpoint Codes and Functions . . . . . . . . 2-16
Appendix A Supplemental
Drive Information
Drive Frame Sizes . . . . . . . . . . . . . . . . . . . A-1
Communication Configurations . . . . . . . . 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
Linking Parameters (Vector Control Only) B-6
Removing/Installing the HIM . . . . . . . . . . B-8
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ii Table of Contents
Appendix C Application Notes External Brake Resistor. . . . . . . . . . . . . . . C-1
Lifting/Torque Proving . . . . . . . . . . . . . . . C-2
Minimum Speed . . . . . . . . . . . . . . . . . . . . C-7
Motor Control Technology . . . . . . . . . . . . C-8
Motor Overload . . . . . . . . . . . . . . . . . . . . C-10
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . C-11
Power Loss Ride Through . . . . . . . . . . . . C-12
Process PI for Standard Control . . . . . . . C-13
Reverse Speed Limit . . . . . . . . . . . . . . . . C-16
Skip Frequency . . . . . . . . . . . . . . . . . . . . C-17
Sleep Wake Mode . . . . . . . . . . . . . . . . . . C-19
Start At PowerUp. . . . . . . . . . . . . . . . . . . C-21
Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . C-22
Voltage Tolerance . . . . . . . . . . . . . . . . . . C-24
Index
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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 Series A User Manual provides programming and
troubleshooting information for Standard Control and Vector Control
drives, Frames 0…6.
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
Literature is 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
Additional Resources P-2
Manual Conventions P-2
General Precautions P-3
Catalog Number Explanation P-5
Who Should Use this Manual?
What Is Not in this Manual
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P-2 Overview
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.
•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.”
Additional Resources
Resource Description
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.
Manual Conventions
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Overview P-3
•The following words are used throughout the manual to describe an
action:
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
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 Installation Instructions
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.
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P-4 Overview
!
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.
!
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.
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