Page 1 Adjustable Frequency AC Drive Volume 1 PowerFlex 70 PowerFlex 700 Standard Control Vector Control Reference Manual www.abpowerﬂex.com...
Page 2 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.
Page 3: Table Of Contents
PowerFlex 70/700 Speciﬁcations ........
Page 4 PowerFlex 70 Power Curves ........
Page 5: Chapter 1 Specifications & Dimensions
300VDC 375VDC Nominal Bus Voltage: 281VDC 324VDC 540VDC 648VDC 810VDC PowerFlex 700 AC Input Overvoltage Trip: See PowerFlex 70 above AC Input Undervoltage Trip: Bus Overvoltage Trip: Bus Undervoltage Shutoff & Fault: 153VDC 153VDC 305VDC 305VDC 381VDC Nominal Bus Voltage:...
Page 6: Powerflex 70/700 Speciﬁcations
PowerFlex 70/700 Speciﬁcations Category Speciﬁcation Protection Control Logic Noise Immunity: Showering arc transients up to 1500V peak (continued) Power Ride-Thru: 15 milliseconds at full load Logic Control Ride-Thru: 0.5 seconds minimum, 2 seconds typical Ground Fault Trip: Phase-to-ground on drive output...
Page 7: Input/Output Ratings
Input/Output Ratings Category Speciﬁcation Control Torque Regulation Torque Regulation - without feedback Vector ±10%, 600 rad/sec bandwidth (continued) Torque Regulation - with feedback Vector ±5%, 2500 rad/sec bandwidth Selectable Motor Control: Sensorless Vector with full tuning. Standard V/Hz with full custom capability.
Page 8: Derating Guidelines
Derating Guidelines Derating Guidelines PowerFlex 70 & 700 Altitude and Efﬁciency Frame Type Derate Altitude 100% 1,000 2,000 3,000 4,000 5,000 6,000 Altitude (m) Efﬁciency (typical) vs. Speed vs. Load % Speed/% Load PowerFlex 70 Ambient Temperature/Load Frame Class Enclosure...
Page 9 Derating Guidelines PowerFlex 700 Ambient Temperature/Load Frame Voltage Rating Enclosure Frequency Derate 400V 5.5 kW Open, NEMA 2-10 kHz None Type 1, IP20 460V 7.5 HP Open, NEMA 2-10 kHz None Type 1, IP20 400V 11 kW Open, NEMA 2-6 kHz Type 1, IP20 6 kHz 8 kHz...
Page 10 Derating Guidelines Frame Voltage Rating Enclosure Frequency Derate 400V 22 kW Open, NEMA 2-10 kHz None Type 1, IP20 30 kW Open, NEMA 6-10 kHz Type 1, IP20 6 kHz 8 kHz 10 kHz % of Output FLA 37 kW Open, NEMA 4-10 kHz Type 1, IP20...
Page 11: Powerflex 70 Dimensions
– 15 (11) 20 (15) – – – – – Figure 1.1 PowerFlex 70 Frames A-D IP20 / NEMA Type 1 Flange Mount 5.8 (0.23) Dimensions are in millimeters and (inches). Weight kg (lbs.) IP20 / NEMA Type 1 122.4 (4.82) 225.7 (8.89)
Page 12 PowerFlex 70 Dimensions Figure 1.2 PowerFlex 70 IP20/NEMA Type 1 Bottom View Dimensions Frame Dimensions in millimeters and (inches) 86.4 (3.40) 22.2 (0.87) Dia. 34.5 (1.36) 4 Places 23.9 (0.94) 155.2 (6.11) 163.7 135.9 (6.45) (5.35) 129.8 (5.11) 102.4 (4.03) 42.7 (1.68)
Page 13 PowerFlex 70 Dimensions Figure 1.3 PowerFlex 70 IP66 (NEMA Type 4X/12) Bottom View Dimensions Frame Dimensions in millimeters and (inches) 28.3 (1.11) 22.1 (0.87) 138.2 (5.44) 99.6 (3.92) 55.2 (2.17) 77.3 (3.04) 99.6 (3.92) 115.9 (4.56) 28.3 22.1 (1.11) (0.87) 140.5...
Page 14 1-10 PowerFlex 70 Dimensions Figure 1.4 PowerFlex 70 Flange Mount Bottom View Dimensions Frame Dimensions in millimeters and (inches) 103.2 (4.06) 22.2 (0.87) Dia. 51.3 (2.02) 4 Places 40.7 (1.60) 95.9 (3.78) 104.4 76.6 (3.02) (4.11) 70.5 (2.78) 43.2 (1.70) 59.6 (2.35)
Page 15 PowerFlex 70 Dimensions 1-11 Figure 1.5 PowerFlex 70 Cutout Dimensions Frame Dimensions in millimeters and (inches) Frame Dimensions in millimeters and (inches) 156,0 219,0 (6.14) (8.62) 140,7 202,0 (5.54) (7.95) 70,7 101,0 (2.78) (3.98) (0.27) (0.25) 127,0 (5.00) 300,0 189,4 (11.81)
Page 16 1-12 PowerFlex 70 Dimensions Figure 1.6 Flange Mounting M4 x 8 x 25 (#10-24 x .75) Dimensions are in millimeters and (inches)
Page 17 PowerFlex 700 Dimensions 1-13 PowerFlex 700 Table 1.B PowerFlex 700 Frames Dimensions 208/240V AC Input 400V AC Input 480V AC Input 600V AC Input Frame ND HP HD HP ND kW HD kW ND HP HD HP ND HP HD HP 0.33 0.37 0.25...
Page 18 1-14 PowerFlex 700 Dimensions Figure 1.8 PowerFlex 700 Frame 4 13.9 (0.55) 8.0 (0.31) dia. 8.0 (0.31) 3 Places Lifting Holes (0.31) 4 Places Dimensions are in millimeters and (inches) Approx. Weight kg (lbs.) Drive & A (Max.) C (Max.) Drive Packaging 4 219.8 (8.65)
Page 19 PowerFlex 700 Dimensions 1-15 Figure 1.9 PowerFlex 700 Frame 5 6.5 (0.26) 15.0 (0.59) 259.1 (10.20) 37.6 (1.48) Detail CAUTION HOT surfaces can cause severe burns Lifting Holes - 4 Places 6.5 (0.26) 12.7 (0.50) Dia. 12.5 (0.49) Dimensions are in millimeters and (inches). Approx.
Page 20: Powerflex 700 Dimensions
1-16 PowerFlex 700 Dimensions Figure 1.10 PowerFlex 700 Frame 6 8.5 (0.33) 18.0 (0.71) 49.6 (1.95) 360.6 (14.20) Detail Lifting Holes 8.5 (0.33) 126.3 4 Places (4.97) 13.5 (0.53) 12.7 (0.50) Dia. Dimensions are in millimeters and (inches) Approx. Weight kg (lbs.) Drive &...
Page 21 PowerFlex 700 Dimensions 1-17 Figure 1.11 PowerFlex 700 Bottom View Dimensions Frame Rating Dimensions in millimeters and (inches) 96.0 (3.78) 75.0 (2.95) 55.0 (2.17) 35.0 (1.38) 22.2 (0.87) Dia. – 4 Places 30.2 (1.19) 185.0 187.5 (7.38) (7.28) 132.9 (5.23) 41.9 (1.65) 56.1 (2.21) 75.9 (2.99)
Page 22 1-18 PowerFlex 700 Dimensions Frame Rating Dimensions in millimeters and (inches) 105.3 (4.15) except 94.7 (3.73) 37.3 (1.47) Dia. 22.2 (0.87) Dia. 2 Places 50 HP, 28.7 (1.13) Dia. 480V 2 Places (37 kW, 400V) 184.5 165.1 (7.26) (6.50) 160.1 (6.30) 151.1 (5.95)
Page 23 PowerFlex 700 Dimensions 1-19 Frame Rating Dimensions in millimeters and (inches) 75 HP, 104.0 (4.09) 34.9 (1.37) Dia. 2 Places 22.2 (0.87) Dia. 480V 93.2 (3.67) 2 Places (55kW, 400V) 62.7 (2.47) Dia. Normal 2 Places Duty Drive 241.9 (9.52) 229.5 (9.04) 220.0...
Page 24 1-20 PowerFlex 700 Dimensions Notes:...
Page 25: Chapter 2 Detailed Drive Operation
Chapter Detailed Drive Operation This chapter explains PowerFlex drive functions in detail. Explanations are organized alphabetically by topic. Refer to the Table of Contents for a listing of topics. Accel Time [Accel Time 1, 2] The Accel Time parameters set the rate at which the drive ramps up its output frequency after a Start command or during an increase in command frequency (speed change).
Page 26: Ac Supply Source Considerations
AC Supply Source Considerations AC Supply Source PowerFlex drives are suitable for use on a circuit capable of delivering up to Considerations a maximum of 200,000 rms symmetrical amperes, 600V. 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 Tables through 2.R.
Page 27 Alarms Drive Alarm word; that is, the same bits in both the Drive Alarm Word and the Alarm Conﬁguration Word represent the same alarm. Drive Alarm Alarm Conﬁg Active Inactive Inactive Alarm Alarm Alarm The conﬁguration bits act as a mask to block or pass through the alarm condition to the active condition.
Page 28 Alarms The signal is designated as the active speed reference by setting [Speed Ref A Sel] to its factory default value of “1” 090 [Speed Ref A Sel] Default: “Analog In 2” Selects the source of the speed Options: “Analog In 1” thru reference to the drive unless [Speed Ref “Analog In 2”...
Page 29 Alarms Finally, a Digital Output relay is conﬁgured to annunciate an alarm by turning on a ﬂashing yellow light mounted on the operator panel of the process control area. [Digital Out1 Sel] Default: “Fault” [Digital Out2 Sel] “Run” [Digital Out3 Sel] “Run”...
Page 30: Analog Inputs
Analog Inputs Alarm Queue (PowerFlex 700 Only) A queue of 8 parameters exists that capture the drive alarms as they occur. A sequential record of the alarm occurrences allows the user to view the history of the eight most recent events. [Alarm 1 Code] Default: Read Only...
Page 31 Analog In 1 Lo Input/Output Analog In 1 Hi Analog Input Volts or mA Parameter Cal Analog 1 1 Scale Analog In 2 Lo Processing Analog In 2 Hi Selection/Control Analog Input Volts or mA Cal Analog 2 2 Scale Speed Ref A Sel Speed Ref B Sel Trim In Select...
Page 32 Input/Output Parameter Processing Selection/Control Anlg In 1 Loss Anlg In Config Anlg In Sqr Root 0-10v Unipolar Loss Limit Cal 1 Detect 0-10V Analog 1 Voltage Cal Analog 1 Analog 1 Current Current Loss Limit 0-20mA Square Cal 1 Detect 4-20mA Root Analog In1 Value...
Page 33 Analog Inputs Scaling Blocks [Analog In Hi] [Analog In Lo] A scaling operation is performed on the value read from an analog input in order to convert it to units usable for some particular purpose. The user controls the scaling by setting parameters that associate a low and high point in the input range (i.e.
Page 34 2-10 Analog Inputs Conﬁguration #1: • [Anlg In Conﬁg], bit 0 = “0” (Voltage) • [Speed Ref A Sel] = “Analog In 1” • [Minimum Speed] = 0 Hz • [Maximum Speed] = 60 Hz • [Speed Ref A Lo] = 0V •...
Page 35 Analog Inputs 2-11 Output Hertz Scaling Block [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 0 Hz [Analog In 1 Lo]] [Speed Ref A Lo]] 30 Hz Conﬁguration #3: • [Anlg In Conﬁg], bit 0 = “1” (Current) •...
Page 36 2-12 Analog Inputs Conﬁguration #4: • [Anlg In Conﬁg], bit 0 = “0” (Voltage) • [Speed Ref A Sel] = “Analog In 1” • [Minimum Speed] = 0 Hz • [Maximum Speed] = 60 Hz • [Speed Ref A Lo] = 10V •...
Page 37 Analog Inputs 2-13 Output Hertz Scaling Block [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 0 Hz [Analog In 1 Lo] [Speed Ref A Lo] 60Hz Square Root [Anlg In Sqr Root] For both analog inputs, the user can enable a square root function for an analog input through the use of [Analog In Sq Root].
Page 38 2-14 Analog Inputs One of the selections for reaction to signal loss is a drive fault, which will stop the drive. All other choices make it possible for the input signal to return to a usable level while the drive is still running. •...
Page 39 Analog Inputs 2-15 Trim An analog input can be used to trim the active speed reference (Speed Reference A/B). If analog is chosen as a trim input, two scale parameters are provide to scale the trim reference. The trim is a +/- value which is summed with the current speed reference.
Page 40 2-16 Analog Inputs Table 2.A Recommended Signal Wire Minimum Signal Type Wire Type(s) Description Insulation Rating Analog I/O Belden 8760/9460(or equiv.) 0.750 mm (18AWG), twisted 300V, pair, 100% shield with drain 60 degrees C (140 degrees F) Belden 8770(or equiv.) 0.750 mm (18AWG), 3 cond., shielded for remote pot only.
Page 41 Analog Inputs 2-17 [Minimum Speed] [Maximum Speed] [Analog In1 Hi] Motor Operating Range Frequency Deadband Frequency Deadband 0-2.5 Volts 7.5-10 Volts Command Frequency [Analog In1 Lo] 0 Hz 15 Hz 45 Hz 60 Hz [Speed Ref A Lo] [Speed Ref A Hi] Slope defined by (Analog Volts)/(Command Frequency) This deadband, as it relates to the analog input, can be calculated as follows: 1.
Page 42 2-18 Analog Inputs [Minimum Speed] [Maximum Speed] [Analog In1 Hi] Motor Operating Range Frequency Deadband Frequency Deadband 0-3 Volts 9-10 Volts Command Frequency [Analog In1 Lo] 0 Hz 15 Hz 45 Hz 50 Hz Slope defined by (Analog Volts)/(Command Frequency) [Speed Ref A Lo] [Speed Ref A Hi] The deadband, as it relates to the analog input, can be calculated as follows:...
Page 43: Analog Outputs
* Vector Control Option Only Conﬁguration The PowerFlex 70 standard I/O analog output is permanently conﬁgured as a 0 -10 volt output. The output has 10 bits of resolution yielding 1024 steps. The analog output circuit has a maximum 1.3% gain error and a maximum 7 mV offset error.
Page 44 2-20 Analog Outputs Scaling Blocks The user deﬁnes the scaling for the analog output by entering analog output voltages into two parameters, [Analog Out1 Lo] and [Analog Out1 Hi]. These two output voltages correspond to the bottom and top of the possible range covered by the quantity being output.
Page 45 Analog Outputs 2-21 Example 3 – Signed Output Quantity, Absolute Value Enabled • [Analog Out1 Sel] = “Output Torque Current” • [Analog Out1 Lo] = 1 volt • [Analog Out1 Hi] = 9 volts • [Anlg Out Absolut] set so that absolute value is enabled for output 1. [Analog Out1 Hi] Output Torque Current vs.
Page 46 2-22 Analog Outputs Filtering Software ﬁltering will be performed on the analog outputs for certain signal sources, as speciﬁed in Table 2.B. “Filter A” is one possible such ﬁlter, and it is described later in this section. Any software ﬁltering is in addition to any hardware ﬁltering and sampling delays.
Page 47: Auto/Manual
Auto/Manual 2-23 Auto/Manual The intent of Auto/Manual is to allow the user to override the selected reference (referred to as the “auto” reference) by either toggling a button on the programming terminal (HIM), or continuously asserting a digital input that is conﬁgured for Auto/Manual. •...
Page 48 2-24 Auto/Manual 2. Manual control can only be granted to the TB or to a programming terminal (e.g. HIM) if Manual control is not already being exercised by the TB or another programming terminal at the time. 3. Manual control can only be granted to a terminal if no other device has Local control already asserted (i.e.
Page 49: Auto Restart (Reset/Run)
Auto Restart (Reset/Run) 2-25 Auto Restart (Reset/ The Auto Restart feature provides the ability for the drive to automatically Run) perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. Only certain faults are allowed to be reset.
Page 50 2-26 Auto Restart (Reset/Run) 3. The drive will then issue an internal Start command to start the drive. 4. If another auto-resettable fault occurs the cycle will repeat itself up to the number of attempts set in [Auto Rstrt Tries]. 5.
Page 51: Bus Regulation
Bus Regulation 2-27 Bus Regulation [Bus Reg Gain] [Bus Reg Mode A, B] Some applications, such as the hide tanning shown here, create an intermittent regeneration condition. When the hides are being lifted (on the left), motoring current exists. However, when the hides reach the top and fall onto a paddle, the motor regenerates power back to the drive, creating the potential for a nuisance overvoltage trip.
Page 52 2-28 Bus Regulation The bus voltage regulation set point (Vreg) in the drive is ﬁxed for each voltage class of drive. The bus voltage regulation set points are identical to the internal dynamic brake regulation set points VDB's. DB Bus Motor Speed Output Frequency To avoid over-voltage faults, a bus voltage regulator is incorporated as part...
Page 53 Bus Regulation 2-29 Figure 2.1 Bus Voltage Regulator, Current Limit and Frequency Ramp. Current Limit U Phase Motor Current Derivative Gain Magnitude W Phase Motor Current Block Calculator SW 3 Current Limit Level PI Gain Block I Limit, No Bus Reg Limit SW 1 No Limit...
Page 54 Note: These faults are not instantaneous and have shown test results that take between 2 and 12 seconds to occur. PowerFlex 70/700 The user selects the bus voltage regulator using the Bus Reg Mode parameters. The available modes include: •...
Page 55 Bus Regulation 2-31 DB Turn On DB Turn Off AC Volts If [Bus Reg Mode A], parameter 161 is set to “Dynamic Brak”: The Dynamic Brake Regulator is enabled. The “blue” (upper) DB turn on and turn off curves apply. In “Dynamic Brak” mode adjust frequency control is turned off.
Page 56: Cable, Control
The Reﬂected Wave phenomenon, also known as transmission line effect, can produce very high peak voltages on the motor due to voltage reﬂection. Allen-Bradley drives have patented software that limits the voltage peak to 2 times the DC bus voltage or 1600 volts, whichever is greater. The software also reduces the number of occurrences.
Page 57 Cable, Motor Lengths 2-33 current. These distances are advisory only and are not intended to assure a trouble free installation. Differences in the cable chosen and other factors can affect maximum distance. Figure 2.2 How to Measure Motor Cable Lengths Limited by Capacitance 15.2 (50) 91.4 (300) 152.4 (500)
Page 58 2-34 Cable, Motor Lengths PowerFlex 70 Maximum Motor Lead Lengths (in Feet) - No External Devices 1488 Volt Motor 1600 Volt Motor Carrier 1000 Volt Motor 1200 Volt Motor NEMA MG1-1998 1329 R/L 480V HP Freq. Rating (kHz) Shld. Shld.
Page 59: Cable, Power
Black sunlight resistant PVC jacket overall. • Three copper grounds on #10 AWG and smaller. Based on ﬁeld and internal testing, Rockwell Automation/Allen-Bradley has determined that conductors manufactured with Poly Vinyl Chloride (PVC) wire insulation are subject to a variety of manufacturing inconsistencies which can lead to premature insulation degradation when used with IGBT drives that produce the reﬂected wave phenomena.
Page 60 2-36 Cable, Power Manufacturing Inconsistencies and their Effects on Cable Life Due to manufacturing inconsistencies, the following conditions can exist: • PVC insulation material may have a dielectric constant ranging between 4 and 8 depending on the manufacturer. The higher the dielectric constant, the lower the dielectric strength (and voltage withstand to transients).
Page 61 Cable, Power 2-37 locations. Because the PVC insulating material absorbs moisture, the Corona Inception Voltage insulation capability of the “damp” or “wet” THHN was found to be less than 1/2 of the same wire when “dry”. For this reason, certain industries where water is prevalent in the environment have refrained from using THHN wire with IGBT drives.
Page 62: Cable, Standard I/O
2-38 Cable, Standard I/O Cable, Standard I/O For analog and encoder cable selection, see page 2-15. Digital input cable selection can be found on page 2-51. CabIe Trays and Conduit must be magnetic steel and be installed so as to provide a Conduit continuous electrical path through the conduit itself.
Page 63: Carrier (Pwm) Frequency
Carrier (PWM) Frequency 2-39 Carrier (PWM) page 1-4 for derating guidelines as they relate to carrier frequency. Frequency In general, the lowest possible switching frequency that is acceptable for any particular application is the one that should be used. There are several beneﬁts to increasing the switching frequency.
Page 64: Ce Conformity
2-40 CE Conformity CE Conformity EMC Instructions CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Ofﬁcial Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manuals.
Page 65 – – Drive with any Comm Option – – – Drive with ControlNet – – Table 2.G PowerFlex 70 – EN61800-3 First Environment Restricted Distribution First Environment Restricted Distribution Restrict Motor Restrict Motor Internal Comm Common Cable to Cable to...
Page 66: Copy Cat
Recommended Filters Class Class Manufacturer Manufacturer Manufacturer Drive Type Frame Part Number (Meters) (Meters) Part Number (Meters) (Meters) Deltron PowerFlex 70 KMF306A – – – B w/o Filter KMF310A – – – B w/Filter KMF306A MIF306 – KMF318A –...
Page 67: Current Limit
Current Limit 2-43 Current Limit [Current Lmt Sel] [Current Lmt Val] [Current Lmt Gain] There are 6 ways that the drive can protect itself from overcurrent or overload situations: • Instantaneous Overcurrent trip • Software Instantaneous Trip • Software Current Limit •...
Page 68 2-44 Current Limit 4. Overload Protection I T - This is a software feature that monitors the output current over time and integrates per IT. The base protection is 110% for 1 minute or the equivalent I T value (i.e. 150% for 3 seconds, etc.).
Page 69: Datalinks
Datalinks 2-45 Datalinks A Datalink is one of the mechanisms used by PowerFlex drives to transfer data to and from a programmable controller. Datalinks allow a parameter value to be changed without using an Explicit Message or Block Transfer. Datalinks consist of a pair of parameters that can be used independently for 16 bit transfers or in conjunction for 32 bit transfers.
Page 70 2-46 Datalinks Rules for Using Datalinks 1. 1. A Datalink consists of 4 words, 2 for Datalink x IN and 2 for Datalink x Out. They cannot be separated or turned on individually. 2. Only one communications adapter can use each set of Datalink parameters in a PowerFlex drive.
Page 71: Dc Bus Voltage / Memory
DC Bus Voltage / Memory 2-47 DC Bus Voltage / [DC Bus Voltage] is a measurement of the instantaneous value. [DC Bus Memory Memory] is a heavily ﬁltered value or “nominal” bus voltage. Just after the pre-charge relay is closed during initial power-up bus pre-charge, bus memory is set equal to bus voltage.
Page 72: Diagnostics
2-48 Diagnostics Diagnostics Diagnostic Parameters – PF700 Vector Control Only The following parameters can only be viewed when “2, Unused” is selected in parameter 196, [Param Access Lvl]. Parameter Name & Description Values 500 [KI Current Limit] Default: Current Limit Integral gain. This gain is Min/Max: applied to the current limit error signal to Units:...
Page 73 Diagnostics 2-49 Parameter Name & Description Values 509 [Lo Freq Reg KpId] Default: This proportional gain adjusts the output Min/Max: voltage at very low frequency in response Units: to the reactive, or d-axis, motor current. A larger value increases the output voltage change.
Page 74 2-50 Diagnostics Parameter Name & Description Values [DAC55-A] Default: [DAC55-B] Min/Max: 0/7432 [DAC55-C] Units: [DAC55-D] Reserved. Do Not Adjust 525 [Torq Adapt Speed] Default: 33.0% Selects the operating frequency/speed at Min/Max: 0.0/100.0% which the adaptive torque control Units: 0.1% regulators become active as a percent of motor nameplate frequency.
Page 75: Digital Inputs
See User Manual. There are 6 digital (discrete) inputs (numbered 1 through 6) available at the terminal block. PowerFlex 70 Each digital input has a maximum response/pass through/function execution time of 25ms. For example, no more than 25ms should elapse from the time the level changes at the Start input to the time voltage is applied to the motor.
Page 76 2-52 Digital Inputs PowerFlex 700 Digital Input Selection [Digital In1 Sel] Default: “Stop – CF” [Digital In2 Sel] Default: “Start” [Digital In3 Sel] Default: “Auto/ Manual” [Digital In4 Sel] Default: “Speed Sel 1” [Digital In5 Sel] Default: “Speed Sel 2” (11) [Digital In6 Sel] Default:...
Page 77 Digital Inputs 2-53 PowerFlex 70 Digital Input Selection [Digital In1 Sel] Default: “Stop – CF” (CF = Clear Fault) [Digital In2 Sel] Default: “Start” [Digital In3 Sel] Default: “Auto/ Manual” [Digital In4 Sel] Default: “Speed Sel 1” [Digital In5 Sel] Default: “Speed Sel 2”...
Page 78 2-54 Digital Inputs Table 2.J Digital Input Function List Input Function Name Purpose Stop - CF Stop drive Clear Faults (open to closed transition) Run Forward Run in forward direction (2-wire start mode) Run Reverse Run in reverse direction (2-wire start mode) Run in current direction (2-wire start mode) Start Start drive (3-wire start mode)
Page 79 Digital Inputs 2-55 If the “Clear Faults” input function is conﬁgured at the same time as “Stop - Clear Faults”, then it will not be possible to reset faults with the “Stop - Clear Faults” input. • Run Forward, Run Reverse An open to closed transition on one input or both inputs while drive is stopped will cause the drive to run unless the “Stop - Clear Faults”...
Page 80 2-56 Digital Inputs The terminal block bit must be set in the [Start Mask] and [Logic Mask] parameters in order for the terminal block to start the drive using this input. If the “Run” input function is conﬁgured, it will not be possible to start or jog the drive from any other control device.
Page 81 Digital Inputs 2-57 start the drive or change direction by using the terminal block digital inputs programmed for both Run and Direction control (i.e. Run/Fwd). Important: Because an open condition (or unwired condition) commands Forward, the terminal block seeks direction ownership as soon as this input function is conﬁgured, which may happen at power-up.
Page 82 2-58 Digital Inputs The drive will not jog while drive is running or while “Stop - Clear Faults” input is open. Start has precedence ATTENTION: If a normal drive start command is received while the drive is jogging, the drive will switch from jog mode to run mode.
Page 83 Digital Inputs 2-59 The terminal block bit must be set in the [Reference Mask] and [Logic Mask] parameters in order for the reference selection to be controlled from the terminal block using the Speed Select inputs functions. Important: Reference Control is an “Exclusive Ownership” function (see Owners on page 2-109).
Page 84 2-60 Digital Inputs conﬁguration allows a single input to choose between [Speed Ref A Sel] and [Speed Ref B Sel]. Speed Select 1 Selected Parameter that determines Reference Open [Speed Ref A Sel] Closed [Speed Ref B Sel] As another example, describes what reference selections can be made if the “Speed Select 3”...
Page 85 Digital Inputs 2-61 • Accel 2, Decel 2 In the ﬁrst scheme, one input function (called “Accel 2”) selects between [Accel Time 1] and [Accel Time 2], and another input function (called “Decel 2”) selects between [Decel Time 1] and [Decel Time 2]. The open state of the function selects [Accel Time 1] or [Decel Time 1], and the closed state selects [Accel Time 2] or [Decel Time 2].
Page 86 2-62 Digital Inputs While the “MOP Decrement” input is closed, MOP value will decrease at rate contained in [MOP Rate]. Units for rate are Hz per second. If both the “MOP Increment” and “MOP Decrement” inputs are closed, MOP value will stay the same. The terminal block bit must be set in the [MOP Mask] and [Logic Mask] parameters in order for the MOP to be controlled from the terminal block.
Page 87 Digital Inputs 2-63 • Auxiliary Fault The “Aux Fault” input function allows external equipment to fault the drive. Typically, one or more machine inputs (limit switches, pushbuttons, etc.) will be connected in series and then connected to this input. If the input function is open, the software detects the change of state then the drive will fault with the “Auxiliary Input”...
Page 88 If the input function is not conﬁgured, then the drive always uses the internal power loss level. This input function is used in PowerFlex 700 drives only. In PowerFlex 70 drives, the power loss level is always internal and not selectable.
Page 89 Digital Inputs 2-65 PowerFlex 70 drives, the drive assumes it is always connected to the DC bus. Digital Input Conﬂict Alarms If the user conﬁgures the digital inputs so that one or more selections conﬂict with each other, one of the digital input conﬁguration alarms will be asserted.
Page 90 2-66 Digital Inputs “DigIn CﬂctB” indicates a digital Start input has been conﬁgured without a Stop input or other functions are in conﬂict. Combinations that conﬂict are marked with a “ ” and will cause an alarm. Table 2.L Input function combinations that produce “DigIn CﬂctB” alarm Fwd/ Start Stop–CF Run Run Fwd Run Rev Jog Jog Fwd Jog Rev...
Page 91 The bits are “1” when the input is closed and “0” when the input is open. Digital In Examples PowerFlex 70 Figure 2.8 shows a typical digital input conﬁguration that includes “3-wire” start. The digital input conﬁguration parameters should be set as shown.
Page 92: Digital Outputs
Each relay is a Form C (1 N.O. – 1 N.C. with shared common) device whose contacts and associated terminals are rated for a maximum of 250V AC or 220V DC. The table below shows speciﬁcations and limits for each relay / contact. PowerFlex 70 PowerFlex 700 Resistive Load Inductive Load...
Page 93 Digital Outputs 2-69 PowerFlex 70 Digital Output Selection [Digital Out1 Sel] Default: “Fault” [Digital Out2 Sel] “Run” Selects the drive status that will energize Options: “Fault” a (CRx) output relay. “Alarm” “Ready” “Run” Contacts shown on page 1-14 of the “Forward Run”...
Page 94 2-70 Digital Outputs 2. The relay changes state because a particular value in the drive has exceeded a preset limit. The following drive values can be selected to cause the relay activation: Condition Description At Speed The drive Output Frequency has equalled the commanded frequency The balance of these functions require that the user set a limit for the speciﬁed value.
Page 95 Digital Outputs 2-71 An Output can be “linked” directly to an Digital Input so that the output “tracks” the input. When the input is closed, the Output will be energized, and when the input is open, the output will be de-energized. This “tracking will occur if two conditions exist: –...
Page 96: Direction Control
3. Control Word bit manipulation from a DPI device such as a communications interface. Bits 4 & 5 control direction. Refer to the Logic Command Word information in Appendix A of the PowerFlex 70 or 700 User Manual. 4. The sign (+/-) of a bipolar analog input.
Page 97: Dpi
2-73 DPI is an enhancement to SCANport that provides more functions and better performance. SCANport was a CAN based, Master-Slave protocol, created to provide a standard way of connecting motor control products and optional peripheral devices together. It allows multiple (up to 6) devices to communicate with a motor control product without requiring conﬁguration of the peripheral.
Page 98 DPI or SCANport devices are), so a proxy function is needed to create a DPI message to access information in an off-board peripheral. If an LCD HIM is attached to the PowerFlex 70 or 700 drive, it will be able to directly request off-board parameters using Peer-to-Peer messages (i.e. no proxy support needed in the drive).
Page 99 2-75 Table 2.M Timing speciﬁcations contained in DPI and SCANport Host status messages only go out to peripherals once they log in and at least every 125ms (to all attached peripherals). Peripherals time out if >250ms. Actual time dependent on number of peripherals attached. Minimum time goal of 5ms (may have to be dependent on Port Baud Rate).
Page 100: Drive Overload
2-76 Drive Overload Drive Overload The drive thermal overload has two primary functions. The ﬁrst requirement is to make sure the drive is not damaged by abuse. The second is to perform the ﬁrst in a manor that does not degrade the performance, as long the drive temperature and current ratings are not exceeded.
Page 101 Drive Overload 2-77 Figure 2.10 Normal Duty Boundary of Operation 1.80 1.70 1.60 1.50 1.40 1.30 1.20 1.10 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 1.00 10.00 100.00 1,000.00 Time (Seconds) The lower curve in Figure 2.11 shows the boundary of heavy duty operation.
Page 102 2-78 Drive Overload Thermal Manager Protection The thermal manager protection assures that the thermal ratings of the power module are not exceeded. The operation of the thermal manager can be thought of as a function block with the inputs and outputs as shown below.
Page 103 Drive Overload 2-79 Current Limit Current Limit as selected by the user can be reduced by the thermal manager. The resulting active current limit may be displayed as a test point parameter. The active current limit will always be less than or equal to the value selected by the user, and will not be less than ﬂux current.
Page 104: Drive Ratings (Kw, Amps, Volts)
2-80 Drive Ratings (kW, Amps, Volts) Low Speed Operation When operation is below 4 Hz, the duty cycle is such that a given IGBT will carry more of the load for a while and more heat will build up in that device. The thermal manager will increase the calculated IGBT temperature at low output frequencies and will cause corrective action to take place sooner.
Page 105: Efﬁciency
Efﬁciency 2-81 Efﬁciency The following chart shows typical efﬁciency for PWM variable frequency drives, regardless of size. Drives are most efﬁcient at full load and full speed. vs. Speed vs. Load % Speed/% Load Fan Curve When torque performance (see page 2-178) is set to Fan/Pump, the relationship between frequency and voltage is shown in the following...
Page 106: Faults
Faults are also logged into a fault queue such that a history of the most recent fault events is retained. Each recorded event includes a fault code (with associated text) and a fault “time of occurrence.” The PowerFlex 70 drive has a four event queue and the PowerFlex 700 has an eight event...
Page 107 Faults 2-83 A fault queue will record the occurrence of each fault event that occurs while no other fault is latched. Each fault queue entry will include a fault code and a time stamp value. A new fault event will not be logged to the fault queue if a previous fault has already occurred, but has not yet been reset.
Page 108 2-84 Faults 1. An off to on transition on a digital input conﬁgured for fault reset or stop/reset. 2. Setting [Fault Clear] to “1.” 3. A DPI peripheral (several ways). 4. Performing a reset to factory defaults via parameter write. 5.
Page 109: Flying Start
Flying Start 2-85 Flying Start The Flying Start feature is used to start into a rotating motor, as quick as possible, and resume normal operation with a minimal impact on load or speed. When a drive is started in its normal mode it initially applies a frequency of 0 Hz and ramps to the desired frequency.
Page 110 2-86 Flying Start Cooling Tower Fans Draft/wind blows idle fans in reverse direction. Restart at zero damages fans, breaks belts. Flying start alleviates the problem...
Page 111: Fuses And Circuit Breakers
Fuses and Circuit Breakers 2-87 Fuses and Circuit Tables through provide drive ratings (including continuous, 1 Breakers minute and 3 second) and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 degree C and the U.S.
Page 112 2-88 Fuses and Circuit Breakers Table 2.N PF70 208/240 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 113 Fuses and Circuit Breakers 2-89 Table 2.Q PF700 208/240 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 114 2-90 Fuses and Circuit Breakers Table 2.R PF700 400/480 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 115: Grounding, General
Grounding, General 2-91 Table 2.S PF700 600 Volt AC Input Recommended Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Ratings Output Amps Delay Fuse Delay Fuse 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 116: Him Memory
2-92 HIM Memory HIM Memory Copy Cat on page 2-42. HIM Operations Selecting a Language See also Language on page 2-96. PowerFlex 700 drives support multiple languages. When you ﬁrst apply drive power, a language screen appears on the HIM. Use the Up or Down Arrow to scroll through the available languages.
Page 117: Input Devices
Input Devices 2-93 Setting the User Display Step Key(s) Example Displays 1. Press the Up Arrow or Down Arrow to scroll Operator Intrfc: to Operator Intrfc. Press Enter. Change Password User Display 2. Press the Up Arrow or Down Arrow to scroll Parameters to User Display.
Page 118: Input Modes
2-94 Input Modes Input Modes The PowerFlex family of drives does not use a direct choice of 2-wire or 3-wire input modes, but allows full conﬁguration of the digital I/O. As a means of deﬁning the modes used, consider the following: •...
Page 119: Input Power Conditioning
[Speed Mode] or [Feedback Select] setting, no modiﬁcations (i.e. no PI adder, no slip adder, no trim adder, etc.) will be made to the reference. For PowerFlex 70 and PowerFlex 700 with Standard Control, the jog reference will always be a positive number limited between Minimum Speed and Maximum Speed.
Page 120: Language
2-96 Language Language PowerFlex drives are capable of communicating in 7 languages; English, Spanish, German, Italian, French, Portuguese and Dutch. All drive functions and information displayed on an LCD HIM are shown in the selected language. The desired language can be selected several different ways: •...
Page 121: Masks
Masks 2-97 Masks A mask is a parameter that contains one bit for each of the possible Adapters. Each bit acts like a valve for issued commands. Closing the valve (setting a bit's value to 0) stops the command from reaching the drive logic. Opening the valve (setting a bit's value to 1) allows the command to pass through the mask into the drive logic.
Page 122 2-98 Masks Direction Mask 0 0 0 0 0 1 0 0 Adapter # X 6 5 4 3 2 1 0 This “masks out” the reverse function from all adapters except Adapter 2, making the local HIM (Adapter 1) REV button inoperable. Also see Owners on page 2-109.
Page 123: Mop
2-99 The Motor Operated Pot (MOP) function is one of the sources for the frequency reference. The MOP function uses digital inputs to increment or decrement the Speed reference at a programmed rate. The MOP has three components: • [MOP Rate] parameter •...
Page 124 2-100 Important: The MOP reset only occurs on the stop edge and is not continuously cleared because the stop is asserted (this is always processed when a stop edge is seen, even if the drive is stopped). The reset only applies to the stop edge and not when a fault is detected.
Page 125: Motor Nameplate
Motor Nameplate 2-101 Motor Nameplate [Motor NP Volts] The motor nameplate base voltage deﬁnes the output voltage, when operating at rated current, rated speed, and rated temperature. [Motor NP FLA] The motor nameplate deﬁnes the output amps, when operating at rated voltage, rated speed, and rated temperature.
Page 126: Motor Overload
2-102 Motor Overload Motor Overload The motor thermal overload uses an IT algorithm to model the temperature of the motor. The curve is modeled after a Class 10 protection thermal overload relay that produces a theoretical trip at 600% motor current in ten (10) seconds and continuously operates at full motor current.
Page 127 Motor Overload 2-103 Changing Overload Factor OL % = 1.20 OL % = 1.00 OL % = 0.80 90 100 % of Base Speed 3. [Motor OL Hertz] is used to further protect motors with limited speed ranges. Since some motors may not have sufﬁcient cooling ability at lower speeds, the Overload feature can be programmed to increase protection in the lower speed areas.
Page 128 2-104 Motor Overload Duty Cycle for the Motor Thermal Overload When the motor is cold motor thermal overload will allow 3 minutes at 150%. When the motor is hot motor thermal overload will allow 1 minute at 150%. A continuous load of 102% will not trip. The duty cycle of the motor thermal overload is deﬁned as follows.
Page 129: Motor Start/Stop Precautions
Motor Start/Stop Precautions 2-105 Motor Start/Stop Input Contactor Precautions Precautions ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor.
Page 130: Output Current
2-106 Output Current Output Current [Output Current] This parameter displays the total output current of the drive. The current value displayed here is the vector sum of both torque producing and ﬂux producing current components. Output Devices Drive Output Contactor ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood.
Page 131: Output Frequency
Output Frequency 2-107 line reactors, it is recommended that the drive PWM frequency be set to its lowest value to minimize losses in the reactors. By using an output reactor the effective motor voltage will be lower because of the voltage drop across the reactor - this may also mean a reduction of motor torque.
Page 132: Overspeed Limit
2-108 Overspeed Limit Overspeed Limit The Overspeed Limit is a user programmable value that allows operation at maximum speed but also provides an “overspeed band” that will allow a speed regulator such as encoder feedback or slip compensation to increase the output frequency above maximum Speed in order to maintain maximum Motor Speed.
Page 133: Owners
Owners 2-109 Owners An owner is a parameter that contains one bit for each of the possible DPI or SCANport adapters. The bits are set high (value of 1) when its adapter is currently issuing that command, and set low when its adapter is not issuing that command.
Page 134 2-110 Owners Conversely, any number of adapters can simultaneously issue Stop Commands. Therefore, Stop Ownership is not exclusive. Example: The operator presses the Stop button on the Local HIM to stop the drive. When the operator attempts to restart the drive by pressing the HIM Start button, the drive does not restart.
Page 135: Parameter Access Level
Parameter Access Level 2-111 Parameter Access The PowerFlex 70 allows the user to restrict the number of parameters that Level are viewable on the LCD or LED HIM. By limiting the parameter view to the most commonly adjusted set, additional features that may make the drive seem more complicated are hidden.
Page 136: Power Loss
Vopen is normally 60VDC below Vtrigger (in a 480VAC drive). Both Vopen and Vtrigger are limited to a minimum of Vmin. This is only a factor if [Power Loss Level] is set to a large value. PowerFlex 70 This is a ﬁxed value. WARNING:...
Page 137 Power Loss 2-113 Line Loss Mode = Decel Line Loss Mode = Coast Recover Recover Close Close Trigger Trigger Open Open AC Input Volts AC Input Volts Table 2.U PF700 Bus Levels Class 200/240V AC 400/480V AC 600/690V AC Vslew 1.2 VDC 2.4 VDC 3.0 VDC...
Page 138 2-114 Power Loss Restart after Power Restoration If a power loss causes the drive to coast and power recovers the drive will return to powering the motor if it is in a “run permit” state. The drive is in a “run permit”...
Page 139 Power Loss 2-115 If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over. The power loss alarm is cleared. If the drive is in a “run permit” state, the reconnect algorithm is run to match the speed of the motor.
Page 140 2-116 Power Loss The inverter output is disabled and the motor coasts if the output frequency drops to zero or if the bus voltage drops below Vopen or if any of the “run permit” inputs are de-energized. The pre-charge relay opens if the bus voltage drops below Vopen. The pre-charge relay closes if the bus voltage rises above Vclose If the bus voltage rises above Vrecover for 20mS, the drive determines the power loss is over.
Page 141 Power Loss 2-117 The pre-charge relay opens if the bus voltage drops below Vopen/Vmin and closes if the bus voltage rises above Vclose. The power loss alarm in [Drive Alarm 1] is set and the power loss timer starts. The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Conﬁg 1] is set.
Page 142 2-118 Power Loss The Alarm bit in [Drive Status 1] is set if the Power Loss bit in [Alarm Conﬁg 1] is set. The drive faults with a F003 – Power Loss fault if the power loss timer exceeds [Power Loss Time] and the Power Loss bit in [Fault Conﬁg 1] is set.
Page 143 Power Loss 2-119 If power recovers while the drive is still in inertia ride through the power loss alarm is cleared and it then accelerates at the programmed rate to the set speed. Otherwise, if power recovers before power supply shutdown, the power loss alarm is cleared.
Page 144: Preset Frequency
2-120 Preset Frequency Preset Frequency There are 7 Preset Frequency parameters that are used to store a discrete frequency value. This value can be used for a speed reference or PI Reference. When used as a speed reference, they are accessed via manipulation of the digital inputs or the DPI reference command.
Page 145: Process Pi Loop
Process PI Loop 2-121 Process PI Loop [PI Conﬁg] [PI Control] [PI Reference Sel] [PI Setpoint] [PI Feedback Sel] [PI Integral Time] [PI Prop Gain] [PI Upper/Lower Limit] [PI Preload] [PI Status] [PI Ref Meter] [PI Feedback Meter] [PI Error Meter] [PI Output Meter] The internal PI function provides closed loop process control with proportional and integral control action.
Page 146 2-122 Process PI Loop There are two ways the PI Controller can be conﬁgured to operate. • Process Trim - The PI Output can be added to the master speed reference • Process Control - PI can have exclusive control of the commanded speed.
Page 147 Process PI Loop 2-123 When the PI is enabled, the output of the PI Controller is added to the ramped speed reference. Slip Comp Slip Adder Open Loop Linear Ramp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller Speed Control PI Fbk...
Page 148 2-124 Process PI Loop Slip Comp Slip Adder Open Loop Linear Ramp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller PI Disabled Speed Control PI Fbk When the PI is enabled, the speed reference is disconnected and PI Output has exclusive control of the commanded speed, passing through the linear ramp and s-curve.
Page 149 Process PI Loop 2-125 The option to invert the sign of PI Error is selected in the PI Conﬁguration parameter. PI_Config .Invert PI Ref Sel PI Error – PI_Config .Sqrt PI Fdbk Sel PI Fbk • Preload Integrator - This feature allows the PI Output to be stepped to a preload value for better dynamic response when the PI Output is enabled.
Page 150 2-126 Process PI Loop Pre-load command may be used when the PI has exclusive control of the commanded speed. With the integrator preset to the commanded speed there is no disturbance in commanded speed when PI is enabled. After PI is enabled the PI output is regulated to the required level.
Page 151 Process PI Loop 2-127 ≥0 +32K PI_Config .ZeroClamp Linear Spd Ref Spd Ramp Spd Cmd Ramp & S-Curve -32K +32K PI Output PI Ref Process PI -32K Controller PI Fbk • Feedback Square Root - This feature uses the square root of the feedback signal as the PI feedback.
Page 152 2-128 Process PI Loop 2. [PI Control] is a set of bits to dynamically enable and disable the operation of the process PI controller. When this parameter is interactively written to from a network it must be done through a data link so the values are not written to EEprom.
Page 153 Resetting the integrator eliminates this windup. NOTE: In the PowerFlex 70, once the drive has reached the programmable positive and negative PI limits, the integrator stops integrating and no further “windup” is possible.
Page 154 2-130 Process PI Loop PF70 options include DPI adapter ports, MOP, preset speeds, analog inputs and PI setpoint parameter. In the PF700, options are expanded to also include additional analog inputs, pulse input, and encoder input. The value used for reference is displayed in PI Reference as a read only parameter.
Page 155 Process PI Loop 2-131 If the application is Process Control, typically these limits would be set to the maximum allowable frequency setting. This allows the PI regulator to control over the entire required speed range. If the application is Process Trim, large trim corrections may not be desirable and the limits would be programmed for smaller values.
Page 156: Reﬂected Wave
Voltages in excess of twice the DC bus voltage (650V DC nominal at 480V input) will occur at the motor and can cause motor winding failure. The patented reﬂected wave correction software in the PowerFlex 70/700 will reduce these over-voltage transients from a VFD to the motor. The correction software modiﬁes the PWM modulator to prevent PWM pulses...
Page 157 Reﬂected Wave 2-133 the damping characteristics of the cable, bus voltage, and the time between pulses, the carrier frequency, modulation technique, and duty cycle. The plot below shows the per unit motor overvoltage as a function of cable length. This is for no correction versus the modulation correction code for varied lengths of #12 AWG cable to 600 feet for 4 and 8 kHz carrier frequencies.
Page 158: Reset Meters
2-134 Reset Meters Reset Meters The Elapsed kW Hour meter and/or Elapsed Time meter parameters are reset when parameter 200 is set to a value not equal to zero. After the reset has occurred, this parameter automatically returns to a value of zero. 200 [Reset Meters] Default: “Ready”...
Page 159: S Curve
S Curve 2-135 S Curve The S Curve function of the PowerFlex family of drives allows control of the “jerk” component of acceleration and deceleration through user adjustment of the S Curve parameter. Jerk is the rate of change of acceleration and controls the transition from steady state speed to acceleration or deceleration and vice versa.
Page 160 2-136 S Curve The acceleration and deceleration times are independent but the same S-curve percentage is applied to both of them. With S-curve set to 50%, acceleration time is extended by 0.5 seconds (1.0 * 50%), and deceleration time is extended by 1.0 seconds (2.0 * 50%). 70.0 60.0 50.0...
Page 161: Scaling Blocks
Scaling Blocks 2-137 The following graph shows an acceleration time of 1.0 second. After 0.75 seconds, the acceleration time is changed to 6.0 seconds. When the acceleration rate is changed, the commanded rate is reduced to match the requested rate based on the initial S-curve calculation. After reaching the new acceleration rate, the S-curve is then changed to be a function of the new acceleration rate.
Page 162: Shear Pin Fault
2-138 Shear Pin Fault Shear Pin Fault This feature allows the user to select programming that will fault the drive if the drive output current exceeds the programmed current limit. As a default, exceeding the set current limit is not a fault condition. However, if the user wants to stop the process in the event of excess current, the Shear Pin feature can be activated.
Page 163: Skip Frequency
Skip Frequency 2-139 Skip Frequency Figure 2.15 Skip Frequency Frequency Command Frequency Drive Output Frequency Skip + 1/2 Band 35 Hz Skip Frequency 30 Hz Skip – 1/2 Band 25 Hz Time Some machinery may have a resonant operating frequency that must be avoided to minimize the risk of equipment damage.
Page 164 2-140 Skip Frequency Skip Frequency Examples The skip frequency will have Max. Frequency hysteresis so the output does not toggle between high and low values. Three distinct bands can Skip Band 1 Skip Frequency 1 be programmed. If none of the skip bands touch or overlap, each band has its own high/low limit.
Page 165: Sleep Mode
Sleep Mode 2-141 Sleep Mode Operation The basic operation of the Sleep-Wake function is to Start (wake) the drive when an analog signal is greater than or equal to the user speciﬁed [Wake Level], and Stop (sleep) the drive when an analog signal is less than or equal to the user speciﬁed [Sleep Level].
Page 166 2-142 Sleep Mode Timers Timers will determine the length of time required for Sleep/Wake levels to produce true functions. These timers will start counting when the Sleep/ Wake levels are satisﬁed and will count in the opposite direction whenever the respective level is dissatisﬁed. If the timer counts all the way to the user speciﬁed time, it creates an edge to toggle the Sleep/Wake function to the respective condition (sleep or wake).
Page 167 Sleep Mode 2-143 Sleep / Wake Sources All deﬁned analog inputs for a product shall be considered as valid Sleep/ Wake sources. The Sleep/Wake function is completely independent of any other functions that are also using the assigned analog input. Thus, using the same analog input for both speed reference and wake control is permitted.
Page 168: Speed Control Speed Mode Speed Regulation
Speed Regulation speciﬁed regulation percentage. The [Speed Mode] parameter selects the speed regulation method for the drive, and can be set to one of 3 choices on the PowerFlex 70. Additional choices are available on the PowerFlex 700 (see page 2-147): •...
Page 169 Speed Control Speed Mode Speed Regulation 2-145 When the slip compensation mode is selected, the drive calculates an amount to increase the output frequency to maintain a consistent motor speed independent of load. The amount of slip compensation to provide is selected in [Slip RPM @ FLA].
Page 170 2-146 Speed Control Speed Mode Speed Regulation Internally, the drive converts the rated slip in RPM to rated slip in frequency. To more accurately determine the rated slip frequency in hertz, an estimate of ﬂux current is necessary. This parameter is either a default value based on motor nameplate data or the auto tune value.
Page 171 Speed Control Speed Mode Speed Regulation 2-147 Dough Stress Cookie Line Relief CUTTERS OVEN 5/40 PowerFlex PowerFlex PowerFlex PowerFlex Drive Drive Drive Drive Process PI – Process PI Loop on page 2-121 Encoder Feedback (PowerFlex 700 Vector Control Only) This section is under construction. If further information is required, please contact factory.
Page 172: Speed Reference
2-148 Speed Reference Speed Reference Operation The output frequency of the drive is controlled, in part, by the speed command or speed reference given to it. This reference can come from a variety of sources including: • HIM (local or remote) •...
Page 173 Speed Reference 2-149 When the drive is not running, pressing the HIM Jog button or a programmed Jog digital input will cause the drive to jog at a separately programmed jog reference. This speed reference value is entered in [Jog Speed], parameter 100.
Page 174 2-150 Speed Reference Polarity The reference can be selected as either unipolar or bipolar. Unipolar is limited to positive values and supplies only the speed reference. Bipolar supplies both the speed reference AND the direction command: + signals = forward direction and – signals = reverse direction. Trim If the speed reference is coming from the source speciﬁed in [Speed Ref A Sel] or [Speed Ref B Sel], the a trim signal can be applied to adjust the...
Page 175 Speed Reference 2-151 Max Spd Max Spd Min Spd Band Min Spd – Min Spd – Max Spd – Max Spd Maximum frequency The maximum frequency deﬁnes the maximum reference frequency. The actual output frequency may be greater as a result of slip compensation and other types of regulation.
Page 176: Start Inhibits
2-152 Start Inhibits Start Inhibits The [Start Inhibits] parameter indicates the inverted state of all start permissive conditions. If the bit is on (HI or 1), the corresponding permissive requirement has not been met and the drive is inhibited from starting.
Page 177: Start Permissives
Start Permissives 2-153 Start Permissives Start permissives are conditions required to permit the drive to start in any mode – run, jog, auto-tune, etc. When all permissive conditions are met the drive is considered ready to start. The ready condition is available as the drive ready status.
Page 178: Start-Up
PowerFlex drives offer a variety of Start Up routines to help the user commission the drive in the easiest manner and the quickest possible time. PowerFlex 70 Drives have the S.M.A.R.T Start routine and a Basic assisted routine for more complex setups. PowerFlex 700 drives have both of the above plus an advanced startup routine.
Page 179 Start-Up 2-155 Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup Basic Start Up (Top Level) Main Menu: Parameter Abort Device Select Memory Storage StartUp Preferences Startup PowerFlex 70 StartUp The drive must be stopped to Drive active? proceed.
Page 180 2-156 Start-Up Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (1) Basic Start Up (Input Voltage) StartUp 1. Input Voltage This step should be done only when "alternate voltage" is needed (see user manual). It will reset all drive...
Page 181 Start-Up 2-157 Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (2) Basic Start Up (Motor Data/Ramp) StartUp 2. Motr Dat/Ramp Use motor name- plate data and required ramp times for the following steps. Enter StartUp 2. Motr Dat/Ramp...
Page 182 2-158 Start-Up Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (3) Basic Start Up (Motor Tests) Startup 3. Motor Tests Enter This section optimizes torque performance and tests for proper Startup direction. Done Go to 0-1 (4) 3. Motor Tests...
Page 183 Start-Up 2-159 Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (4) Basic Start Up (Speed Limits) StartUp 4. Speed Limits This section defines min/max speeds, and direction method Enter StartUp StartUp 4. Speed Limits 4. Speed Limits Disable reverse...
Page 184 2-160 Start-Up Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (5) Basic Start Up (Speed Control) StartUp 5. Speed Control 5-13 Enter This section defines a source StartUp from which to control 5. Speed Control speed. StartUp Enter choice for 5.
Page 185 Start-Up 2-161 Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (6) Basic Start Up (Start,Stop,I/O) StartUp StartUp 6. Strt,Stop,I/O 6. Strt,Stop,I/O This section Complete these D. Done Go to 0-1 (7) defines I/O fun- steps in order: Enter B.
Page 186 2-162 Start-Up Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (7) Basic Start Up (Start,Stop,I/O [2]) 6-24 Go to 6-1 (C) StartUp B . Dig Outputs Done Make a selection 6-29 Digital Out 2 StartUp Done C.
Page 187 Start-Up 2-163 Figure 2.22 PowerFlex 700 Vector Control Option Startup For first time powerup... Select: Flux Vector Start Up (Top Level) Francais Espanol Deustch Italiano Main Menu: Abort (allow Start/Jog) Parameter Start-Up/Continue Device Select (disallow Start/Jog) Memory Storage Start-Up Preferences Any state...
Page 188 2-164 Start-Up Figure 2.22 PowerFlex 700 Vector Control Option Startup (1) Flux Vector Start Up (Motor Control Select) Start-Up 1-31 V/Hz The Fan/Pump option selects a B = Basic mode predefined V/Hz curve. Start-Up The Custom/Std. Start-Up 1. Motor Control option allows 1.
Page 189 Start-Up 2-165 Figure 2.22 PowerFlex 700 Vector Control Option Startup (2) Flux Vector Start Up (Motor Dat/Ramp) Start-Up 2. Motr Dat/Ramp Use motor name- plate data and required ramp times for the following steps. B = Basic mode Enter Start-Up 2.
Page 190 2-166 Start-Up Figure 2.22 PowerFlex 700 Vector Control Option Startup (3) 3-22 Flux Vector Start Up (Motor Tests) Start-Up Start-Up 3-21 Start-Up 3. Motor Tests 3. Motor Tests C.Inertia Test This section Select source of V/Hz Control optimizes motor Start/Stop 3-25 does not require performance and...
Page 191 Start-Up 2-167 Figure 2.22 PowerFlex 700 Vector Control Option Startup (4) Flux Vector Start Up (Speed Limits) Start-Up 4. Speed Limits This section defines min/max speeds and direction method Start-Up 4. Speed Limits Enter value for Maximum Speed +60.00 Hz xxx.xx <>...
Page 192 2-168 Start-Up Figure 2.22 PowerFlex 700 Vector Control Option Startup (5) Start-Up Flux 5-34 Flux Vector Start Up (Speed/Torque Control) 5. Speed Control Start-Up Vector This section C. Anlg Inputs Mode? 5-13 selects the Enter choice for Torque Go to 6-49 speed/torque Reference:: Start-Up...
Page 193 Start-Up 2-169 Figure 2.22 PowerFlex 700 Vector Control Option Startup (6) Flux Vector Start Up (Strt,Stop,I/O) Start-Up 6. Strt,Stop,I/O This section B = Basic mode defines I/O Start-Up Go to 6-27 B. Dig functions 6. Strt,Stop,I/O Outputs including Start Enter/ Complete these and Stop.
Page 194 2-170 Start-Up Figure 2.22 PowerFlex 700 Vector Control Option Startup (7) 6-27 Flux Vector Start Up (Start,Stop,I/O [2]) Start-Up Go to 6-1 (C.Anlg B. Dig Outputs Done Inputs) Make a selection Digital Out 2 6-34 Digital Out 1 Digital Out 3 6-28 Digital Out 3...
Page 195 Start-Up 2-171 Figure 2.22 PowerFlex 700 Vector Control Option Startup (8) Flux Vector Start Up (Application Functions) Start-Up 7.Appl. Features This allows programming of additional drive features. Start-Up Auto 7.Appl Features Restart Make a Selection Flying Start Auto Restart Done Start-Up Start-Up...
Page 196 2-172 Start-Up Figure 2.22 PowerFlex 700 Vector Control Option Startup (9) Flux Vector Start Up (S.M.A.R.T.) Start-Up SMART Enter choice of Speed units: Start-Up SMART Enter value for Digital In 2 Sel Start Start-Up 2. Motr Dat/Ramp Enter choice for Stop Mode A Coast ...
Page 197 Start-Up 2-173 Figure 2.22 PowerFlex 700 Vector Control Option Startup (10) Flux Vector Start Up (Motor Control Select) Start-Up Start-Up 1. Motor Control 1. Motor Control This section Enter choice of selects the type Control: of Motor Control the drive will Torque use.
Page 198: Stop Modes
2-174 Stop Modes Stop Modes [Stop Mode A, B] [DC Brake Lvl Sel] [DC Brake Level] [DC Brake Time] 1. Coast to Stop - When in Coast to Stop, the drive acknowledges the Stop command by shutting off the output transistors and releasing control of the motor.
Page 199 Stop Modes 2-175 4. Ramp To Stop is selected by setting [Stop Mode x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. The “normal” mode of machine operation can utilize [Decel Time 1].
Page 200 2-176 Stop Modes 5. Ramp To Hold is selected by setting [Stop Select x]. The drive will ramp the frequency to zero based on the deceleration time programmed into [Decel Time 1/2]. Once the drive reaches zero hertz, a DC Injection holding current is applied to the motor.
Page 201: Test Points
Test Points 2-177 Test Points [Testpoint 1 Sel] Default: [Testpoint 2 Sel] Min/Max: 0/999 Selects the function whose value is Display: displayed value in [Testpoint x Data]. These are internal values that are not accessible through parameters. See Testpoint Codes and Functions on page 4-10 for a listing of available codes and functions.
Page 202: Torque Performance Modes
2-178 Torque Performance Modes Torque Performance [Torque Perf Mode] selects the output mode of the drive. The choices are: Modes • Custom Volts/Hertz Used in multi-motor or synchronous motor applications. • Fan/Pump Volts/Hertz Used for centrifugal fan/pump (variable torque) installations for additional energy savings.
Page 203 Torque Performance Modes 2-179 2. Custom Custom Volts/Hertz allows a wide variety of patterns using linear segments. The default conﬁguration is a straight line from zero to rated voltage and frequency. This is the same volts/hertz ratio that the motor would see if it were started across the line.
Page 204 2-180 Torque Performance Modes Sensorless Vector Sensorless Vector technology consists of a basic V/Hz core surrounded by excellent current resolution (the ability to differentiate ﬂux producing current from torque producing current), a slip estimator, a high performance current limiter (or regulator) and the vector algorithms. CURRENT FEEDBACK - TOTAL Current CURRENT FEEDBACK...
Page 205 Torque Performance Modes 2-181 Autotune The purpose of Autotune is to identify the motor ﬂux current and stator resistance for use in Sensorless Vector Control and Economizer modes. The result of the ﬂux current test procedure is stored in the parameter [Flux Current].
Page 206 2-182 Torque Performance Modes If any errors are encountered during the Autotune process drive parameters are not changed, the appropriate fault code will be displayed in the fault queue, and the [Autotune] parameter is reset to 0. If the Autotune procedure is aborted by the user, the drive parameters are not changed and the [Autotune] parameter is reset to 0.
Page 207 Torque Performance Modes 2-183 The ﬁrst method is a normal start. During a normal start, ﬂux is established as the output voltage and frequency are applied to the motor. While the ﬂux is being built, the unpredictable nature of the developed torque may cause the rotor to oscillate even though acceleration of the load may occur.
Page 208 2-184 Torque Performance Modes Figure 2.25 Rated Flux Reached Ir Voltage - SVC Greater of IR Voltage or Voltage Boost - V/Hz Stator Voltage Flux Up Rotor Speed Voltage Motor Flux Motor Flux Stator Freq Flux Up Normal Operation Time Torque Current This parameter displays only the torque producing component of output current.
Page 209: Troubleshooting
Troubleshooting 2-185 Troubleshooting See also Diagnostics on page 2-48. Power Up Marker Copy of factory “drive under power” timer at the last power-up of the drive. Used to provide relevance of Fault 'n' Time values with respect to the last power-up of the drive.
Page 210: Unbalanced Or Ungrounded Distribution Systems
2-186 Unbalanced or Ungrounded Distribution Systems Unbalanced or Unbalanced Distribution Systems Ungrounded This drive is designed to operate on three-phase supply systems whose line Distribution Systems voltages are symmetrical. Surge suppression devices are included to protect the drive from lightning induced overvoltages between line and ground. Where the potential exists for abnormally high phase-to-ground voltages (in excess of 125% of nominal), or where the supply ground is tied to another system or equipment that could cause the ground potential to vary with...
Page 211: User Sets
User Sets 2-187 User Sets After a drive has been conﬁgured for a given application the user can store a copy of all of the parameter settings in a speciﬁc EEPROM area known as a “User Set.” Up to 3 User Sets can be stored in the drives memory to be used for backup, batch “switching”...
Page 212: Voltage Class
2-188 Voltage class Voltage class PowerFlex drives are sometimes referred to by voltage “class.” This class identiﬁes the general input voltage to the drive. This general voltage includes a range of actual voltages. For example, a 400 Volt Class drive will have an input voltage range of 380-480VAC.
Page 213: Watts Loss
PWM Frequency of 4 kHz. PowerFlex 70 For PowerFlex 70 drives, Internal Watts are those dissipated by the control structure of the drive and will be dissipated into the cabinet regardless of mounting style. External Watts are those dissipated directly through the heatsink and will be outside the cabinet for ﬂange mount and inside the...
Page 214 2-190 Watts Loss Table 2.Y PowerFlex 700 Watts Loss at Full Load/Speed, 4kHz Voltage ND HP Internal External Total 480V 1146 1143 1475 (1) Includes HIM and Standard I/O Board.
Page 215: Appendix A Dynamic Brake Selection Guide
Appendix Dynamic Brake Selection Guide The Dynamic Braking Selection Guide provided on the following pages contains detailed information on selecting and using dynamic brakes. Dynamic Braking Selection Guide www.abpowerflex.com...
Page 216 Dynamic Brake Selection Guide...
Page 217 Dynamic Braking Resistor Calculator www.abpowerﬂex.com...
Page 218 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.
Page 219 Internal Dynamic Brake Resistor ......3-1 PowerFlex 70 Power Curves ......3-4 PowerFlex 700 Power Curves .
Page 220 Table of Contents...
Page 221: Understanding How Dynamic Braking Works
Section Understanding How Dynamic Braking Works How Dynamic Braking Works When an induction motor’s rotor is turning slower than the synchronous speed set by the drive’s output power, the motor is transforming electrical energy obtained from the drive into mechanical energy available at the drive shaft of the motor.
Page 222: Dynamic Brake Components
Understanding How Dynamic Braking Works Dynamic Brake Components A Dynamic Brake consists of a Chopper (the chopper transistor and related control components are built into PowerFlex drives) and a Dynamic Brake Resistor. Figure 1.1 shows a simpliﬁed Dynamic Braking schematic. Figure 1.1 Simpliﬁed Dynamic Brake Schematic + DC Bus Voltage...
Page 223 Understanding How Dynamic Braking Works Chopper Transistor Voltage Control regulates the voltage of the DC bus during regeneration. The average values of DC bus voltages are: • 395V DC (for 240V AC input) • 658V DC (for 400V AC input) •...
Page 224 Understanding How Dynamic Braking Works Notes:...
Page 225: Determining Dynamic Brake Requirements
Section Determining Dynamic Brake Requirements How to Determine Dynamic Brake Requirements When a drive is consistently operating in the regenerative mode of operation, serious consideration should be given to equipment that will transform the electrical energy back to the ﬁxed frequency utility grid. As a general rule, Dynamic Braking can be used when the need to dissipate regenerative energy is on an occasional or periodic basis.
Page 226 Determining Dynamic Brake Requirements Gather the Following Information • Power rating from motor nameplate in watts, kilowatts, or horsepower • Speed rating from motor nameplate in rpm or rps (radians per second) • Required decel time (per 2.1, t – t Figure ).
Page 227 Determining Dynamic Brake Requirements Figure 2.1 Application Speed, Torque and Power Proﬁles Speed ω(t) ω b ω o t 1 + t 4 Torque T(t) t 1 + t 4 Power P(t) t 1 + t 4 -P b Drive Rated Regen Power P rg t 1 + t 4...
Page 228: Determine Values Of Equation Variables
Determining Dynamic Brake Requirements Determine Values of Equation Variables Step 2 Total Inertia × = Total inertia reﬂected to the motor shaft (kg-m or lb.-ft. = Motor inertia (kg-m or lb.-ft. = Gear ratio for any gear between motor and load (dimensionless) = Load inertia (kg-m or lb.-ft.
Page 229 Determining Dynamic Brake Requirements Step 3 Peak Braking Power ω ω ω – ---------------------------------------- – = Peak braking power (watts) 1.0 HP = 746 watts = Total inertia reﬂected to the motor shaft (kg-m 2πN ω = Rated angular rotational speed -------- - ----------- - ω...
Page 230 Determining Dynamic Brake Requirements For the purposes of this document, it is assumed that the motor used in the application is capable of producing the required regenerative torque and power. Step 4 Minimum Power Requirements for the Dynamic Brake Resistors It is assumed that the application exhibits a periodic function of acceleration and deceleration.
Page 231 Determining Dynamic Brake Requirements Step 5 Percent Average Load of the Internal Dynamic Brake Resistor Skip this calculation if an external dynamic brake resistor will be used. × ------- - = Average load in percent of dynamic brake resistor = Average dynamic brake resistor dissipation calculated in Step 4 (watts) = Steady state power dissipation capacity of dynamic brake...
Page 232 Determining Dynamic Brake Requirements Step 6 Percent Peak Load of the Internal Dynamic Brake Resistor Skip this calculation if an external dynamic brake resistor will be used. × ------- - = Peak load in percent of dynamic brake resistor = Peak braking power calculated in Step 2 (watts) = Steady state power dissipation capacity of dynamic brake resistors obtained from Table A.A...
Page 233: Example Calculation
• Load inertia is 4.0 lb.-ft. and is directly coupled to the motor • Motor rotor inertia is 2.2 lb.-ft. • A PowerFlex 70, 10 HP 480V Normal Duty rating is chosen. Calculate the necessary values to choose an acceptable Dynamic Brake. ×...
Page 234 2-10 Determining Dynamic Brake Requirements 750 Volts This was known because the drive is rated at 480 Volts rms. If the drive were rated 230 Volts rms, then V = 395 Volts. All of the preceding data and calculations were made from knowledge of the application under consideration.
Page 235 Determining Dynamic Brake Requirements 2-11 × Percent Peak Load ------- - 608.6 × ----------- - 1521% This is the result of the calculation outlined in Step 6. Record this value page 3-1. Now that the values of AL and PL have been calculated, they can be used to determine whether an internal or external resistor can be used.
Page 236 2-12 Determining Dynamic Brake Requirements Notes:...
Page 237: Evaluating The Internal Resistor
Section Evaluating the Internal Resistor Evaluating the Capability of the Internal Dynamic Brake Resistor To investigate the capabilities of the internal resistor package, the values of AL (Average Percent Load) and PL (Peak Percent Load) are plotted onto a graph of the Dynamic Brake Resistor’s constant temperature power curve and connected with a straight line.
Page 238 Evaluating the Internal Resistor 2. Find the correct constant temperature Power Curve for your drive type, voltage and frame. Power Curves for PowerFlex 70 Internal DB Resistors Drive Voltage Drive Frame(s) Figure Number A and B 400/480 A and B...
Page 239 Evaluating the Internal Resistor If the line connecting AL and PL lies entirely to the left of the Power Curve, then the capability of the internal resistor is sufﬁcient for the proposed application. Figure 3.1 Example of an Acceptable Resistor Power Curve 3000 480V Frame C 2800...
Page 240: Powerflex 70 Power Curves
Evaluating the Internal Resistor PowerFlex 70 Power Curves Figure 3.2 PowerFlex 70 – 240 Volt, Frames A and B 3000 240V Frames A & B 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.3 PowerFlex 70 –...
Page 241 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.5 PowerFlex 70 – 480 Volt, Frames A and B 3000 480V Frames A &...
Page 242 Evaluating the Internal Resistor Figure 3.6 PowerFlex 70 – 480 Volt, Frame C 3000 480V Frame C 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Decel Time (Seconds) Figure 3.7 PowerFlex 70 –...
Page 243: Powerflex 700 Power Curves
Evaluating the Internal Resistor PowerFlex 700 Power Curves Figure 3.8 PowerFlex 700 – 480 Volt, Frame 0 10000 480V Frame 0 9000 8000 7000 6000 5000 4000 3000 2000 1000 Decel Time (Seconds) Figure 3.9 PowerFlex 700 – 480 Volt, Frame 1 10000 480V Frame 1 9000...
Page 244 Evaluating the Internal Resistor Figure 3.10 PowerFlex 700 – 480 Volt, Frame 2 10000 480V Frame 2 9000 8000 7000 6000 5000 4000 3000 2000 1000 Decel Time (Seconds)
Page 245: Selecting An External Resistor
Section Selecting An External Resistor How to Select an External Dynamic Brake Resistor In order to select the appropriate External Dynamic Brake Resistor for your application, the following data must be calculated. Peak Regenerative Power (Expressed in watts) This value is used to determine the maximum resistance value of the Dynamic Brake Resistor.
Page 246 Selecting An External Resistor Protecting External Resistor Packages ATTENTION: PowerFlex drives do not offer protection for externally mounted brake resistors. A risk of ﬁre exists if external braking resistors are not protected. External resistor packages must be self-protected from over temperature or the protective circuit show below, or equivalent, must be supplied.
Page 247 Selecting An External Resistor Record the Values Calculated in Section 2 Calculate Maximum Dynamic Brake Resistance Value When using an internal Dynamic Brake Resistor, the value is ﬁxed. However, when choosing an external resistor, the maximum allowable Dynamic Brake resistance value (R ) must be calculated.
Page 248 Selecting An External Resistor Select Resistor Select a resistor bank from Table 4.A or your resistor supplier that has all of the following: • a resistance value that is less than the value calculated (R in ohms) • a resistance value that is greater than the minimum resistance listed Table A.A •...
Page 249 Selecting An External Resistor Table 4.A Resistor Selection for 240V AC Drives Catalog Catalog Ohms Watts Number Ohms Watts Number 222-1A 222-5A 222-1 222-5 225-1A 1378 225-5A 225-1 2056 220-5A 220-1A 2066 225-5 220-1 3125 220-5 222-2A 222-6A 222-2 1162 222-6 225-2A 1955...
Page 250 Selecting An External Resistor Table 4.B Resistor Selection for 480V AC Drives Catalog Catalog Ohms Watts Number Ohms Watts Number 442-1A 442-6A 442-1 1162 442-6 445-1A 1951 445-6A 440-1A 2906 445-6 445-1 2912 440-6A 440-1 4395 440-6 442-2A 1389 442-7A 442-2 1837 442-7...
Page 251 Selecting An External Resistor Table 4.C Resistor Selection for 600V AC Drives Catalog Catalog Ohms Watts Number Ohms Watts Number 552-1A 552-6A 552-1 1180 552-6 555-1A 1987 555-6A 550-1A 2950 555-6 555-1 2965 550-6A 550-1 4460 550-6 552-2A 1386 552-7A 552-2 1850 552-7...
Page 252 Selecting An External Resistor Notes:...
Page 253 Appendix Table A.A Minimum Dynamic Brake Resistance Rated Continuous Power, Minimum Ohms ( 10%), Internal Resistors (P External Resistors PowerFlex 70 PowerFlex 700 PowerFlex Product Nearest Drive Normal Regen DC Bus Standard Duty Rating Voltage (V Frame Watts Frame Watts Resistor 240V, 0.5 HP...
Page 254 Rated Continuous Power, Minimum Ohms ( 10%), Internal Resistors (P External Resistors PowerFlex 70 PowerFlex 700 PowerFlex Product Nearest Drive Normal Regen DC Bus Standard Duty Rating Voltage (V Frame Watts Frame Watts Resistor 400V, 55 kW – 10.4 10.4...
Page 256 Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201 Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444...
Page 257 Index Power, 2-35 Cable Termination, 2-106 AC Supply Source Considerations, Cable Trays, 2-38 Accel Mask, 2-97 Carrier (PWM) Frequency, 2-39 Accel Owner, 2-109 Accel Time, Conformity, 2-40 Accel Time 1/2, Requirements, 2-40 Agency Certiﬁcation, Circuit Breakers, 2-87 Alarm Queue, Clear Fault Owner, 2-109 Alarm x Code, Coast,...
Page 258 Digital Outx Sel, 2-5, 2-68, 2-69 Power Loss, 2-114 Dimensions Speed References, Bottom View, 1-17 Mounting PowerFlex 700, 1-13, 1-15 HIM Memory, 2-92 PowerFlex 70 Bottom View, HIM Operations, 2-92 Mounting, Human Interface Module Direction Control, 2-72 Language, 2-92 Direction Mask, 2-97 Password,...
Page 259 Index-3 Motor Nameplate, 2-101 Decel Owner, 2-109 Dig Outx Level, 2-70 Motor NP FLA, 2-101 Dig Outx OffTime, 2-71 Motor NP Hz, 2-101 Dig Outx OnTime, 2-71 Motor NP Power, 2-101 Digital Inx Sel, 2-52, 2-53 Motor NP Pwr Units, 2-101 Digital Outx Sel, 2-5, 2-68, 2-69...
Page 260 Index-4 PI Upper/Lower Limit, 2-121 Speed Regulation, 2-144 Power Loss, 2-112 Start Inhibits, 2-152 Power Loss Group, 2-114 Start Mask, 2-97 Power Loss Mode, 2-114 Start Owner, 2-109 Power Up Marker, 2-185 Start Permissives, 2-153 Power Wire, 2-35 Start/Stop, Repeated, 2-105 Preset Frequency, 2-120...
Page 261 Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201 Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444...

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Powerflex 700

Allen-Bradley PowerFlex 70 Reference Manual

Chapter 1 Specifications & Dimensions

Chapter 2 Detailed Drive Operation

Appendix A Dynamic Brake Selection Guide

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