Page 1 70 & 700 Adjustable Frequency AC Drive 70 Firmware Versions Standard Control xxx.x - 2.001 Enhanced Control xxx.x - 2.xxx 700 Firmware Versions Standard Control xxx.x - 3.001 Vector Control xxx.x - 3.001 Reference Manual www.abpowerflex.com...
Page 2 = Applies to PowerFlex 700 drives with [Motor Cntl Sel] set to “FVC Vector.” Vector = Indicates that the information presented is specific to the PowerFlex 70 Enhanced Control Option. DriveExplorer, DriveExecutive and SCANport are trademarks of Rockwell Automation, Inc.
Page 3 Summary of Changes The information below summarizes the changes to the PowerFlex 70/700 Reference Manual, publication PFLEX-RM001 since the last release. Change Page PowerFlex 700 60 HP, 600V Derate added PowerFlex 70 dimensions updated PowerFlex 700 Frame 4 dimensions updated...
Page 4 Summary of Changes Notes:...
Page 5: Table Of Contents
PowerFlex 70/700 Specifications ........
Page 6 Table of Contents Motor Control ..............2-116 Motor Nameplate .
Page 7 PowerFlex 70 Power Curves ........
Page 8 Table of Contents...
Page 9: 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 10: Powerflex 70/700 Specifications
PowerFlex 70/700 Specifications Category Specification Environment Altitude: 1000 m (3300 ft) max. without derating Maximum Surrounding Air Temperature without Derating: PowerFlex 70 IP20, NEMA Type 1: 0 to 50 degrees C (32 to 122 degrees F) Flange Mount: 0 to 50 degrees C (32 to 122 degrees F)
Page 11: Input/Output Ratings
Each PowerFlex Drive has normal and heavy duty torque capabilities. The listings can be found in Tables through 2.W. Heat Dissipation Watts Loss on page 2-213. Derating Guidelines PowerFlex 70 & 700 Altitude and Efficiency Frame Type Derate Altitude 100% 1,000 2,000...
Page 12 Derating Guidelines PowerFlex 70 Ambient Temperature/Load Frame Class Enclosure Frequency Derate 400V Open, NEMA 2-10 kHz None Type 1, IP20, Flange 400V Open, NEMA 2-10 kHz None Type 1, IP20, Flange 400V NEMA Type 2-8 kHz None 1, Flange 10 kHz...
Page 13 Derating Guidelines Frame Voltage Rating Enclosure Frequency Derate 460V 15 HP Open, NEMA 2-6 kHz cont. Type 1, IP20 6 kHz 8 kHz 10 kHz % of Output FLA 400V 15 kW Open, NEMA 8-10 kHz Type 1, IP20 8 kHz 10 kHz % of Output FLA 460V...
Page 14 Derating Guidelines Frame Voltage Rating Enclosure Frequency Derate 400V 37 kW Open, NEMA 4-10 kHz cont. Type 1, IP20 4 kHz 6 kHz 10 kHz 8 kHz % of Output FLA 460V 30 HP Open, NEMA 2-10 kHz None Type 1, IP20 40 HP Open, NEMA 6-10 kHz...
Page 15 – – 22 (18.5) 30 (25) – – – – – – – Figure 1.1 PowerFlex 70 Frames A-D IP20/66 (NEMA Type 1/4X/12) Flange Mount 123.0 55.6 (4.84) (2.19) (0.23) Dimensions are in millimeters and (inches). Weight Frame A kg (lbs.) IP20 / NEMA Type 1 122.4 (4.82)
Page 16: Powerflex 70 Dimensions
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 17 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 18 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 19 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 20 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 21 PowerFlex 700 Dimensions 1-13 PowerFlex 700 Table 1.B PowerFlex 700 Frames Dimensions AC Input DC Input 208/240 400V 480V 600V 540V 650V Frame ND HP HD HP ND kW HD kW ND HP HD HP ND HP HD HP ND HP HD HP ND HP HD HP 0.33 0.37 0.25...
Page 22 1-14 PowerFlex 700 Dimensions Figure 1.8 PowerFlex 700 Frame 4 15.0 (0.59) 7.0 (0.28) dia. 7.0 (0.28) 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 4 220.0 (8.66)
Page 23 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 24: 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 25 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 26 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 27 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 28 1-20 PowerFlex 700 Dimensions Notes:...
Page 29: 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 30: Advanced Tuning
Advanced Tuning Advanced Tuning Advanced Tuning Parameters – PF700 Vector Control Only ATTENTION: To guard against unstable or unpredictable operation, the following parameters must only be changed by qualified service personnel. The following parameters can only be viewed when “2, Unused” is selected in parameter 196, [Param Access Lvl].
Page 31 Advanced Tuning Parameter Name & Description Values 505 [Kd Ln Ls Bus Reg] Default: Line Loss Bus Reg Kd is a derivative gain, Min/Max: 0/10000 which is applied to the sensed bus voltage to Units: anticipate dynamic changes and minimize them.
Page 32 Advanced Tuning Parameter Name & Description Values 538 [Rec Delay Time] Default: 1000 Min/Max: 1/30000 Units: 513 [PWM DAC Enable] Default: Reserved. Do Not Adjust Min/Max: Units: [DAC47-A] Default: [DAC47-B] Min/Max: 0/7432 [DAC47-C] Units: [DAC47-D] Reserved. Do Not Adjust 518 [Host DAC Enable] Default: Reserved.
Page 33: Alarms
Alarms Parameter Name & Description Values 540 [Freq Reg Kp] Default: 2000 Proportional gain for the Frequency Min/Max: 0/32767 Regulator. Units: 541 [Encdlss Ang Comp] Default: Min/Max: –1023/1023 Units: 542 [Encdlss Vlt Comp] Default: Min/Max: 0/115 Units: 544 [Excitation Kp] Default: 1800 Min/Max:...
Page 34 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 35 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 36 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” “Run” [Digital Out3 Sel] Vector Selects the drive status that will energize Options:...
Page 37: 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 38 2-10 Analog Inputs...
Page 39 Analog Inputs 2-11...
Page 40 2-12 Analog Inputs Analog Scaling [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 41 Analog Inputs 2-13 Output Hertz Analog Scaling [Speed Reference A Sel] = “Analog In 1” [Analog In 1 Hi] [Speed Ref A Hi] 60 Hz [Analog In 1 Lo] [Speed Ref A Lo] 0 Hz Configuration #2: • [Anlg In Config], bit 0 = “0” (Voltage) •...
Page 42 2-14 Analog Inputs Configuration #3: • [Anlg In Config], bit 0 = “1” (Current) • [Speed Ref A Sel] = “Analog In 1” • [Speed Ref A Hi] = 60 Hz • [Speed Ref A Lo] = 0 Hz • [Analog In 1 Hi] = 20 mA •...
Page 43 Analog Inputs 2-15 Output Hertz Analog Scaling [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] 60 Hz Configuration #5: • [Anlg In Config], bit 0 = “0” (Voltage) •...
Page 44 2-16 Analog Inputs Configuration #6 – Torque Ref: Vector • [Anlg In Config], bit 0 = “0” (Voltage) • [Torque Ref A Sel] = “Analog In 1” • [Torque Ref A Hi] = 200% • [Torque Ref A Lo] = 0% •...
Page 45 Analog Inputs 2-17 Signal Loss [Analog In 1, 2 Loss] Signal loss detection can be enabled for each analog input. The [Analog In x Loss] parameters control whether signal loss detection is enabled for each input and defines what action the drive will take when loss of any analog input signal occurs.
Page 46 2-18 Analog Inputs No signal loss detection is possible while an input is in bipolar voltage mode. The signal loss condition will never occur even if signal loss detection is enabled. 1.9V 1.6V Signal Loss End Signal Loss Condition Condition Trim An analog input can be used to trim the active speed reference (Speed Reference A/B).
Page 47 Analog Inputs 2-19 How [Analog Inx Hi/Lo] & [Speed Ref A Hi/Lo] Scales the Frequency Command Slope with [Minimum/Maximum Speed] Example 1: Consider the following setup: • [Anlg In Config], bit 0 = “0” (voltage) • [Speed Ref A Sel] = “Analog In 1” •...
Page 48 2-20 Analog Inputs Example 2: Consider the following setup: • [Anlg In Config], bit 0 = “0” (voltage) • [Speed Ref A Sel] = “Analog In 1” • [Analog In1 Hi] = 10V • [Analog In1 Lo] = 0V • [Speed Ref A Hi] = 50hz •...
Page 49: Analog Outputs
Refer to Option Definitions in User Manual.. 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 50 2-22 Analog Outputs Important: If absolute value is enabled but the quantity selected for output is not a signed quantity, then the absolute value operation will have no effect. 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].
Page 51 Analog Outputs 2-23 This example shows that you can have [Analog Out1 Lo] greater than [Analog Out1 Hi]. The result is a negative slope on the scaling from original quantity to analog output voltage. Negative slope could also be applied to any of the other examples in this section.
Page 52 2-24 Analog Outputs Filtering Software filtering will be performed on the analog outputs for certain signal sources, as specified in Table 2.A. “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 53 Analog Outputs 2-25 [Anlg Out1 Scale] Default: Vector v3 [Anlg Out2 Scale] Vector v3 Min/Max: [Analog Out1 Sel] Sets the high value for the range of Units: 0.01 analog out scale. Entering 0.0 will disable this scale and max scale will be used. Example: If [Analog Out Sel] = “Commanded Trq,”...
Page 54 2-26 Analog Outputs Parameter Controlled Analog Output Enables the analog outputs to be controlled by Datalinks to the drive. [Anlg1 Out Setpt] Default: 20.000 mA, 10.000 Volts Vector v3 [Anlg2 Out Setpt] Vector v3 Min/Max: 0.000/20.000mA Sets the analog output value from a –/+10.000V Units: 0.001 mA...
Page 55: Auto/Manual
Auto/Manual 2-27 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 56 2-28 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 57: Auto Restart (Reset/Run)
Auto Restart (Reset/Run) 2-29 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 58 2-30 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 59: Autotune
Autotune 2-31 Autotune Description of parameters determined by the autotune tests. Flux Current Test [Flux Current Ref] is set by the flux current test. Flux current is the reactive portion of the motor current (portion of the current that is out of phase with the motor voltage) and is used to magnetize the motor.
Page 60 2-32 Autotune Next, the Dynamic or Static Autotune should be performed: • Dynamic - the motor shaft will rotate during this test. The dynamic autotune procedure determines both the stator resistance and motor flux current. The test to identify the motor flux current requires the load to be uncoupled from the motor to find an accurate value.
Page 61 Autotune 2-33 Next the Dynamic or Static Autotune should be performed: • Dynamic - the motor shaft will rotate during this test. The dynamic autotune procedure determines the stator resistance, motor flux current, and leakage inductance. The test to identify the motor flux current requires the load to be uncoupled from the motor to find an accurate value.
Page 62: Block Diagrams
2-34 Block Diagrams Block Diagrams The following pages contain the block diagrams for the PowerFlex 700 Vector Control drive. Figure 2.1 PowerFlex 700VC Block Diagams (1)
Page 63 Block Diagrams 2-35 Figure 2.2 PowerFlex 700VC Block Diagams (2)
Page 64 2-36 Block Diagrams Figure 2.3 PowerFlex 700VC Block Diagams (3)
Page 65 Block Diagrams 2-37 Figure 2.4 PowerFlex 700VC Block Diagams (4)
Page 66 2-38 Block Diagrams Figure 2.5 PowerFlex 700VC Block Diagams (5)
Page 67 Block Diagrams 2-39 Figure 2.6 PowerFlex 700VC Block Diagams (6)
Page 68 2-40 Block Diagrams Figure 2.7 PowerFlex 700VC Block Diagams (7)
Page 69 Block Diagrams 2-41 Figure 2.8 PowerFlex 700VC Block Diagams (8) Save MOP Ref MOP Control (At Stop) Drive Logic Rslt (2.0 ms) (Stop) Clear Drive Logic Rslt (Mop Inc) Add Rate To MOP Output MOP Rate [3B2] [3D4] Ramp Drive Logic Rslt (Mop Dec) MOP Frequency Scale...
Page 70 2-42 Block Diagrams Figure 2.9 PowerFlex 700VC Block Diagams (9)
Page 71 Block Diagrams 2-43 Figure 2.10 PowerFlex 700VC Block Diagams (10)
Page 72 2-44 Block Diagrams Figure 2.11 PowerFlex 700VC Block Diagams (11)
Page 73 Block Diagrams 2-45 Figure 2.12 PowerFlex 700VC Block Diagams (12)
Page 74: Bus Regulation
2-46 Bus Regulation 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 75 Bus Regulation 2-47 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 76 2-48 Bus Regulation Figure 2.13 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 77 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 78 2-50 Bus Regulation Table 2.C Voltage Class DC Bus Memory DB On Setpoint DB Off Setpoint < 342V DC 375V DC On – 4V DC > 342V DC Memory + 33V DC < 685V DC 750V DC On – 8V DC >...
Page 79: Cable, Control
Cable, Control 2-51 If [Bus Reg Mode A], parameter 161 is set to “Both-DB 1st” Both regulators are enabled, and the operating point of the Dynamic Brake Regulator is lower than that of the Bus Voltage Regulator. The Bus Voltage Regulator setpoint follows the “DB Turn On”...
Page 80: Carrier (Pwm) Frequency
2-52 Carrier (PWM) Frequency Carrier (PWM) page 1-3 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 81: Ce Conformity
CE Conformity 2-53 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 82 Drive with any Comm Option – – – ✔ ✔ Drive with ControlNet – – Table 2.F PowerFlex 70 – EN61800-3 First Environment Restricted Distribution First Environment Restricted Distribution Restrict Motor Internal External Comm Cable Common Drive Description Cable to:...
Page 83: Copy Cat
Table 2.H 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 84: Current Limit
2-56 Current Limit 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 85 Current Limit 2-57 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 86: Datalinks
2-58 Datalinks 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 87 Datalinks 2-59 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 88: Dc Bus Voltage / Memory
2-60 DC Bus Voltage / Memory 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 89: Digital Inputs
Cable Selection for Digital Inputs. Wiring Examples Refer to the appropriate PowerFlex user manual for wiring diagrams. 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 90 2-62 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 91 Digital Inputs 2-63 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 92 2-64 Digital Inputs Table 2.I 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 93 Digital Inputs 2-65 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 94 2-66 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 95 Digital Inputs 2-67 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 96 2-68 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 97 Digital Inputs 2-69 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 2-127).
Page 98 2-70 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 99 Digital Inputs 2-71 • 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 100 2-72 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 101 Digital Inputs 2-73 • 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 102 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 103 Digital Inputs 2-75 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 104 2-76 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.K Input function combinations that produce “DigIn CflctB” alarm Fwd/ Start Stop–CF Run Run Fwd...
Page 105 The bits are “1” when the input is closed and “0” when the input is open. Digital In Examples PowerFlex 70 Figure 2.16 shows a typical digital input configuration that includes “3-wire” start. The digital input configuration parameters should be set as shown.
Page 106: 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 107 Digital Outputs 2-79 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 108 2-80 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 109 Digital Outputs 2-81 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 110: 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 111: Dpi
PowerFlex 70 & 700 support the existing SCANport and DPI communication protocols. Multiple devices of each type (SCANport or DPI) can be attached to and communicate with PowerFlex 70 & 700 drives at the same time. This communication interface is the primary way to interact with, and control the drive.
Page 112 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 113 2-85 Table 2.L 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 114: Drive Overload
2-86 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 115 Drive Overload 2-87 Figure 2.18 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 2.19 shows the boundary of heavy duty operation.
Page 116 2-88 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 117 Drive Overload 2-89 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 118: Drive Ratings (Kw, Amps, Volts)
2-90 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 119: Economizer (Auto-Economizer)
Economizer (Auto-Economizer) 2-91 Economizer Refer to Torque Performance Modes on page 2-205. (Auto-Economizer) Economizer mode consists of the sensorless vector control with an additional energy savings function. When steady state speed is achieved, the economizer becomes active and automatically adjusts the drive output voltage based on applied load. By matching output voltage to applied load, the motor efficiency is optimized.
Page 120: Fan Curve
2-92 Fan Curve Fan Curve When torque performance (see page 2-205) is set to Fan/Pump, the relationship between frequency and voltage is shown in the following figure. The fan/pump curve generates voltage that is a function of the stator frequency squared up to the motor nameplate frequency. Above base frequency voltage is a linear function of frequency.
Page 121: 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 122 2-94 Faults 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 123 Faults 2-95 Resetting or Clearing a Fault A latched fault condition can be cleared by the following: 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.
Page 124: Flux Braking
2-96 Flux Braking Flux Braking You can use flux braking to stop the drive or to shorten the Vector deceleration time to a lower speed. Other methods of deceleration or stopping may perform better depending on the motor and the load. To enable flux braking: 1.
Page 125: Flux Up
Flux Up 2-97 Flux Up [Flux Up Mode] AC induction motors require flux to be established before controlled torque can be developed. To build flux in these motors, voltage is applied to them. PowerFlex drives have two methods to flux the motor. The first method is a normal start.
Page 126: Flying Start
2-98 Flying Start 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 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.
Page 127 Flying Start 2-99 Application Example In some applications, such as large fans, wind or drafts may rotate the fan in the reverse direction when the drive is stopped. If the drive were started in the normal manner, its output would begin at zero Hz, acting as a brake to bring the reverse rotating fan to a stop and then accelerating it in the correct direction.
Page 128: Fuses And Circuit Breakers
2-100 Fuses and Circuit Breakers 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 129 Fuses and Circuit Breakers 2-101 Table 2.M PF70 208/240 Volt AC Input Recommended Protection Devices Dual Circuit Motor Input Element Time Non-Time Breaker Circuit Drive (7)(8) Rating Ratings Output Amps Delay Fuse Delay Fuse Protector 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 130 2-102 Fuses and Circuit Breakers Table 2.O PF70 600 Volt AC Input Recommended Protection Devices Dual Motor Input Element Time Non-Time Circuit Circuit Drive (7)(8) Rating Ratings Output Amps Delay Fuse Delay Fuse Breaker Protector 140M Motor Starter with Adjustable Current Range Catalog Number ND HD Amps kVA Cont.
Page 131 Fuses and Circuit Breakers 2-103 Table 2.P PF700 208 Volt AC Input Protection Devices Motor Dual Circuit Circuit Input Element Time Non-Time Breaker Protector 140M Motor Starter with Adjustable Current Drive (5)(6) Rating Freq. Temp. Ratings Output Amps Delay Fuse Delay Fuse Range Catalog...
Page 132 2-104 Fuses and Circuit Breakers Table 2.R PF700 400 Volt AC Input Protection Devices Dual Motor Input Element Time Non-Time Circuit Circuit 140M Motor Starter with Adjustable Drive (5)(6) Rating Freq. Temp. Ratings Output Amps Delay Fuse Delay Fuse Breaker Protector Current Range Catalog...
Page 133 Fuses and Circuit Breakers 2-105 Table 2.T PF700 600 Volt AC Input Protection Devices Motor Dual Circuit Circuit 140M Motor Starter with Adjustable Current Input Element Time Non-Time Breaker Protector Drive (5)(6) Rating Freq. Temp. Ratings Output Amps Delay Fuse Delay Fuse Range Catalog...
Page 134 2-106 Fuses and Circuit Breakers Table 2.V PF700 540 Volt DC Input Protection Devices DC Input Drive Rating Ratings Output Amps Catalog Number ND HD Amps kW Cont. 1 Min. 3 Sec. Fuse Bussmann Style Fuse 540 Volt DC Input 20BC1P3 1 0.37 0.25 1.3 BUSSMANN_JKS-3...
Page 135: Grounding, General
Grounding, General 2-107 Grounding, General Refer to “Wiring and Grounding Guidelines for PWM AC Drives,” publication DRIVES-IN001. HIM Memory Copy Cat on page 2-55. HIM Operations Selecting a Language See also Language on page 2-111. PowerFlex 700 drives support multiple languages.
Page 136: Input Devices
2-108 Input Devices The User Display The User Display is shown when module keys have been inactive for a predetermined amount of time. The display can be programmed to show pertinent information. Setting the User Display Step Key(s) Example Displays 1.
Page 137: Input Modes
Input Modes 2-109 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 138: 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 139: Language
Language 2-111 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 140: Linking Parameters
2-112 Linking Parameters Linking Parameters (Vector Control Option Only) Most parameter values are entered directly by the user. However, certain parameters can be “linked,” so the value of one parameter becomes the value of another. For Example: the value of an analog input can be linked to [Accel Time 2].
Page 141 Linking Parameters 2-113 Table 2.X Linkable Parameters Number Parameter Number Parameter Maximum Voltage Bus Reg Ki Compensation Bus Reg Kp Flux Up Mode Bus Reg Kd Flux Up Time Flying StartGain SV Boost Filter Auto Rstrt Delay IR Voltage Drop Wake Level Flux Current Ref Wake Time...
Page 142: Masks
2-114 Masks 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 143: Mop
2-115 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 2-127.
Page 144: Motor Control
2-116 Motor Control If the value is “SAVE MOP Ref” when the drive power returns, the MOP reference is reloaded with the value from the non-volatile memory. When the bit is set to 0, the MOP reference defaults to zero when power is restored.
Page 145: Motor Nameplate
Motor Nameplate 2-117 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 146: Motor Overload
2-118 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 147 Motor Overload 2-119 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 148 2-120 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 149: Motor Start/Stop Precautions
• 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.
Page 150: Mounting
2-122 Mounting Mounting Refer to the Chapter 1 of the correct drive User Manual for mounting instructions and limitations. As a general rule, drives should be mounted on a metallic flat surface in the vertical orientation. If other orientations are being considered, contact the factory for additional data.
Page 151 Notch Filter 2-123 Figure 2.25 Resonance The insert shows the resonant frequency in detail. Figure 2.26 shows the same mechanical gear train as Figure 2.25. [Notch Filter Freq] is set to 10. Figure 2.26 10 Hz Notch...
Page 152: Output Current
2-124 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 153: Output Frequency
Output Frequency 2-125 against insulation breakdown resulting from high dv/dt. When using motor 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 154: Overspeed Limit
2-126 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 155: Owners
Owners 2-127 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 156 2-128 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 157: Parameter Access Level
Parameter Access Level 2-129 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 158: Power Loss
Vopen is normally 60V DC 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 159 Power Loss 2-131 Line Loss Mode = Decel Line Loss Mode = Coast Recover Recover Close Close Trigger Trigger Open Open AC Input Volts AC Input Volts Table 2.Z PF700 Bus Levels Class 200/240V AC 400/480V AC 600/690V AC Vslew 1.2V DC 2.4V DC 3.0V DC...
Page 160 2-132 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 161 Power Loss 2-133 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 162 2-134 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 163 Power Loss 2-135 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 164 2-136 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 165: Preset Frequency
Preset Frequency 2-137 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 166 2-138 Process PI Loop control by itself is a ramp output correction. This type of control gives a smoothing effect to the output and will continue to integrate until zero error is achieved. By itself, integral control is slower than many applications require and therefore is combined with proportional control (PI).
Page 167 Process PI Loop 2-139 Slip Comp Slip Adder Open Loop Linear Ramp Spd Ref Spd Cmd & S-Curve Process PI Ref Process PI Controller Speed Control PI Fbk PI Disabled When the PI is enabled, the output of the PI Controller is added to the ramped speed reference.
Page 168 2-140 Process PI Loop regardless of flow changes. With the drive turning the pump at the required speed, the pressure is maintained in the system. Pump Pressure Transducer Motor PI Feedback Desired Pressure [PI Reference Sel] However, when additional valves in the system are opened and the pressure in the system drops, the PI error will alter its output frequency to bring the process back into control.
Page 169 Process PI Loop 2-141 Configuration To operate the drive in PI Regulator Mode for the Standard Control option, change the mode by selecting “Process PI” through the [Speed Mode] parameter. Three parameters are used to configure, control, and indicate the status of the logic associated with the Process PI controller;...
Page 170 2-142 Process PI Loop As below shown on the left, when the PI is enabled the PI output will start from zero and regulate to the required level. When PI is enabled with PI Load Value is set to a non-zero value the output begins with a step as shown below on the right.
Page 171 Process PI Loop 2-143 When PI Ramp Reference is selected in the PI Configuration parameter, and PI is disabled, the value used for the PI reference will be the PI feedback. This will cause PI error to be zero. Then when the PI is enabled the value used for the PI reference will ramp to the selected value for PI reference at the selected acceleration or deceleration rate.
Page 172 2-144 Process PI Loop 100.0 75.0 50.0 25.0 -25.0 -50.0 -75.0 -100.0 -100.0 -75.0 -50.0 -25.0 25.0 50.0 75.0 100.0 Normalized Feedback to operate during the decel ramp until the PI output becomes more than the master reference. When set to “0,” the drive will disable PI and perform a normal stop.
Page 173 Process PI Loop 2-145 may become enabled as soon as the drive goes into run. If analog input signal loss is detected, the PI loop is disabled. DigInCfg DigIn PI_Control PI_Status Running Stopping .PI_Enable .PI_Enable Signal Loss .Enabled .PI_Enable DigInCfg PI_Control .PI_Enable .PI_Enable...
Page 174 2-146 Process PI Loop 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. 3. [PI Status] parameter is a set of bits that indicate the status of the process PI controller •...
Page 175 Process PI Loop 2-147 Configuration Example: The PI reference meter and PI feedback meter should be displayed as positive and negative values. Feedback from our dancer comes into Analog Input 2 as a 0-10V DC signal. • [PI Reference Sel] = 0 “PI Setpoint” •...
Page 176 2-148 Process PI Loop Positive and Negative Limits The PI has parameters to define the positive and negative limits of the output PI Positive Limit, and PI Negative Limit. The limits are used in two places; on the integrator and on the sum of the Kp + Ki terms. Providing an external source doesn't turn on Hold, the integrator is allowed to integrate all the way to Positive or Negative limit.
Page 177 Process PI Loop 2-149 Figure 2.28 Process PI Block Diagram PI_Config .ZeroClamp PI_Config .Exclusive PI_Status .Enabled +32K Linear Ramp Spd Ref Spd Ramp Spd Cmd & S-Curve -32K PI Pos Limit +32K PI Neg Limit PI Kp -32K ≥0 PI ExcessErr ≥...
Page 178 2-150 Process PI Loop Figure 2.29 Vector Control Option Process PI Loop Overview PI Lower Limit PI Upper Limit PI Ref Hi PI Configuration PI Prop Gain Reference PI Ref PI Error Linear Hi/Lo PI Cmd Ramp PI BW Limit PI Status Filter Scale...
Page 179 Process PI Loop 2-151 Percent of Reference 124 [PI Configuration] thru Sets configuration of the PI regulator. 1 =Enabled 0 =Disabled x =Reserved Bit # * Vector Control Option Only ** Vector firmware 3.001 & later Factory Default Bit Values When using Process PID control the output can be selected as percent of the Speed Reference.
Page 180: 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 less than a minimum time from being applied to the motor.
Page 181 Reflected Wave 2-153 Initially, the cable is in a fully charged condition. A transient disturbance occurs by discharging the cable for approximately 4ms. The propagation delay between the inverter terminals and motor terminals is approximately 1ms. The small time between pulses of 4ms does not provide sufficient time to allow the decay of the cable transient.
Page 182: Regen Power Limit
2-154 Regen Power Limit Regen Power Limit The [Regen Power Lim] is programmed as a percentage of the Vector rated power. The mechanical energy that is transformed into electrical power during a deceleration or overhauling load condition is clamped at this level.
Page 183 S Curve 2-155 80.0 60.0 40.0 20.0 -20.0 -40.0 -60.0 -80.0 Seconds S-Curve Selection S-curve is enabled by defining the time to extend the acceleration and deceleration. The time is entered as a percentage of acceleration and deceleration time. In this case acceleration time is 2.0 seconds. The line on the left has s-curve set to 0%.
Page 184 2-156 S Curve Time to Max Speed Note that S-curve time is defined for accelerating from 0 to maximum speed. With maximum speed = 60 Hz, Ta = 2.0 sec, and S-curve = 25%, acceleration time is extended by 0.5 seconds (2.0 * 25%). When accelerating to only 30 Hz the acceleration time is still extended by the same amount of time.
Page 185: Scale Blocks
Scale Blocks 2-157 Scale Blocks See also Analog Scaling on page 2-12 page 2-22. Scale blocks are used to scale a parameter value. [Scalex In Vector Value] is linked to the parameter that you wish to scale. [Scalex In Hi] determines the high value for the input to the scale block.
Page 186 2-158 Scale Blocks Parameter Settings Parameter Value Description [Trim In Select] 11, Preset 1 Preset 1 becomes the trim speed [Scale1 In Hi] 10.0 V Hi value of Analog In 2 [Scale1 In Lo] Lo value of Analog In 2 [Scale1 Out Lo] 0 RPM Lo value of desired Trim...
Page 187 Scale Blocks 2-159 Parameter Links Destination Parameter Source Parameter Description [Scale1 In Value] [Encoder Speed] We are scaling Encoder Speed = Link Scale1 In Hi Analog Out1 Hi Encoder Speed Scale1 Out Scale1 In Value Analog Out1 Value Scale1 In Lo Analog Out1 Lo Example Configuration #3 In this configuration Analog In 2 is a –10V to +10V signal which...
Page 188: Shear Pin Fault
2-160 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 189: Skip Frequency
Skip Frequency 2-161 Skip Frequency Figure 2.30 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 190 2-162 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 191: Sleep Mode
Sleep Mode 2-163 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 192 2-164 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 193 Sleep Mode 2-165 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 194: Speed Control, Mode, Regulation & Vector Speed Feedback
The [Speed Mode] parameter selects the speed regulation method for the drive, and can be set to one of 3 choices on the PowerFlex 70/700. The PowerFlex 700 Vector option has 5 choices. In addition, [Feedback Select] in the Vector option, chooses the feedback used for the speed regulator.
Page 195 Speed Control, Mode, Regulation & Vector Speed Feedback 2-167 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 196 2-168 Speed Control, Mode, Regulation & Vector Speed Feedback 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 197 Speed Control, Mode, Regulation & Vector Speed Feedback 2-169 Dough Stress Cookie Line Relief CUTTERS OVEN 5/40 PowerFlex PowerFlex PowerFlex PowerFlex Drive Drive Drive Drive Process PI – Process PI Loop on page 2-137 Encoder Vector There is (1) encoder input on the I/O board of the PowerFlex 700VC. The encoder input must be line driver type, quadrature (dual channel) or pulse (single channel).
Page 198: Speed Feedback Filter
2-170 Speed Feedback Filter Encoderless/Deadband Vector Encoderless/Deadband is recommended when more than a 120:1 speed range of operation is not required and the user will set the speed reference below 0.5Hz/15 RPM. The deadband will help prevent cogging and unstable motor operation below a reference of 0.5Hz/15RPM by clamping the speed and torque regulators to zero.
Page 199: Speed Reference
Speed Reference 2-171 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 200 SpeedRef = CommandFreq x 32767 [Maximum Freq] For example, to send out a command frequency of 60 Hz on a PowerFlex 70 or 700 with default settings we would calculate the following: 60 Hz SpeedRef =...
Page 201 Speed Reference 2-173 For example, to send out a command frequency of 60 Hz with [Maximum Freq] = 70 Hz, we would calculate the following: 60 Hz SpeedRef = x 32767 = 28086 70 Hz 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.
Page 202 2-174 Speed Reference For example, if the following parameters are set: [Analog In x Hi] = 10 V [Analog In x Lo] = 0 V [Speed Ref A Hi] = 45 Hz [Speed Ref x Lo] = 5 Hz then the speed command for the drive will be linearly scaled between 45 Hz at maximum analog signal and 5 Hz at minimum analog signal.
Page 203 Speed Reference 2-175 Min/Max Speed [Max Speed] Maximum and minimum speed limits are applied to the reference. These limits apply to the positive and negative references. The minimum speed limits will create a band that the drive will not run continuously within, but will ramp through.
Page 204: Speed Regulator
2-176 Speed Regulator Speed Regulator The drive takes the speed reference that is specified by the Vector speed reference control loop and compares it to the speed feedback. The speed regulator uses proportional and integral gains to adjust the torque reference that is sent to the motor.
Page 205: Speed/Torque Select
Speed/Torque Select 2-177 Speed/Torque Select [Speed/Torque Mod] is used to choose the operating mode for Vector the drive. The drive can be programmed to operate as a velocity regulator, a torque regulator, or a combination of the two. Refer to 2.36. Figure 2.36 Speed/Torque Mod Spd Reg PI Out...
Page 206 2-178 Speed/Torque Select Torque Regulation Mode A torque regulated application can be described as any process that requires some tension control. An example of this is a winder or unwind where material is being “drawn” or pulled with a specific tension required. The process requires another element setting the speed.
Page 207 Speed/Torque Select 2-179 Figure 2.38 Internal Torque Command At Speed Relay Load Step (Decrease) Speed Feedback Sum Mode Configuring the drive in this mode allows an external torque input to be summed with the torque command generated by the speed regulator. The drive requires both a speed reference and a torque reference to be linked.
Page 208: Speed Units
2-180 Speed Units Speed Units [Speed Units] selects the units to be used for all speed related Vector parameters. The options for [Speed Units] are: • “Hz” – converts status parameters only to Hz. • “RPM” – converts status parameters only to RPM. •...
Page 209: 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 210 2-182 Start-Up Figure 2.39 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 211 Start-Up 2-183 Figure 2.39 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 212 2-184 Start-Up Figure 2.39 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 213 Start-Up 2-185 Figure 2.39 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 214 2-186 Start-Up Figure 2.39 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 215 Start-Up 2-187 Figure 2.39 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 216 2-188 Start-Up Figure 2.39 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 217 Start-Up 2-189 Figure 2.39 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 218 2-190 Start-Up Figure 2.40 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 219 Start-Up 2-191 Figure 2.40 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 220 2-192 Start-Up Figure 2.40 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 221 Start-Up 2-193 Figure 2.40 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 222 2-194 Start-Up Figure 2.40 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 223 Start-Up 2-195 Figure 2.40 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 224 2-196 Start-Up Figure 2.40 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 225 Start-Up 2-197 Figure 2.40 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 226 2-198 Start-Up Figure 2.40 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 227 Start-Up 2-199 Figure 2.40 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 228 2-200 Start-Up Figure 2.40 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 229: Stop Modes
Stop Modes 2-201 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 230 2-202 Stop Modes 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 231 Stop Modes 2-203 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 232: Test Points
2-204 Test Points 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 233: Torque Performance Modes
Torque Performance Modes 2-205 Torque Performance [Torque Perf Mode] or [Motor Cntl Sel] (Vector) selects the output mode of Modes the drive. The choices are: • 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 234 2-206 Torque Performance Modes would see if it were started across the line. As seen in the diagram below, the volts/hertz ratio can be changed to provide increased torque performance when required. The shaping takes place by programming 5 distinct points on the curve: –...
Page 235 Torque Performance Modes 2-207 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 236: Torque Reference
2-208 Torque Reference Flux Vector Control Vector The drive takes the speed reference that is specified by the Speed Reference Selection Block and compares it to the speed feedback. The speed regulator uses Proportional and Integral gains to adjust the torque reference for the motor.
Page 237: Troubleshooting
Troubleshooting 2-209 [Torque Ref B], parameter 431 is used to supply an external reference for how much torque is desired. The scaling of this parameter is from –800 to +800, via [Torq Ref B Hi] and [Torq Ref B Lo]. The Torque Ref B is then multiplied by [Torq Ref B Mul], parameter 434.
Page 238: Unbalanced Or Ungrounded Distribution Systems
2-210 Unbalanced or Ungrounded Distribution Systems Unbalanced or Refer to “Wiring and Grounding Guidelines for Pulse Width Modulated Ungrounded (PWM) AC Drives,” publication DRIVES-IN001 for detailed information on Unbalanced or Ungrounded Distribution Systems. Distribution Systems 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.”...
Page 239: Voltage Class
Voltage Class 2-211 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 240: Voltage Tolerance
2-212 Voltage Tolerance Voltage Tolerance Drive Rating Nominal Line Nominal Motor Drive Full Power Drive Operating Voltage Voltage Range Range 200-240 200* 200-264 180-264 208-264 230-264 380-400 380* 380-528 342-528 400-528 460-528 500-600 575* 575-660 432-660 (Frames 0-4 Only) 500-690 575* 575-660 475-759...
Page 241: 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 cabinet for panel mount.
Page 242 2-214 Watts Loss Voltage ND HP External Watts Internal Watts Total Watts Loss 480V 1107 1130 1479 1402 1845 1711 2204 1930 2512 600V 1053 1361 1467 1874 1400 1900 1668 2280 Worst case condition including Vector Control board, HIM and Communication Module...
Page 243 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 Resistor Calculator Selection Guide www.abpowerflex.com...
Page 244 Dynamic Brake Selection Guide...
Page 245 Dynamic Braking Resistor Calculator www.abpowerflex.com...
Page 246 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls” (Publication SGI-1.1 available from your local Rockwell Automation Sales Office or online at http://www.ab.com/ manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices.
Page 247 Internal Dynamic Brake Resistor..... . 3-1 PowerFlex 70 Power Curves ......3-4 PowerFlex 700 Power Curves .
Page 248 Table of Contents...
Page 249: 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 250: 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 251 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: Transistor Turn-On Maximum Power Calculation Drive Input Voltage Voltage Voltage 375V DC 395V DC 375V DC 395V DC 750V DC...
Page 252 Understanding How Dynamic Braking Works Notes:...
Page 253: 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 254 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 Figure 2.1, t –...
Page 255 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 256: 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 WK in lb.-ft. = Motor inertia (kg-m or WK in lb.-ft. = Gear ratio for any gear between motor and load (dimensionless) Load Speed -----------------------------...
Page 257 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 258 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 259 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. Important: The value of AL should not exceed 100%. = Average dynamic brake resistor dissipation calculated in Step 4 (watts)
Page 260 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 261: 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 262 Skip this calculation if an external dynamic brake resistor will be used. In this case, a 10 HP PowerFlex 70 drive has an internal resistor rated for 40 continuous watts. Because P = 114.1 watts, and is greater than the...
Page 263 Determining Dynamic Brake Requirements 2-11 If the cycle cannot be adjusted, the decel time must be extended or the system inertia lowered to reduce the average load on the resistor. Another option is to use an external resistor. Calculate the Percent Average Load. You will need this number to calculate the Percent Peak Load.
Page 264 2-12 Determining Dynamic Brake Requirements Notes:...
Page 265: 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 266 Evaluating the Internal Resistor 3. 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 267 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 268: 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 269 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 270 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 271 Evaluating the Internal Resistor Figure 3.8 PowerFlex 70 – 600 Volt, Frames A and B 3000 600V 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 3.9 PowerFlex 70 –...
Page 272: Powerflex 700 Power Curves
Evaluating the Internal Resistor PowerFlex 700 Power Curves Figure 3.10 PowerFlex 700 – 240 Volt, Frame 1 to 5 HP 3000 240V Frame 1 to 5 HP 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 Decel Time (Seconds) Figure 3.11 PowerFlex 700 –...
Page 273 Evaluating the Internal Resistor Figure 3.12 PowerFlex 700 – 240 Volt, Frame 2 3000 240V Frame 2 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 Decel Time (Seconds) Figure 3.13 PowerFlex 700 – 480 Volt, Frame 0 3000 400V Frame 0 2800 2600...
Page 274 3-10 Evaluating the Internal Resistor Figure 3.14 PowerFlex 700 – 480 Volt, Frame 1 3000 480V Frame 1 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 Decel Time (Seconds) Figure 3.15 PowerFlex 700 – 480 Volt, Frame 2 3000 480V Frame 2 2800...
Page 275: 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 276 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 277 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 278 Selecting An External Resistor Select Resistor Select a resistor bank from the following tables or from 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 279 Selecting An External Resistor Table 4.A Resistor Selection – 240V AC Drives Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 2700 24600 T80R2K7 16431 220-1 2100 19100 T80R2K1 16431 220-1A 1500 17500 T80R1K5 16431 225-1 1200 13700 T80R1K2 6416...
Page 280 Selecting An External Resistor 240V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 2700 23300 T48R2K7 2400 30100 T34R2K4 1500 16600 T48R1K5 1800 25100 T34R1K8 1200 20800 T48R1K2 19100 T34R900W 17500 T48R900W 14700 T34R300W 16500 T48R600W...
Page 281 Selecting An External Resistor 240V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 20700 T14R900W 10200 310000 T23R10K2 19400 T14R600W 7490 328000 T23R7K49 15400 T14R300W 6310 179000 T23R6K31 2100 23100 T23R2K1 12784 890985 220-9 1500 20200...
Page 282 Selecting An External Resistor 240V AC Drives Continued Watt Catalog Ohms Watts Seconds Number 5080 401000 T5F4R5K8 2680 185000 T5F4R2K68 1670 55700 T5F4R1K67 132000 8077000 T4F8R132K0 99300 6159000 T4F8R99K3 61000 3916000 T4F8R61K0 58200 3696000 T4F8R58K2 34600 2310000 T4F8R34K6 25800 984000 T4F8R25K8 19200 586000...
Page 283 Selecting An External Resistor Table 4.B Resistor Selection – 480V AC Drives Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 10600 T117R900W 13302 440-1 10100 T117R600W 13615 445-1 7950 T117R300W 13302 440-1A 4225 445-1A 4200 19100 T97R4K2 4225 442-1...
Page 284 4-10 Selecting An External Resistor 480V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 10600 T77R600W 12784 369388 440-9 8210 T77R300W 8537 302807 440-9A 8454 305624 445-9 11000 448000 T60R11K0 5720 184031 445-9A 6900 164000 T60R6K9...
Page 285 Selecting An External Resistor 4-11 480V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 8920 267000 T20R8K92 19396 615920 440-10 5940 260000 T20R5K94 12826 359925 445-10 1500 28000 T20R1K5 12667 359925 440-10A 18500 T20R900W 8487 253840...
Page 286 4-12 Selecting An External Resistor 480V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 10.4 15500 1742000 T10F4R15K5 132000 8077000 T4F8R132K0 10.4 11000 359000 T10F4R11K0 99300 6159000 T4F8R99K3 10.4 8890 801000 T10F4R8K89 61000 3916000 T4F8R61K0 10.4...
Page 287 Selecting An External Resistor 4-13 Table 4.C Resistor Selection – 600V AC Drives Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 52000 AKR2120P1K2 6260 550-1 6260 555-1 3000 20800 T117R3K0 6260 550-1A 2700 14300 T117R2K7 6260 555-1A 2100 18600...
Page 288 4-14 Selecting An External Resistor 600V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 3000 21300 T77R3K0 8672 370410 555-10A 2700 23800 T77R2K7 6000 125000 T45R6K0 2100 19100 T77R2K1 5138 308128 552-10 1500 16400 T77R1K5 3883...
Page 289 Selecting An External Resistor 4-15 600V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 7490 328000 T23R7K49 18000 1017000 T32R18K0 6310 179000 T23R6K31 17100 931000 T32R17K1 2100 23100 T23R2K1 12700 410000 T32R12K7 1500 20200 T23R1K5 8420...
Page 290 4-16 Selecting An External Resistor 600V AC Drives Continued Watt Catalog Watt Catalog Ohms Watts Seconds Number Ohms Watts Seconds Number 15400 T14R300W 2680 185000 T5F4R2K68 1670 55700 T5F4R1K67 68911 10015318 550-16 46464 3891643 552-20 46170 2247026 555-16 30978 1651395 552-20A 45934 2387466...
Page 291 Appendix Table A.A Minimum Dynamic Brake Resistance Rated Continuous Power, Minimum Ohms (±10%), Internal Resistors (P External Resistors Regen DC PowerFlex 70 PowerFlex 700 PowerFlex Product Drive Normal Bus Voltage Duty Rating Frame Watts Frame Watts 240V, 0.5 HP 30.4 35.8...
Page 292 Rated Continuous Power, Minimum Ohms (±10%), Internal Resistors (P External Resistors Regen DC PowerFlex 70 PowerFlex 700 PowerFlex Product Drive Normal Bus Voltage Duty Rating Frame Watts Frame Watts 400V, 37 kW 18.7 480V, 50 HP 400V, 45 kW 15.4...
Page 295 Index Motor, Length, 2-51 Cable Termination, 2-124 Accel Mask, 2-114 Cable Trays, 2-51 Accel Owner, 2-127 Carrier (PWM) Frequency, 2-52 Accel Time, Accel Time 1/2, Conformity, 2-53 Advanced Tuning, 2-61 Requirements, 2-53 Agency Certification, Circuit Breakers, 2-100 Alarm Queue, Clear Fault Owner, 2-127 Alarm x Code, Coast,...
Page 296 Index-2 Bottom View, 1-17 Human Interface Module Mounting Language, 2-107 PowerFlex 700, 1-13, 1-15 Password, 2-107 PowerFlex 70 User Display, 2-108 Bottom View, Mounting, I/O Wiring Direction Control, 2-82 Analog, 2-18 Direction Mask, 2-114 Digital, 2-61 Direction Owner, 2-127 Input Contactor...
Page 297 Index-3 Mounting Dimensions, Direction Mask, 2-114 Direction Owner, 2-127 Fault Clr Mask, 2-114 Notch Filter, 2-122 Fault Config x, 2-160 Feedback Select, 2-166 Flying Start En, 2-98 Output Contactor Flying Start Gain, 2-98 Start/Stop, 2-121 Flying StartGain, 2-98 Output Current, 2-124 Jog Mask, 2-114...
Page 298 Index-4 PI Status, 2-137 Speed Units, 2-180 PI Upper/Lower Limit, 2-137 Speed/Torque Select, 2-177 Power Loss, 2-130 Start Inhibits, 2-180 Power Loss Group, 2-132 Start Mask, 2-114 Power Loss Mode, 2-132 Start Owner, 2-127 Power Up Marker, 2-95 Start Permissives, 2-180 Preset Frequency, 2-137...

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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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