Allen-Bradley PowerFlex 70, powerflex 700 Reference guide

Allen-Bradley PowerFlex 70, powerflex 700 Reference guide
Adjustable
Frequency AC Drive
Volume 1
PowerFlex 70
PowerFlex 700
Standard Control
Vector Control
Reference Manual
www.abpowerflex.com
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls” (Publication SGI-1.1
available from your local Allen-Bradley Sales Office or online at http://
www.ab.com/manuals/gi) describes some important differences between
solid state equipment and hard-wired electromechanical devices. Because of
this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will the Allen-Bradley Company be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for
illustrative purposes. Because of the many variables and requirements
associated with any particular installation, the Allen-Bradley Company
cannot assume responsibility or liability for actual use based on the
examples and diagrams.
No patent liability is assumed by Allen-Bradley Company with respect to
use of information, circuits, equipment, or software described in this
manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety
considerations.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss.
Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
Shock Hazard labels may be located on or inside the drive to
alert people that dangerous voltage may be present.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
COLOR-KEYED is a registered trademark of Thomas & Betts Corporation.
Table of Contents
Chapter 1
Specifications & Dimensions
PowerFlex 70/700 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Input/Output Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
PowerFlex 70 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
PowerFlex 700 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Chapter 2
Detailed Drive Operation
Accel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Analog Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Auto/Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Bus Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Cable, Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Cable, Motor Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Cable, Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Cable, Standard I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
CabIe Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Carrier (PWM) Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Copy Cat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Current Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Datalinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
DC Bus Voltage / Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Decel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
DPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Drive Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Drive Ratings (kW, Amps, Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Economizer
(Auto-Economizer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Fan Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Grounding, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
HIM Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
HIM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Input Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Jog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
MOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Motor Start/Stop Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
ii
Table of Contents
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Output Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Output Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Output Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Output Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Overspeed Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
Owners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
PET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Power Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
Preset Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
Process PI Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Reflected Wave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Reset Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
Reset Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
RFI Filter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
S Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135
Scaling Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
Shear Pin Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-139
Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
Speed Control, Speed Mode, Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
Speed Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-148
Start Inhibits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-152
Start Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154
Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-174
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-177
Thermal Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-177
Torque Performance Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-185
Unbalanced or Ungrounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-186
User Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-187
Voltage class. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-188
Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-189
Appendix A
Dynamic Brake Selection Guide
Section 1
Understanding How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dynamic Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Determining Dynamic Brake Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
How to Determine Dynamic Brake Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Determine Values of Equation Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Section 3
Evaluating the Internal Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Evaluating the Capability of the Internal Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PowerFlex 70 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PowerFlex 700 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Section 4
Selecting An External Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
How to Select an External Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chapter
1
Specifications & Dimensions
PowerFlex 70/700
Specifications
Category
Specification
PF70
PF700
Agency
Certification Type 1, Flange Type 4X/
IP 30
Type
✔
✔
12, IP 66 All
✔
✔
Description
c UL

✔
✔
✔
✔
✔
Listed to UL508C and CAN/CSA-C2.2 No. 14-M91.
US
NA
Listed to UL508C for plenums (rear heatsink only).
✔
✔
✔
✔
Marked for all applicable European Directives (1)
EMC Directive (89/336/EEC)
EN 61800-3 Adjustable Speed electrical power drive systems
Low Voltage Directive (73/23/EEC)
EN 50178 Electronic Equipment for use in Power Installations
Certified to AS/NZS, 1997 Group 1, Class A.
✔
NA
Listed to UL2128.
✔
NA
Certified to Criteria, 1983.
N223
The drive is also designed to meet the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and Operation of
Adjustable Speed Drive Systems.
IEC 146 - International Electrical Code.
(1)
Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high [Pulse Freq] readings.
Category
Protection
Specification
PowerFlex 70 Drive
AC Input Overvoltage Trip:
AC Input Undervoltage Trip:
Bus Overvoltage Trip:
Bus Undervoltage Output Shutoff:
Bus Undervoltage Fault Level:
Nominal Bus Voltage:
PowerFlex 700
AC Input Overvoltage Trip:
AC Input Undervoltage Trip:
Bus Overvoltage Trip:
Bus Undervoltage Shutoff & Fault:
Nominal Bus Voltage:
All Drives
Heat Sink Thermistor:
Drive Overcurrent Trip
Software Overcurrent Trip:
Hardware Overcurrent Trip:
Line transients:
200-208V
Drive
247VAC
120VAC
405VDC
204VDC
160VDC
281VDC
240V
Drive
285VAC
138VAC
405VDC
204VDC
160VDC
324VDC
380/400
Drive
475VAC
233VAC
810VDC
407VDC
300VDC
540VDC
480V
Drive
570VAC
280VAC
810VDC
407VDC
300VDC
648VDC
600V
690V
Drive
Drive
690VAC
345VAC
1013VDC
508VDC
375VDC
810VDC
153VDC 153VDC 305VDC
See PowerFlex 70 above
305VDC
381VDC
See PowerFlex 70 above
Monitored by microprocessor overtemp trip
200% of rated current (typical)
220-300% of rated current (dependent on drive rating)
up to 6000 volts peak per IEEE C62.41-1991
1-2
PowerFlex 70/700 Specifications
Category
Protection
(continued)
Environment
Electrical
Control
Specification
Control Logic Noise Immunity:
Power Ride-Thru:
Logic Control Ride-Thru:
Ground Fault Trip:
Short Circuit Trip:
Altitude:
Maximum Surrounding Air
Temperature without Derating:
PowerFlex 70
Open Type, IP20, NEMA
Type 1 and Flange Mount:
IP56, NEMA Type 4X:
PowerFlex 700
IP20, NEMA Type 1:
IP56, NEMA Type 4X:
Storage Temperature (all const.):
Atmosphere
Relative Humidity:
Shock:
Vibration:
Voltage Tolerance:
Frequency Tolerance:
Input Phases:
Displacement Power Factor
All Drives:
Efficiency:
Maximum Short Circuit Rating:
Actual Short Circuit Rating:
Method:
Carrier Frequency
PF70 - A-D Frame Drives:
PF700 - 0-6 Frames:
Output Voltage Range:
Output Frequency Range:
Frequency Accuracy
Digital Input:
Analog Input:
Frequency Control
Speed Control
Showering arc transients up to 1500V peak
15 milliseconds at full load
0.5 seconds minimum, 2 seconds typical
Phase-to-ground on drive output
Phase-to-phase on drive output
1000 m (3300 ft) max. without derating
0 to 50 degrees C (32 to 122 degrees F)
0 to 40 degrees C (32 to 104 degrees F)
0 to 50 degrees C (32 to 122 degrees F)
0 to 50 degrees C (32 to 122 degrees F)
–40 to 70 degrees C (–40 to 158 degrees F)
Important: Drive must not be installed in an area where the ambient
atmosphere contains volatile or corrosive gas, vapors or dust. If the drive
is not going to be installed for a period of time, it must be stored in an area
where it will not be exposed to a corrosive atmosphere.
5 to 95% non-condensing
15G peak for 11ms duration (±1.0 ms)
0.152 mm (0.006 in.) displacement, 1G peak
–10% of minimum, +10% of maximum.
47-63 Hz.
Three-phase input provides full rating for all drives. Single-phase
operation provides 50% of rated current.
0.98 across entire speed range.
97.5% at rated amps, nominal line volts.
200,000 Amps symmetrical.
Determined by AIC rating of installed fuse/circuit breaker.
Sine coded PWM with programmable carrier frequency. Ratings apply to
all drives (refer to the Derating Guidelines on page 1-4). The drive can be
supplied as 6 pulse or 12 pulse in a configured package.
2, 4, 8 & 10 kHz. Drive rating based on 4 kHz.
2, 4, 8 & 10 kHz. Drive rating based on 4 kHz.
0 to rated motor voltage
Standard Control – 0 to 400 Hz., Vector Control – 0 to 420 Hz
Within ±0.01% of set output frequency.
Within ±0.4% of maximum output frequency.
Speed regulation - with Slip Compensation
Standard
0.5% of base speed across 40:1 speed range
40:1 operating range
10 rad/sec bandwidth
Speed regulation - with Slip Compensation
Standard
0.5% of base speed across 80:1 speed range
80:1 operating range
20 rad/sec bandwidth
Speed regulation - with feedback
Vector
0.1% of base speed across 80:1 speed range
80:1 operating range
20 rad/sec bandwidth
Speed regulation - without feedback
Vector
0.1% of base speed across 120:1 speed range
120:1 operating range
50 rad/sec bandwidth
Speed regulation - with feedback
Vector
0.001% of base speed across 120:1 speed range
1000:1 operating range
250 rad/sec bandwidth
Vector
Vector
Input/Output Ratings
Category
Control
(continued)
Specification
Torque Regulation
Selectable Motor Control:
Stop Modes:
Accel/Decel:
Intermittent Overload:
Current Limit Capability:
Electronic Motor Overload Protection
Encoder
Type:
PowerFlex 700 Supply:
Only
Quadrature:
Duty Cycle:
Requirements:
1-3
Torque Regulation - without feedback
Vector
±10%, 600 rad/sec bandwidth
Torque Regulation - with feedback
Vector
±5%, 2500 rad/sec bandwidth
Sensorless Vector with full tuning. Standard V/Hz with full custom
capability. PF700 adds Vector Control.
Multiple programmable stop modes including - Ramp, Coast, DC-Brake,
Ramp-to-Hold and S-curve.
Two independently programmable accel and decel times. Each time may
be programmed from 0 - 3600 seconds in 0.1 second increments.
110% Overload capability for up to 1 minute
150% Overload capability for up to 3 seconds
Proactive Current Limit programmable from 20 to 160% of rated output
current. Independently programmable proportional and integral gain.
Class 10 protection with speed sensitive response. Investigated by U.L. to
comply with N.E.C. Article 430. U.L. File E59272, volume 12.
Incremental, dual channel
12V, 500 mA. 12V, 10 mA minimum inputs isolated with differential
transmitter, 250 kHz maximum.
90°, ±27 degrees at 25 degrees C.
50%, +10%
Encoders must be line driver type, quadrature (dual channel) or pulse
(single channel), 8-15V DC output, single-ended or differential and
capable of supplying a minimum of 10 mA per channel. Maximum input
frequency is 250 kHz. The Encoder Interface Board accepts 12V DC
square-wave with a minimum high state voltage of 7.0V DC (12 volt
encoder). Maximum low state voltage is 0.4V DC.
Input/Output Ratings
Each PowerFlex Drive has normal and heavy duty torque capabilities. The
listings can be found in Tables 2.N through 2.R.
Heat Dissipation
See Watts Loss on page 2-189.
Derating Guidelines
PowerFlex 70 & 700 Altitude and Efficiency
Frame Type
All
Altitude
Derate
100%
% of Drive Rated Amps
90%
80%
70%
0
1,000
2,000
3,000
4,000
5,000
6,000
Altitude (m)
Efficiency
(typical)
100
vs. Speed
95
vs. Load
90
85
80
75
10
20
30
40 50 60 70
% Speed/% Load
80
90
100
PowerFlex 70 Ambient Temperature/Load
Frequency Derate
2-10 kHz None
2-10 kHz
None
2-8 kHz
10 kHz
None
50
Max Ambient Temperature, C
Frame Class Enclosure
A
400V Open, NEMA
Type 1, IP20,
Flange
B
400V Open, NEMA
Type 1, IP20,
Flange
C
400V NEMA Type
1, Flange
10kHz
49
48
40
D
400V
NEMA Type
1, Flange
2-6 kHz
8-10 kHz
50
60
70
80
% of Output FLA
90
100
None
50
Max Ambient Temperature, C
Derating Guidelines
% Efficiency
1-4
8kHz
48
46
44
10kHz
42
40
50
60
70
% of Full Load Amps
80
90
100
Derating Guidelines
1-5
PowerFlex 700 Ambient Temperature/Load
7.5 HP
400V
11 kW
Frequency (1) Derate
2-10 kHz
None
2-10 kHz
2-6 kHz
None
50
o
1
460V
Enclosure
Open, NEMA
Type 1, IP20
Open, NEMA
Type 1, IP20
Open, NEMA
Type 1, IP20
Max. Surrounding Air Temp, C
ND
Frame Voltage Rating
0
400V
5.5 kW
45
6 kHz
40
35
8 kHz
30
25
10 kHz
20
40
50
60
70
80
90
100
% of Output FLA
Open, NEMA 2-6 kHz
Type 1, IP20
o
15 HP
Max. Surrounding Air Temp, C
460V
50
45
6 kHz
40
35
8 kHz
30
25
10 kHz
20
40
50
60
70
80
90
100
% of Output FLA
15 kW
Open, NEMA 8-10 kHz
Type 1, IP20
50
o
400V
Max. Surrounding Air Temp, C
2
8 kHz
45
40
10 kHz
35
40
Open, NEMA 10 kHz
Type 1, IP20
o
20 HP
Max. Surrounding Air Temp, C
460V
70
80
% of Output FLA
90
100
48
10 kHz
46
44
42
40
50
60
70
% of Output FLA
80
90
100
50
o
Max. Surrounding Air Temp, C
Open, NEMA 6-10 kHz
Type 1, IP20
60
50
40
25 HP
50
40
6 kHz
30
8 kHz
20
10 kHz
10
0
40
50
60
70
80
90
100
400V
18.5 kW
Open, NEMA 6-10 kHz
Type 1, IP20
o
3
Max. Surrounding Air Temp, C
% of Output FLA
50
40
6 kHz
30
8 kHz
20
10
10 kHz
0
40
50
60
70
% of Output FLA
80
90
100
Derating Guidelines
o
30 kW
Enclosure
Frequency (1) Derate
Open, NEMA 2-10 kHz
None
Type 1, IP20
Open, NEMA 6-10 kHz
50
Type 1, IP20
Max. Surrounding Air Temp, C
ND
Frame Voltage Rating
3
400V
22 kW
6 kHz
40
8 kHz
30
20
10 kHz
10
Open, NEMA 4-10 kHz
Type 1, IP20
o
37 kW
Max. Surrounding Air Temp, C
40
50
60
70
80
% of Output FLA
90
100
50
4 kHz
40
30
6 kHz
20
10 kHz
10
8 kHz
0
40
50
60
70
80
90
100
% of Output FLA
40 HP
Open, NEMA 2-10 kHz
Type 1, IP20
Open, NEMA 6-10 kHz
Type 1, IP20
None
50
o
30 HP
Max. Surrounding Air Temp, C
460V
6 kHz
40
30
8 kHz
20
10 kHz
10
Open, NEMA 6-10 kHz
Type 1, IP20
o
50 HP
Max. Surrounding Air Temp, C
40
50
60
70
80
% of Output FLA
90
100
50
40
6 kHz
30
20
10 kHz
8 kHz
10
0
40
5
400V
55 kW
460V
75 HP
2-8 kHz
None
2-8 kHz
None
4 kHz
6-8 kHz
None
o
100 HP
Open, NEMA
Type 1, IP20
Open, NEMA
Type 1, IP20
Open, NEMA
Type 1, IP20
Max. Surrounding Air Temp, C
1-6
50
60
70
80
% of Output FLA
90
100
50
6 kHz
45
40
35
30
8 kHz
25
20
15
40
(1)
Consult the factory for further derate information at other frequencies.
50
60
70
80
% of Output FLA
90
100
PowerFlex 70 Dimensions
Table 1.A PowerFlex 70 Frames
Output Power
kW
ND (HD)
0.37 (0.25)
0.75 (0.55)
1.5 (1.1)
2.2 (1.5)
4 (3)
5.5 (4)
7.5 (5.5)
11 (7.5)
15 (11)
HP
ND (HD)
0.5 (0.33)
1 (0.75)
2 (1.5)
3 (2)
5 (3)
7.5 (5)
10 (7.5)
15 (10)
20 (15)
Frame Size
208-240V AC Input
Not
IP66
Filtered Filtered (4X/12)
A
B
B
A
B
B
B
B
B
B
B
B
–
C
D
–
D
D
–
D
D
–
–
–
–
–
–
400-480V AC Input
Not
IP66
Filtered Filtered (4X/12)
A
B
B
A
B
B
A
B
B
B
B
B
B
B
B
–
C
D
–
C
D
–
D
D
–
D
D
600V AC Input
Not
Filtered Filtered
A
–
A
–
A
–
B
–
B
–
C
–
C
–
D
–
D
–
IP66
(4X/12)
B
B
B
B
B
D
D
D
D
Figure 1.1 PowerFlex 70 Frames A-D
IP20 / NEMA Type 1
A
D
Flange Mount
A
C
E
C
B
B
5.8 (0.23)
Dimensions are in millimeters and (inches).
Frame
(see Table 1.A)
PowerFlex 70
Dimensions
1-7
A
B
IP20 / NEMA Type 1
A
122.4 (4.82)
225.7 (8.89)
B
171.7 (6.76)
234.6 (9.24)
C
185.0 (7.28)
300.0 (11.81)
D
219.9 (8.66)
350.0 (13.78)
IP66 / NEMA Type 4X/12
B
171.7 (6.76)
239.8 (9.44)
D
219.9 (8.66)
350.0 (13.78)
Flange Mount
A
156.0 (6.14)
225.8 (8.89)
B
205.2 (8.08)
234.6 (9.24)
C
219.0 (8.62)
300.0 (11.81)
D
248.4 (9.78)
350.0 (13.78)
(1)
C
D
E
Weight (1)
kg (lbs.)
179.8 (7.08)
179.8 (7.08)
179.8 (7.08)
179.8 (7.08)
94.2 (3.71)
122.7 (4.83)
137.6 (5.42)
169.0 (6.65)
211.6 (8.33)
220.2 (8.67)
285.6 (11.25)
335.6 (13.21)
5.22 (11.5)
7.03 (15.5)
12.52 (27.6)
18.55 (40.9)
203.3 (8.00)
210.7 (8.29)
122.7 (4.83)
169.0 (6.65)
220.2 (8.67)
335.6 (13.21)
–
–
178.6 (7.03)
178.6 (7.03)
178.6 (7.03)
178.6 (7.03)
–
–
–
–
–
–
–
–
5.22 (11.5)
7.03 (15.5)
12.52 (27.6)
18.55 (40.9)
Weights include HIM and Standard I/O.
1-8
PowerFlex 70 Dimensions
Figure 1.2 PowerFlex 70 IP20/NEMA Type 1 Bottom View Dimensions
Frame
Dimensions in millimeters and (inches)
A
86.4 (3.40)
22.2 (0.87) Dia.
4 Places
34.5 (1.36)
23.9 (0.94)
155.2
(6.11)
135.9
(5.35)
163.7
(6.45)
129.8
(5.11)
102.4
(4.03)
42.7 (1.68)
55.4 (2.18)
79.3 (3.12)
85.1 (3.35)
B
127.5 (5.02)
43.4 (1.71)
32.8 (1.29)
22.2 (0.87) Dia.
5 Places
155.2
(6.11)
163.7
(6.45)
136.7
(5.38)
126.2
(4.97)
101.6
(4.00)
55.6 (2.19)
75.5 (2.97)
85.7 (3.37)
113.5 (4.47)
123.8 (4.87)
C
112.3 (4.42)
58.4 (2.30)
47.7 (1.88)
22.2 (0.87) Dia.
4 Places
163.5
(6.44)
155.2
(6.11)
129.3
(5.09)
101.3
(3.99)
36.1 (1.42)
56.1 (2.21)
75.2 (2.96)
94.2 (3.71)
D
149.7 (5.89)
22.2 (0.87) Dia.
2 Places
69.3 (2.73)
58.6 (2.31)
28.5 (1.12) Dia.
2 Places
164.1
(6.46)
155.2
(6.11)
134.7
(5.30)
103.2
(4.06)
37.5 (1.48)
64.0 (2.52)
93.0 (3.66)
121.0 (4.76)
PowerFlex 70 Dimensions
Figure 1.3 PowerFlex 70 IP66 (NEMA Type 4X/12) Bottom View Dimensions
Frame Dimensions in millimeters and (inches)
B
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)
D
28.3
(1.11)
140.5
(5.53)
138.6
(5.46)
102.9
(4.05)
31.0 (1.22)
49.1 (1.93)
75.5 (2.97)
102.0 (4.02)
120.1 (4.73)
22.1
(0.87)
1-9
1-10
PowerFlex 70 Dimensions
Figure 1.4 PowerFlex 70 Flange Mount Bottom View Dimensions
Frame Dimensions in millimeters and (inches)
A
103.2 (4.06)
51.3 (2.02)
40.7 (1.60)
95.9
(3.78)
22.2 (0.87) Dia.
4 Places
104.4
(4.11)
76.6
(3.02)
70.5
(2.78)
43.2
(1.70)
59.6 (2.35)
72.4 (2.85)
96.1 (3.78)
101.9 (4.01)
B
144.4 (5.69)
60.3 (2.37)
49.7 (1.96)
95.0
(3.74)
76.6
(3.02)
65.9
(2.59)
22.2 (0.87) Dia.
5 Places
103.5
(4.07)
41.4
(1.63)
70.9 (2.79)
92.4 (3.64)
102.7 (4.04)
130.5 (5.14)
140.6 (5.54)
C
129.3 (5.09)
75.4 (2.97)
64.7 (2.55)
22.2 (0.87) Dia.
4 Places
94.6
(3.72)
102.9
(4.05)
68.7
(2.70)
40.6
(1.60)
53.1 (2.09)
73.0 (2.87)
92.2 (3.63)
111.2 (4.38)
D
164.1 (6.46)
22.2 (0.87) Dia.
2 Places
83.7 (3.30)
73.0 (2.87)
94.6
(3.27)
74.1
(2.92)
42.3
(1.67)
28.5 (1.12) Dia.
2 Places
103.5
(4.07)
51.9 (2.04)
78.3 (3.08)
107.3 (4.22)
135.5 (5.33)
PowerFlex 70 Dimensions
1-11
Figure 1.5 PowerFlex 70 Cutout Dimensions
Frame Dimensions in millimeters and (inches)
Frame Dimensions in millimeters and (inches)
A
C
156,0
(6.14)
6,9
(0.27)
70,7
(2.78)
219,0
(8.62)
140,7
(5.54)
6,3
(0.25)
127,0
(5.00)
300,0
(11.81)
189,4
(7.46)
225,8
(8.89)
210,6
(8.29)
197.9
(7.80)
202,0
(7.95)
101,0
(3.98)
283,0
(11.14)
272,3
(10.72)
241,5
(9.51)
105,3
(4.15)
141,5
(5.57)
8x: ∅3,5
(∅0.14)
41,5
(1.63)
5.0
(0.20)
4x: 3,0R
(0.12R)
12x: ∅3,5
(∅0.14)
4x: 3,0R
(0.12R)
5,1
(0.20)
58,8
(2.31)
58,8
(2.31)
B
D
205,2
(8.08)
6,9
(0.27)
248,4
(9.78)
190,0
(7.48)
95,0
(3.74)
231,4
(9.11)
4,5
(0.18)
40,7
(1.60)
190,7
(7.51)
115,7
(4.56)
176,3
(6.94)
234,6
219,3 (9.24)
(8.63)
205,5
(8.09)
350,0
(13.78)
222,4
(8.76)
333,0
(13.11)
321,4
(12.65)
109,7
(4.32)
271,5
(10.69)
201,5
(7.93)
8x: ∅3,5
(∅0.14)
4x: 3,0R
(0.12R)
6,9
(0.27)
131,5
(5.18)
61,5
(2.42)
58,8
(2.31)
14x: ∅3,5
(∅0.14)
4x: 3,0R
(0.12R)
4,5
(0.18)
58,8
(2.31)
1-12
PowerFlex 70 Dimensions
Figure 1.6 Flange Mounting
1
M4 x 8 x 25
(#10-24 x .75)
2
3
Dimensions are in millimeters and (inches)
PowerFlex 700 Dimensions
Table 1.B PowerFlex 700 Frames
208/240V AC Input
Frame ND HP HD HP
0
0.5
0.33
1
0.75
–
–
–
–
–
–
–
–
1
2
1.5
3
2
5
3
7.5
5
2
10
7.5
–
–
3
15
10
20
15
–
–
4
25
20
30
25
5
40
30
50
40
6
60
50
75
60
–
–
400V AC Input
ND kW HD kW
0.37
0.25
0.75
0.55
1.5
0.75
2.2
1.5
4
2.2
5.5
4
7.5
5.5
11
7.5
–
–
–
–
15
11
18.5
15
22
18.5
30
22
37
30
45
37
–
–
55
45
–
–
75
55
90
75
110
90
480V AC Input
ND HP HD HP
0.5
0.33
1
0.75
2
1.5
3
2
5
3
7.5
5
10
7.5
15
10
–
–
–
–
20
15
25
20
30
25
40
30
50
40
60
50
–
–
75
60
100
75
125
100
150
125
–
–
600V AC Input
ND HP HD HP
–
–
–
–
–
–
–
–
–
–
–
–
10
7.5
15
10
–
–
–
–
20
15
25
20
30
25
40
30
50
40
60
50
–
–
75
60
–
–
–
–
–
–
–
–
Figure 1.7 PowerFlex 700 Frames 0-3 (0 Frame Shown)
A
D
15.0 (0.59)
5.8 (0.23) dia.
see below
C
B
E
CAUTION
HOT surfaces can cause severe burns
8.0
(0.31)
5.5 (0.22) - Frames 0-1
7.0 (0.28) - Frames 2-3
3 Places
Dimensions are in millimeters and (inches)
Frame (1)
PowerFlex 700
Dimensions
1-13
0
1
2
3
Weight (2) kg (lbs.)
A
110.0 (4.33)
135.0 (5.31)
222.0 (8.74)
222.0 (8.74)
B
336.0 (13.23)
336.0 (13.23)
342.5 (13.48)
517.5 (20.37)
C
200.0 (7.87)
200.0 (7.87)
200.0 (7.87)
200.0 (7.87)
(1)
Refer to Table 1.B for frame information.
(2)
Weights include HIM and Standard I/O.
D
80.0 (3.15)
105.0 (4.13)
192.0 (7.56)
192.0 (7.56)
E
320.0 (12.60)
320.0 (12.60)
320.0 (12.60)
500.0 (19.69)
Drive
5.22 (11.5)
7.03 (15.5)
12.52 (27.6)
18.55 (40.9)
Drive &
Packaging
8.16 (18)
9.98 (22)
15.20 (33.5)
22.68 (50)
PowerFlex 700 Dimensions
Figure 1.8 PowerFlex 700 Frame 4
A
13.9 (0.55)
8.0 (0.31) dia.
D
C
B
E
8.0 (0.31)
8.0
3 Places
(0.31) Lifting Holes
4 Places
Dimensions are in millimeters and (inches)
Frame (1)
1-14
A (Max.)
4 219.8 (8.65)
B
758.9 (29.88)
C (Max.)
201.6 (7.94)
(1)
Refer to Table 1.B for frame information.
(2)
Weights include HIM and Standard I/O.
D
192.0 (7.56)
E
738.2 (29.06)
Approx. Weight (2) kg (lbs.)
Drive &
Drive
Packaging
24.49 (54.0) 29.03 (64.0)
PowerFlex 700 Dimensions
1-15
Figure 1.9 PowerFlex 700 Frame 5
6.5 (0.26)
A
37.6 (1.48)
15.0 (0.59)
259.1 (10.20)
D
Detail
C
B
E
CAUTION
HOT surfaces can cause severe burns
Lifting Holes - 4 Places
12.7 (0.50) Dia.
6.5 (0.26)
12.5
(0.49)
Frame (1)
Dimensions are in millimeters and (inches).
5
(1)
(2)
Approx. Weight (3) kg (lbs.)
A (Max.)
B
C (Max.)
308.9 (12.16) 644.5 (25.37) (2) 275.4 (10.84)
D
225.0 (8.86)
Drive &
E
Packaging
Drive
625.0 (24.61) 37.19 (82.0) 42.18 (93.0)
Refer to Table 1.B for frame information.
When using the supplied junction box (100 HP drives Only), add an additional 45.1 mm (1.78 in.) to this
dimension.
(3) Weights include HIM and Standard I/O.
PowerFlex 700 Dimensions
Figure 1.10 PowerFlex 700 Frame 6
8.5 (0.33)
A
49.6 (1.95)
18.0 (0.71)
360.6 (14.20)
D
Detail
C
B
E
Lifting Holes
4 Places
12.7 (0.50) Dia.
8.5 (0.33)
126.3
(4.97)
13.5 (0.53)
Dimensions are in millimeters and (inches)
Frame (1)
1-16
6
A (Max.)
B
403.9 (15.90) 850.0 (33.46)
C (Max.)
D
E
275.5 (10.85) 300.0 (11.81) 825.0 (32.48)
(1)
Refer to Table 1.B for frame information.
(2)
Weights include HIM and Standard I/O.
Approx. Weight (2) kg (lbs.)
Drive &
Drive
Packaging
71.44 (157.5) 91.85 (202.5)
PowerFlex 700 Dimensions
Figure 1.11 PowerFlex 700 Bottom View Dimensions
Frame Rating Dimensions in millimeters and (inches)
All
0
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
(7.28)
187.5
(7.38)
132.9
(5.23)
41.9 (1.65)
56.1 (2.21)
75.9 (2.99)
96.0 (3.78)
1
All
108.5 (4.27)
87.5 (3.44)
67.5 (2.66)
47.5 (1.87)
28.6 (1.13) Dia.
22.2 (0.87) Dia.
3 Places
25.5
(1.00)
162.3
(6.39)
187.6
(7.39)
185.1
(7.29)
133.3
(5.25)
43.0 (1.69)
70.0 (2.76)
75.9 (2.99)
96.0 (3.78)
2
All
167.5 (6.59)
156.9 (6.18)
22.4 (0.88) Dia.
2 Places
28.7 (1.13) Dia.
3 Places
184.8
(7.28)
157.5
(6.20)
150.9
(5.94)
112.1
(4.41)
39.3 (1.55)
57.2 (2.25)
72.7 (2.86)
106.0 (4.17)
139.4 (5.49)
177.4 (6.98)
1-17
1-18
PowerFlex 700 Dimensions
Frame Rating Dimensions in millimeters and (inches)
All
3
105.3 (4.15)
94.7 (3.73)
except
22.2 (0.87) Dia.
50 HP,
28.7 (1.13) Dia.
2 Places
480V
(37 kW,
400V)
37.3 (1.47) Dia.
2 Places
184.5
(7.26)
165.1
(6.50)
160.1
(6.30)
151.1
(5.95)
127.7
(5.03)
22.7 (0.89)
29.0 (1.14)
66.0 (2.60)
97.0 (3.82)
137.2 (5.40)
187.0 (7.36)
50 HP,
480V
(37 kW,
400V)
Normal
Duty
Drive
34.9 (1.37) Dia.
2 Places
46.7 (1.84) Dia.
2 Places
105.3 (4.15)
94.7 (3.73)
28.7 (1.13) Dia.
2 Places
184.5
(7.26)
165.1
(6.50)
160.1
(6.30)
127.7
(5.03)
Vent Plate
22.7 (0.89)
29.0 (1.14)
66.0 (2.60)
130.0 (5.12)
186.0 (7.32)
4
All
28.7 (1.13) Dia.
2 Places
76.0 (2.99)
65.3 (2.57)
22.2 (0.87) Dia.
189.7
(7.47)
177.9
(7.00)
157.9
(6.21)
141.9
(5.59)
105.1
(4.14)
26.8 (1.06)
36.8 (1.45)
51.1 (2.01)
63.8 (2.51)
112.8 (4.44)
180.8 (7.12)
47.0 (1.85) Dia.
2 Places
54.1 (2.13) Dia.
2 Places
PowerFlex 700 Dimensions
Frame Rating Dimensions in millimeters and (inches)
75 HP,
104.0 (4.09)
93.2 (3.67)
480V
(55kW,
400V)
Normal
Duty
Drive
241.9
5
(9.52)
229.5
(9.04)
34.9 (1.37) Dia.
2 Places
22.2 (0.87) Dia.
2 Places
62.7 (2.47) Dia.
2 Places
220.0
(8.66)
184.0
(7.24)
159.5
(6.28)
96.0
(3.78)
28.0 (1.10)
45.0 (1.77)
85.0 (3.35)
150.0 (5.91)
215.0 (8.46)
255.0 (10.04)
100 HP,
480V
Normal
Duty
Drive
34.9 (1.37) Dia.
22.2 (0.87) Dia.
2 Places
42.6 (1.68)
241.9
(9.52)
223.5
(8.80)
62.7 (2.47) Dia.
2 Places
Removable Junction Box
31.9 (1.26)
188.5
(7.42)
184.3
(7.26)
153.5
(6.04)
96.0
(3.78)
28.0 (1.10)
44.0 (1.73)
66.4 (2.61)
128.0 (5.04)
232.3 (9.15)
6
All
34.9 (1.37) Dia.
3 Places
56.2 (2.21)
45.6 (1.80)
62.7 (2.47) Dia.
3 Places
22.2 (0.87) Dia.
4 Places
Removable Junction Box
242.0
(9.53)
219.0
(8.62)
222.3
(8.75)
185.4
(7.30)
148.5
(5.85)
151.8
(5.98)
116.6
(4.59)
47.1 (1.85)
52.1 (2.05)
69.1 (2.72)
130.1 (5.12)
230.1 (9.06)
280.1 (11.03)
330.1 (13.00)
1-19
1-20
Notes:
PowerFlex 700 Dimensions
Chapter
2
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 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). The rate established is the result of the
programmed Accel Time and the Minimum and Maximum Frequency, as
follows:
Maximum Speed = Accel Rate (Hz./sec.)
Accel Time
(1)
(1)
(1)
Two accel times exist to allow the user to change acceleration rates “on the
fly” via PLC command or digital input. The selection is made by
programming [Accel Time 1] & [Accel Time 2] and then using one of the
digital inputs ([Digital Inx Sel]) programmed as “Accel 2” (see Table 2.J for
further information). However, if a PLC is used, manipulate the bits of the
command word as shown below.
MO
P
Sp Dec
dR
Sp ef I
d
D
Sp Ref 2
d ID
De Ref 1
ce ID
De l 2 0
ce
Ac l 1
ce
Ac l 2
c
Mo el 1
p
Lo Inc
ca
Re l Co
ve n
Fo rse trl
rw
Cle ard
a
Jo r Fa
g ult
Sta
r
Sto t
p
Accel Time
0 0 0 0 1 1 1 0 1 0 0 0 1 1 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
0
0
0
1
0
0
1
0
0
1
0
0
1
0
0
0
1 =Condition True
0 =Condition False
x =Reserved
Accel 1
Accel 2
Decel 1
Decel 2
The effectiveness of these bits or digital inputs can be affected by [Accel
Mask]. See Masks on page 2-97 for more information.
Times are adjustable in 0.1 second increments from 0.0 seconds to 3600.0
seconds.
In its factory default condition, when no accel select inputs are closed and
no accel time bits are “1,” the default acceleration time is Accel Time 1 and
the rate is determined as above.
2-2
AC Supply Source Considerations
AC Supply Source
Considerations
PowerFlex drives are suitable for use on a circuit capable of delivering up to
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 2.N through 2.R.
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Alarms
Alarms are indications of situations that are occurring within the drive or
application that should be annunciated to the user. These situations may
affect the drive operation or application performance. Conditions such as
Power Loss or Analog input signal loss can be detected and displayed to the
user for drive or operator action.
There are two types of alarms:
• Type 1 Alarms are conditions that occur in the drive or application that
may require alerting the operator. These conditions, by themselves, do
not cause the drive to “trip” or shut down, but they may be an indication
that, if the condition persists, it may lead to a drive fault.
• Type 2 Alarms are conditions that are caused by improper programming
and they prevent the user from Starting the drive until the improper
programming is corrected. An example would be programming one
digital input for a 2-wire type control (Run Forward) and another digital
input for a 3-wire type control (Start). These are mutually exclusive
operations, since the drive could not determine how to properly issue a
“Run” command. Because the programming conflicts, the drive will
issue a type 2 alarm and prevent Starting until the conflict is resolved.
Alarm Status Indication
[Drive Alarm 1]
[Drive Alarm 2]
Two 16 bit Drive Alarm parameters are available to indicate the status of
any alarm conditions. Both Type 1 and Type 2 alarms are indicated.
A “1” in the bit indicates the presence of the alarm and a “0” indicates no
alarm is present
Configuration
In order for a drive alarm to be annunciated to the “outside” world, it must
first be “configured” or activated. Configuration parameters contain a
configuration bit for each Type 1 alarm. Type 2 alarms are permanently
configured to annunciate. The configuration word is a mirror image of the
Alarms
2-3
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
1
1
1
1
0
0
X
X
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. An active alarm will be indicated on the
LCD HIM and will cause the drive alarm status bit to go high (“1”) in the
Drive Status word (Bit 6, parameter 209). This bit can then be linked to a
digital output for external annunciation. As default, all configuration bits
are high (“1”). Note that setting a configuration bit to “0” to “mask” an
alarm does not affect the status bit in the Drive Alarm parameter, only its
ability to annunciate the condition.
Application
A process is being controlled by a PowerFlex drive. The speed reference to
the drive is a 4-20 mA analog signal from a sensor wired to Analog Input 1.
The input is configured for mA by setting the corresponding bit in [Anlg In
Config] to “1”
320 [Anlg In Config]
322
325
Selects the mode for the analog inputs.
An
a
An log In
alo 2
gI
n1
323
326
x x x x x x x x x x x x x x 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Current
0 =Voltage
x =Reserved
Bit #
Factory Default Bit Values
Analog In Config
0
1
The input is scaled for 4-20 mA by setting [Analog In 1 Lo] to “4” mA and
[Analog In 1 Hi] to “20” mA.
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:
Selects the source of the speed
Options:
reference to the drive unless [Speed Ref
B Sel] or [Preset Speed 1-7] is selected.
(1) See User Manual for DPI port
locations.
Speed References
2-4
2
“Analog In 2”
1
2
3-6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
“Analog In 1”
“Analog In 2”
“Reserved”
“Pulse In”
“Encoder”
“MOP Level”
“Reserved”
“Preset Spd1”
“Preset Spd2”
“Preset Spd3”
“Preset Spd4”
“Preset Spd5”
“Preset Spd6”
“Preset Spd7”
“DPI Port 1”(1)
“DPI Port 2”(1)
“DPI Port 3”(1)
“DPI Port 4”(1)
“DPI Port 5”(1)
002
091
thru
093
101
thru
107
117
thru
120
192
thru
194
213
272
273
320
361
thru
366
By setting Speed Ref A Hi to 60 Hz and Speed ref A Lo to 0 Hz, the speed
reference is scaled to the application needs. Because of the Input scaling
and link to the speed reference, 4 mA represents minimum frequency (0
Hz.) and 20 mA represents Maximum Frequency (60 Hz.)
Scale Block
P322
20mA
P325
4mA
P091
60 Hz
P092
0 HZ
The input is configured to recognize a loss of signal and react accordingly to
the programming.
324 [Analog In 1 Loss]
327 [Analog In 2 Loss]
Default:
0
0
“Disabled”
“Disabled”
Selects drive action when an analog
Options:
signal loss is detected. Signal loss is
defined as an analog signal less than 1V
or 2mA. The signal loss event ends and
normal operation resumes when the
input signal level is greater than or equal
to 1.5V or 3mA.
0
1
2
3
4
5
6
“Disabled”
“Fault”
“Hold Input”
“Set Input Lo”
“Set Input Hi”
“Goto Preset1”
“Hold OutFreq”
091
092
The loss action is chosen as Hold Input, meaning that the last received
signal will be maintained as the speed reference.
Alarms
2-5
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.
380 [Digital Out1 Sel]
384 [Digital Out2 Sel]
388
[Digital Out3 Sel]
Vector
Default:
(1)Contacts shown in User Manual are in
drive powered state with condition
present. Refer to “Fault” and “Alarm”
information.
Digital Outputs
INPUTS & OUTPUTS
Selects the drive status that will energize Options:
a (CRx) output relay.
(2)Vector Control Option Only.
1
4
4
“Fault”
“Run”
“Run”
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2126
27
28
29
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed”
“At Freq”
“At Current”
“At Torque”
“At Temp”
“At Bus Volts”
“At PI Error”
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1-6 Link”
381
385
382
386
383
002
001
003
004
218
012
137
157
147
053
048
184
“PI Enable”(2)
“PI Hold”(2)
“PI Reset”(2)
While the process is normal and running from the analog input, everything
proceeds normally. However, if the wire for the analog input should be
severed or the sensor malfunction so that the 4-20mA signal is lost, the
following sequence occurs:
1. The drive will sense the signal loss.
2. An active Type 1 Alarm is created and the last signal value is maintained
as the speed reference.
3. The alarm activates the digital output relay to light the alarm light for the
operator.
4. The operator uses the HIM to switch the drive to Manual Control (see
Auto/Manual).
5. The operator manually brings the process to a controlled stop until the
signal loss is repaired.
2-6
Analog Inputs
Alarm Queue (PowerFlex 700 Only)
Alarms
UTILITY
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.
262
263
264
265
266
267
268
269
[Alarm 1 Code]
[Alarm 2 Code]
[Alarm 3 Code]
[Alarm 4 Code]
[Alarm 5 Code]
[Alarm 6 Code]
[Alarm 7 Code]
[Alarm 8 Code]
Default:
Read Only
261
Min/Max: 0/256
Display: 1
A code that represents a drive alarm.
The codes will appear in the order they
occur (first 4 alarms in – first 4 out alarm
queue). A time stamp is not available with
alarms.
Analog Inputs
Possible Uses of Analog Inputs
The analog inputs provide data that can be used for the following purposes:
• Provide a value to [Speed Ref A] or [Speed Ref B].
• Provide a trim signal to [Speed Ref A] or [Speed Ref B].
• Provide a reference when the terminal block has assumed manual control
of the reference
• Provide the reference and feedback for the PI loop. See Process PI
Loop on page 2-121.
• Provide an external and adjustable value for the current limit and DC
braking level
• Enter and exit sleep mode.
Analog Input Configuration
[Anlg In Config]
[Current Lmt Sel] allows an analog input to control the set point while [DC
Brk Levl Sel] allows an analog input to define the DC hold level used when
Ramp-to-Stop, Ramp-to-Hold, or Brake-to-Stop is active.
To provide local adjustment of a master command signal or to provide
improved resolution the input to analog channel 1 or 2 can be defined as a
trim input. Setting [Trim In Select] allows the selected channel to modify
the commanded frequency by 10%.The speed command will be reduced by
10% when the input level is at [Anlg In x Lo] with it linearly increasing to
10% above command at [Anlg In xHi].
Feedback can be used to control an operation using the “Process PI”
(proportional-integral) feature of the control. In this case one signal, defined
using [PI Reference Sel], provides a reference command and a second,
defined using [PI Feedback Sel], provides a feedback signal for frequency
compensation. Please refer to the Process PI Loop on page 2-121 for details
on this mode of operation.
Analog In 1 Lo
Input/Output
Analog In 1 Hi
Volts or mA
Analog Input
1 Scale
Parameter
Cal Analog 1
Analog In 2 Lo
Processing
Analog In 2 Hi
Speed Ref A Sel
Analog Input
2 Scale
Speed Ref B Sel
Volts or mA
Trim In Select
Selection/Control
Cal Analog 2
TB Man Ref Sel
PI Reference Sel
PI Feedback Sel
Current Lmt Sel
DC Brk Levl Sel
Sleep-Wake Ref
Speed Ref A Lo
Speed Ref A Hi
Speed Ref B Lo
Ref A
Scale/Limit
Speed Ref B Hi
Trim Lo
Ref B
Scale/Limit
Sleep Level
Brake Level
Scale/Limit
Wake Level
Sleep Level
Compare
Trim Hi
Trim
Scale/Limit
Hz
TB Manual
Scale/Limit
Trim Out Sel
PI
Reference
Scale/Limit
PI Feedback
Scale/Limit
+
Hz
Reference A
Hz
Reference B
Hz
TB Manual
%
PI Reference
%
PI Feedback
% Rated
Current
Current Limit
% Rated
Current
DC Brake
Sleep/
Wake
Analog Inputs
Current Limit
Scale/Limit
+
Sleep/Wake
2-7
2-8
Input/Output
Analog Inputs
Parameter
Processing
Selection/Control
Anlg In 1 Loss
Anlg In Config
0-10v
Analog 1
Voltage
Unipolar
Cal 1
Loss
Detect
Anlg In Sqr Root
Limit
0-10V
Cal Analog 1
ADC
Analog 1
Current
0-20mA
Current
Cal 1
Loss
Detect
Limit
4-20mA
Square
Root
Analog In1 Value
Analog In 2 Lo
Anlg In Config
Analog 2
Current
ADC
Anlg In 2 Loss
Analog In 2 Hi
0-10v
Unipolar
Cal 2
(voltage)
-10v - +10v
Bipolar
Cal 2
(current)
0-20mA
Current
Cal 2
Analog 2
Unipolar
Analog 2
Bipolar
Note: If either of these
parameters is < 0, input will go
into bipolar mode, otherwise
unipolar.
Loss
Detect
Anlg In Sqr Root
Limit
0-10V
Limit
-10V to
10V
Loss
Detect
Limit
4-20mA
Analog In2 Value
Cal Analog 2
Square
Root
Analog Inputs
2-9
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. in volts or mA) with a low and high point in the
target range (e.g. reference frequency).
Two sets of numbers may be used to specify the analog input scaling. One
set (called the “input scaling points”) defines low and high points in terms
of the units read by the input hardware, i.e. volts or mA.
The second set of numbers (called the “output scaling points”) used in the
analog input scaling defines the same low and high points in units
appropriate for the desired use of the input. For instance, if the input is to be
used as a frequency reference, this second set of numbers would be entered
in terms of Hz. For many features the second set of numbers is fixed. The
user sets the second set for speed and reference trim.
An analog input or output signal can represent a number of different
commands. Typically an analog input is used to control output frequency,
but it could control frequency trim, current limit or act as a PI loop input.
An analog output typically is a frequency indication, but it could represent
output current, voltage, or power. For this reason this document defines an
analog signal level as providing a “command” value rather than a
“frequency.” However when viewing a command value it is presented as a
frequency based on the [Minimum Speed] and [Maximum Freq] settings.
The 0-10 volt input scaling can be adjusted using the following parameters:
• [Analog In x Lo]
• [Analog In x Hi]
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
[Speed Ref A Hi] = 10V
This is the default setting, where minimum input (0 volts) represents
[Minimum Speed] of 0 Hz and maximum input (10 volts) represents
[Maximum Speed] of 60 Hz (it provides 6 Hz change per input volt).
12
10
Input Volts
2-10
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
0V
0 Hz
[Speed Ref A Lo]
[Analog In 1 Lo]
10V
60 Hz
Configuration #2:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “0” (Voltage)
[Speed Ref A Sel] = “Analog In 1”
[Minimum Speed] = 0 Hz
[Maximum Speed] = 30 Hz
[Speed Ref A Lo] = 0V
[Speed Ref A Hi] = 10V
This is an application that only requires 30 Hz as a maximum output
frequency, but is still configured for full 10 volt input. The result is that the
resolution of the input has been doubled, providing only 3 Hz change per
input volt (Configuration #1 is 6 Hz/Volt).
Analog Inputs
12
Input Volts
10
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
0V
0 Hz
[Speed Ref A Lo]]
[Analog In 1 Lo]]
10V
30 Hz
Configuration #3:
•
•
•
•
•
•
[Anlg In Config], bit 0 = “1” (Current)
[Speed Ref A Sel] = “Analog In 1”
[Minimum Speed] = 0 Hz
[Maximum Speed] = 60 Hz
[Speed Ref A Lo] = 4 mA
[Speed Ref A Hi] = 20 mA
This configuration is referred to as offset. In this case, a 4-20 mA input
signal provides 0-60 Hz output, providing a 4 mA offset in the speed
command.
20
Input mA
16
12
8
4
0
6
12
18
24
30
36
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi
[Speed Ref A Hi]
4 mA
0 Hz
[Analog In 1 Lo]
[Speed Ref A Lo]
20 mA
60 Hz
42
48
54
60
2-11
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
[Speed Ref A Hi] = 0V
This configuration is used to invert the operation of the input signal. Here,
maximum input (10 Volts) represents [Minimum Speed] of 0 Hz and
minimum input (0 Volts) represents [Maximum Speed] of 60 Hz.
10
Input Volts
2-12
8
6
4
2
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi
[Speed Ref A Hi]
10V
0 Hz
[Speed Ref A Lo]
[Analog In 1 Lo]
0V
60 Hz
Configuration #5:
•
•
•
•
•
•
[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
[Speed Ref A Hi] = 5V
This configuration is used when the input signal is 0-5 volts. Here,
minimum input (0 Volts) represents [Minimum Speed] of 0 Hz and
maximum input (5 Volts) represents [Maximum Speed] of 60 Hz. This
allows full scale operation from a 0-5 volt source.
Analog Inputs
2-13
6
Input Volts
5
4
3
2
1
0
6
12
18
24
30
36
42
48
54
60
Output Hertz
Scaling Block
[Speed Reference A Sel] = “Analog In 1”
[Analog In 1 Hi]
[Speed Ref A Hi]
0V
0 Hz
[Speed Ref A Lo]
[Analog In 1 Lo]
5V
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]. The function should
be set to enabled if the input signal varies with the square of the quantity
(i.e. drive speed) being monitored.
If the mode of the input is bipolar voltage (-10v to 10v), then the square root
function will return 0 for all negative voltages.
The square root function is scaled such that the input range is the same as
the output range. For example, if the input is set up as a unipolar voltage
input, then the input and output ranges of the square root function will be 0
to 10 volts, as shown in figure below.
Output (Volts)
10
8
6
4
2
0
2
4
6
8
10
Input (Volts)
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.
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.
•
•
•
•
•
Hold input
Set input Lo
Set input Hi
Goto Preset 1
Hold Output Frequency
Value
0
1
2
3
4
5
6
Action on Signal Loss
Disabled (default)
Fault
Hold input (continue to use last frequency command.)
Set Input Hi - use [Minimum Speed] as frequency command.
Set Input Lo - use [Maximum Speed] as frequency command.
use [Preset 1] as frequency command.
Hold Out Freq (maintain last output frequency)
If the input is in current mode, 4 mA is the normal minimum usable input
value. Any value below 3.2 mA will be interpreted by the drive as a signal
loss, and a value of 3.8 mA will be required on the input in order for the
signal loss condition to end.
4 mA
3.8 mA
3.2 mA
Signal Loss
Condition
End Signal Loss
Condition
If the input is in unipolar voltage mode, 2V is the normal minimum usable
input value. Any value below 1.6 volts will be interpreted by the drive as a
signal loss, and a value of 1.9 volts will be required on the input in order for
the signal loss condition to end.
2V
1.9V
1.6V
Signal Loss
Condition
End Signal Loss
Condition
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.
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. See also Speed Reference on
page 2-148.
•
•
•
•
[Trim In Select]
[Trim Out Select]
[Trim Hi]
[Trim Lo]
Value Display
Parameters are available in the Monitoring Group to view the actual value
of an analog input regardless of its use in the application. Whether it is a
current limit adjustment, speed reference or trim function, the incoming
value can be read via these parameters.
Metering
The value displayed includes the input value plus any factory hardware
calibration value, but does not include scaling information programmed by
the user (i.e. [Analog In 1 Hi/Lo]). The units displayed are determined by
the associated configuration bit (Volts or mA)
016 [Analog In1 Value]
017 [Analog In2 Value]
Value of the signal at the analog inputs.
Default:
Read Only
Min/Max: 0.000/20.000 mA
–/+10.000V
Display: 0.001 mA
0.001 Volt
Cable Selection
Important points to remember:
• Always use copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
Important: I/O terminals labeled “–” or “Common” are not referenced to
ground and are designed to greatly reduce common mode
interference. Grounding these terminals can cause signal noise.
!
!
ATTENTION: Configuring an analog input for 0-20mA operation
and driving it from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.
ATTENTION: Hazard of personal injury or equipment damage
exists when using bipolar input sources. Noise and drift in sensitive
input circuits can cause unpredictable changes in motor speed and
direction. Use speed command parameters to help reduce input
source sensitivity.
2-16
Analog Inputs
Table 2.A Recommended Signal Wire
Signal Type Wire Type(s)
Analog I/O Belden 8760/9460(or equiv.)
Encoder/
Pulse I/O
EMC
Compliance
Description
0.750 mm2 (18AWG), twisted
pair, 100% shield with drain (1).
Belden 8770(or equiv.)
0.750 mm2 (18AWG), 3 cond.,
shielded for remote pot only.
Less than or equal to 30 m (98 0.196 mm2 (24AWG),
ft.) – Belden 9730 (or equiv.)
individually shielded.
Greater than 30 m (98 ft.) –
0.750 mm2 (18AWG), twisted
Belden 9773(or equiv.)
pair, shielded.
Refer to EMC Instructions on page 2-40 for details.
Minimum
Insulation Rating
300V,
60 degrees C
(140 degrees F)
(1) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire
may not be necessary, but is always recommended.
Refer to Table 2.I on page 2-51 for recommended digital I/O control wire.
Terminal Designations & Wiring Examples
Refer to the appropriate PowerFlex User Manual for I/O terminal
designations and wiring examples.
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”
[Analog In1 Hi] = 10V
[Analog In1 Lo] = 0V
[Speed Ref A Hi] = 60 Hz
[Speed Ref A Lo] = 0 Hz
[Maximum Speed] = 45 Hz
[Minimum Speed] = 15 Hz
This operation is similar to the 0-10 volts creating a 0-60 Hz signal until the
minimum and maximum speeds are added. [Minimum Speed] and
[Maximum Speed] limits will create a command frequency deadband.
Analog Inputs
[Minimum Speed]
[Analog In1 Hi]
10V
2-17
[Maximum Speed]
Motor Operating Range
Frequency Deadband
0-2.5 Volts
Frequency Deadband
7.5-10 Volts
Command Frequency
[Analog In1 Lo]
0V
0 Hz
[Speed Ref A Lo]
15 Hz
Slope defined by (Analog Volts)/(Command Frequency)
45 Hz
60 Hz
[Speed Ref A Hi]
This deadband, as it relates to the analog input, can be calculated as follows:
1. The ratio of analog input volts to frequency (Volts/Hz) needs to be
calculated. The voltage span on the analog input is 10 volts. The
frequency span is 60 Hz.
10 Volts/60 Hz = 0.16667 Volts/Hz
2. Determine the frequency span between the Minimum and Maximum
Speed limits and Speed Ref A Hi and Lo.
[Speed Ref A Hi] – [Maximum Speed] = 60 – 45 = 15 Hz and . . .
[Minimum Speed] – [Speed Ref A Lo] = 15 – 0 = 15 Hz.
3. Multiply by the Volts/Hertz ratio
15 Hz x 0.16667 Volts/Hz = 2.5 Volts
Therefore the command frequency from 0 to 2.5 volts on the analog input
will be 15 Hz. After 2.5 volts, the frequency will increase at a rate of
0.16667 volts per hertz to 7.5 volts. After 7.5 volts on the analog input the
frequency command will remain at 45 Hertz.
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
[Speed Ref A Lo] = 0hz
[Maximum Speed] = 45hz
[Minimum Speed] = 15hz
The only change from Example 1 is the [Speed Ref A Hi] is changed to 50
Hz.
2-18
Analog Inputs
[Minimum Speed]
[Maximum Speed]
[Analog In1 Hi]
10V
Motor Operating Range
Frequency Deadband
9-10 Volts
Frequency Deadband
0-3 Volts
Command Frequency
[Analog In1 Lo]
0V
0 Hz
[Speed Ref A Lo]
15 Hz
Slope defined by (Analog Volts)/(Command Frequency)
45 Hz
50 Hz
[Speed Ref A Hi]
The deadband, as it relates to the analog input, can be calculated as follows:
1. The ratio of analog input volts to frequency (Volts/Hertz) needs to be
calculated. The voltage span on the analog input is 10 volts. The
frequency span is 60 Hz.
10 Volts/50 Hz = 0.2 Volts/Hz
2. Determine the frequency span between the minimum and maximum
speed limits and the Speed Ref A Hi and Lo.
[Speed Ref A Hi] – [Maximum Speed] = 50 – 45 = 5 Hz and . . .
[Minimum Speed] – [Speed Ref A Lo] = 15 – 0 = 15 Hz
3. Multiply by the volts/hertz ratio
5 Hz x 0.2 Volts/Hz = 1 Volt
15 Hz x 0.2 Volts/Hz = 3 Volts
Here, the deadband is “shifted” due to the 50 Hz limitation. The command
frequency from 0 to 3 volts on the analog input will be 15 Hz. After 3 volts,
the frequency will increase at a rate of 0.2 volts per hertz up to 9 volts. After
9 volts on the analog input the frequency command will remain at 45 Hz.
Analog Outputs
Explanation
Each drive has one or more analog outputs that can be used to annunciate a
wide variety of drive operating conditions and values.
The user selects the source for the analog output by setting [Analog Outx
Sel].
342 [Analog Out1 Sel]
345
[Analog Out2 Sel]
Vector
Default:
0 “Output Freq”
Options:
See Table
Selects the source of the value that
drives the analog output.
Analog Outputs
[Analog Out1 Lo] Value
INPUTS & OUTPUTS
Analog Outputs
2-19
Options
0 “Output Freq”
1 “Command Freq”
1* “Commanded Spd”
2 “Output Amps”
3 “Torque Amps”
4 “Flux Amps”
5 “Output Power”
6 “Output Volts”
7 “DC Bus Volts”
8 “PI Reference”
9 “PI Feedback”
10 “PI Error”
11 “PI Output”
12 “%Motor OL”
13 “%Drive OL”
14* “CommandedTrq”
15* “MtrTrqCurRef”
16* “Speed Ref”
17* “Speed Fdbk”
18* “Pulse In Ref”
Param. 341 = Signed
Param. 341 = Absolute
–[Maximum Speed]
–[Maximum Speed]
–[Maximum Speed]
0 Amps
–200% Rated
0 Amps
0 kW
0 Volts
0 Volts
–100%
–100%
–100%
–100%
0%
0%
–800%
–800%
–[Maximum Speed]
–[Maximum Speed]
–25200.0 RPM
0 Hz
0 Hz
0 Hz/RPM
0 Amps
0 Amps
0 Amps
0 kW
0 Volts
0 Volts
0%
0%
0%
0%
0%
0%
0%
0%
0 Hz
0 Hz
0 RPM
001
002
003
004
005
007
006
[Analog Out1 Hi] Value
012
+[Maximum Speed]
135
+[Maximum Speed]
136
+[Maximum Speed]
137
200% Rated
138
200% Rated
220
200% Rated
219
200% Rated
120% Rated Input Volts
200% Rated Input Volts
100%
100%
100%
100%
100%
100%
+800%
+800%
+[Maximum Speed]
+[Maximum Speed]
+25200.0 RPM
* 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. For a step from minimum to maximum value, the output
will be within 0.2% of its final value after 12ms.
The PowerFlex 700 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 100 mV offset error. For a step from minimum to maximum
value, the output will be within 0.2% of its final value after 12ms.
Absolute (default)
Certain quantities used to drive the analog output are signed, i.e. the
quantity can be both positive and negative. The user has the option of
having the absolute value (value without sign) of these quantities taken
before the scaling occurs. Absolute value is enabled separately for each
analog output via the bitmapped parameter [Anlg Out Absolut].
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.
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. The output voltage will vary
linearly with the quantity being output. The analog output voltage will not
go outside the range defined by [Analog Out1 Lo] and [Analog Out1 Hi].
Analog Output Configuration Examples
This section gives a few examples of valid analog output configurations and
describes the behavior of the output in each case.
Example 1 -- Unsigned Output Quantity
• [Analog Out1 Sel] = “Output Current”
• [Analog Out1 Lo] = 1 volt
• [Analog Out1 Hi] = 9 volts
10V
[Analog Out1 Hi]
Output Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
0%
200%
Output Current
Note that analog output value never goes outside the range defined by
[Analog Out1 Lo] and [Analog Out1 Hi]. This is true in all cases, including
all the following examples.
Example 2 -- Unsigned Output Quantity, Negative Slope
• [Analog Out1 Sel] = “Output Current”
• [Analog Out1 Lo] = 9 volts
• [Analog Out1 Hi] = 1 volts
10V
[Analog Out1 Lo]
Output Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Hi]
0V
0%
200%
Output Current
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.
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.
10V
[Analog Out1 Hi]
Output Torque Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
– 200%
0%
200%
Output Torque Current
Example 4 – Signed Output Quantity, Absolute Value Disabled
• [Analog Out1 Sel] = “Output Torque Current”
• [Analog Out1 Lo] = 1 volt
• [Analog Out1 Hi] set to 9 volts
• [Anlg Out Absolut] set so that absolute value is disabled for output 1.
10V
[Analog Out1 Hi]
Output Torque Current vs.
Analog Output Voltage
Analog
Output Voltage
Marker Lines
[Analog Out1 Lo]
0V
– 200%
0%
Output Torque Current
200%
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.
Table 2.B Software Filters
Quantity
Output Frequency
Commanded Frequency
Output Current
Output Torque Current
Output Flux Current
Output Power
Output Voltage
DC Bus Voltage
PI Reference
PI Feedback
PI Error
PI Output
Filter
No extra filtering
No extra filtering
Filter A
Filter A
Filter A
Filter A
No extra filtering
Filter A
No extra filtering
No extra filtering
No extra filtering
No extra filtering
Analog output software filters are specified in terms of the time it will take
the output of the filter to move from 0% to various higher levels, given an
instantaneous step in the filter input from 0% to 100%. The numbers
describing filters in this document should be considered approximate; the
actual values will depend on implementation.
Filter A is a single pole digital filter with a 162ms time constant. Given a
0% to 100% step input from a steady state, the output of Filter A will take
500ms to get to 95% of maximum, 810 ms to get to 99%, and 910 ms to get
to 100%.
Auto/Manual
Auto/Manual
2-23
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.
• “Alt” Function on the HIM
By toggling the “Alt” and “Auto/Man” function on the HIM, the user can
switch the speed reference back and forth between the active “Auto”
source (per drive programming and inputs) and the HIM requesting the
manual control. “Manual” switches the Reference Source to the HIM,
“Auto” switches it back to drive programming.
The HIM manual reference can be preloaded from the auto source by
enabling the [Man Ref Preload] parameter. With the preload function
enabled, when the HIM requests Manual control, the current value of the
auto source is loaded into the HIM reference before manual control is
granted. This allows the manual control to begin at the same speed as the
auto source, creating a smooth transition. If the preload function is
disabled, the speed will ramp to whatever manual reference was present
in the HIM at the time manual control was granted.
• Digital Input
By toggling the digital input programmed as Auto/Manual, the user can
switch the speed reference back and forth between the active “Auto”
source (per drive programming and inputs) and the designated Terminal
Block manual reference. When this digital input is asserted, the TB will
attempt to gain exclusive control (Manual) of the reference. If granted
control of the reference, the specific source for the reference is
determined by the parameter TB manual reference select.
The TB manual reference is selected in [TB Man Ref Sel]. The choices
for this parameter are:
– Analog Input 1
– Analog Input 2
– MOP Level
– Analog Input 3 (PF700 Only)
– Pulse Input (PF700 Only)
– Encoder input (PF700 Only)
– Releasing this input sends the control back to the Auto source.
General Rules
The following rules apply to the granting and releasing of Manual control:
1. Manual control is requested through a one-time request (Auto/Man
toggle, not continuously asserted). Once granted, the terminal holds
Manual control until the Auto/Man button is pressed again, which
releases Manual control (i.e. back to Auto mode).
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. no other device has ownership of the
Local control function).
4. A HIM (or TB) with Manual control active can have it taken away if
another DPI port requests, and is granted Local control. In this case
when Local control is released the drive will not go back to Manual
control, Manual control must be again requested (edge based request, see
1. above). This is true for both the HIM and the TB (i.e. if the TB switch
was in the Manual position it must be switched to Auto and back to
Manual to get Manual control again).
5. The status indicator (point LED on LED HIM & Text on LCD HIM) will
indicate when that particular terminal has been granted Manual control,
not the fact any terminal connected has Manual control and not the fact
that the particular terminal has simply asked for Manual control.
6. When Manual control is granted, the drive will latch and save the current
reference value prior to entering Manual. When Manual control is then
released the drive will use that latched reference for the drive until
another DPI device arbitrates ownership and changes the reference to a
different value.
7. If a terminal has Manual control and clears its DPI reference mask
(disallows reference ownership), then Manual control will be released.
By extension, if the drive is configured such that the HIM can not select
the reference (via reference mask setting), then the drive will not allow
the terminal to acquire Manual control.
8. If a terminal has Manual control and clears its DPI logic mask (allowing
disconnect of the terminal), then Manual control will be released. By
extension if the drive is configured such that the HIM can be unplugged
(via logic mask setting), then the drive will not allow the terminal to
acquire Manual control. The disconnect also applies to a DPI HIM that
executes a soft “Logout.”
9. If a com loss fault occurs on a DPI that has Manual control, then Manual
control will be released as a consequence of the fault (on that port which
had Manual control).
10.There will be no way to request and hence no support of the Auto/
Manual feature on old SCANport based HIMs.
11.You can not acquire Manual control if you are already an assigned
source for the DPI port requesting Manual.
12.When a restore factory defaults is performed Manual control is aborted.
Auto Restart (Reset/Run)
The Auto Restart feature provides the ability for the drive to automatically
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. Certain faults (Type 2) that indicate possible
drive component malfunction are not resettable.
Caution should be used when enabling this feature, since the drive will
attempt to issue its own start command based on user selected
programming.
Configuration
This feature is configured through two user parameters
174 [Auto Rstrt Tries]
Default:
0
175
Sets the maximum number of times the Min/Max: 0/9
drive attempts to reset a fault and restart. Display: 1
!
ATTENTION: Equipment damage and/or personal injury may result
if this parameter is used in an inappropriate application. Do Not use
this function without considering applicable local, national and
international codes, standards, regulations or industry guidelines.
175 [Auto Rstrt Delay]
Sets the time between restart attempts
when [Auto Rstrt Tries] is set to a value
other than zero.
Default:
1.0 Secs
174
Min/Max: 0.5/30.0 Secs
Display: 0.1 Secs
Setting [Auto Rstrt Tries] to a value greater than zero will enable the Auto
Restart feature. Setting the number of tries equal to zero will disable the
feature.
The [Auto Rstrt Delay] parameter sets the time, in seconds, between each
reset/run attempt.
The auto-reset/run feature provides 2 status bits in [Drive Status 2] – an
active status, and a countdown status.
210 [Drive Status 2]
Read Only
209
DP
I
Mo at 50
to 0
Bu r Ov k
s
e
Cu Freq rld
rr
R
Au Lim eg
toR it
Au st
toR Ac
st t
Ctd
n
Au
to
DC Tun
i
n
B
Sto raki g
p n
Jo ping g
gg
Ru ing
nn
Ac ing
ti
Re ve
ad
y
UTILITY
Present operating condition of the drive.
Diagnostics
Auto Restart (Reset/
Run)
2-25
x x 0 0 0 0 0 0 x 0 0 0 0 0 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Condition True
0 =Condition False
x =Reserved
Bit #
The typical steps performed in an Auto-Reset/Run cycle are as follows:
1. The drive is running and an auto-resettable fault occurs, tripping the
drive.
2. After the number of seconds in [Auto Rstrt Delay], the drive will
automatically perform an internal Fault Reset, resetting the faulted
condition.
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. If the drive faults repeatedly for more than the number of attempts set in
[Auto Rstrt Tries] with less than five minutes between each fault, the
auto-reset/run is considered unsuccessful and the drive remains in the
faulted state.
6. Aborting an Auto-Reset/Run Cycle (see Aborting an Auto-Reset/Run
Cycle for details).
7. If the drive remains running for five minutes or more since the last reset/
run without a fault, or is otherwise stopped or reset, the auto-reset/run is
considered successful. The entire process is reset to the beginning and
will repeat on the next fault.
Beginning an Auto-Reset/Run Cycle
The following conditions must be met when a fault occurs for the drive to
begin an auto-reset/run cycle.
• The fault must be defined as an auto-resettable fault
• [Auto Rstrt Tries] setting must be greater than zero.
• The drive must have been running, not jogging, not autotuning, and not
stopping, when the fault occurred. (Note that a DC Hold state is part of a
stop sequence and therefore is considered stopping.)
Aborting an Auto-Reset/Run Cycle
During an auto-reset/run cycle the following actions/conditions will abort
the reset/run attempt process.
• Issuing a stop command from any source. (Note: Removal of a 2-wire
run-fwd or run-rev command is considered a stop assertion).
• Issuing a fault reset command from any source.
• Removal of the enable input signal.
• Setting [Auto Rstrt Tries] to zero.
• The occurrence of a fault which is not auto-resettable.
• Removing power from the drive.
• Exhausting an Auto-Reset/Run Cycle
After all [Auto Rstrt Tries] have been made and the drive has not
successfully restarted and remained running for five minutes or more, the
auto-reset/run cycle will be considered exhausted and therefore
unsuccessful. In this case the auto-reset/run cycle will terminate and an
additional fault, “Auto Rstrt Tries” (Auto Restart Tries) will be issued if bit
5 of [Fault Config 1] = “1.”
Bus Regulation
Bus Regulation
2-27
[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.
When an AC motor regenerates energy from the load, the drive DC bus
voltage increases unless there is another means (dynamic braking chopper/
resistor, etc.) of dissipating the energy.
Motoring
Regenerating
Without bus regulation, if the bus voltage exceeds the operating limit
established by the power components of the drive, the drive will fault,
shutting off the output devices to protect itself from excess voltage.
Single Seq 500 S/s
0V Fault @Vbus Max
3
Drive Output Shut Off
2
1
Ch1 100mV
Ch3 500mV
Ch2 100mV
M 1.00s Ch3
1.47 V
With bus regulation enabled, the drive can respond to the increasing voltage
by advancing the output frequency until the regeneration is counteracted.
This keeps the bus voltage at a regulated level below the trip point.
Since the same integrator is used for bus regulation as for normal frequency
ramp operation, a smooth transition between normal frequency ramp
operation and bus regulation is accomplished.
The regulator senses a rapid rise in the bus voltage and activates prior to
actually reaching the internal bus voltage regulation set point Vreg. This is
important since it minimizes overshoot in the bus voltage when bus
regulation begins thereby attempting to avoid an over-voltage fault.
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
of the acceleration/deceleration control. As the bus voltage begins to
approach the bus voltage regulation point (Vreg), the bus voltage regulator
increases the magnitude of the output frequency and voltage to reduce the
bus voltage. The bus voltage regulator function takes precedence over the
other two functions. See Figure 2.1.
The bus voltage regulator is shown in the lower one-third of Figure 2.1. The
inputs to the bus voltage regulator are the bus voltage, the bus voltage
regulation set point Vreg, proportional gain, integral gain, and derivative
gain. The gains are intended to be internal values and not parameters. These
will be test points that are not visible to the user. Bus voltage regulation is
selected by the user in the Bus Reg Mode parameter.
Operation
Bus voltage regulation begins when the bus voltage exceeds the bus voltage
regulation set point Vreg and the switches shown in Figure 2.1 move to the
positions shown in Table 2.C.
Table 2.C Switch Positions for Bus Regulator Active
Bus Regulation
SW 1
Limit
SW 2
Bus Reg
SW 3
Open
SW 4
Closed
SW 5
Don’t Care
Bus Regulation
2-29
Figure 2.1 Bus Voltage Regulator, Current Limit and Frequency Ramp.
Current Limit
U Phase Motor Current
Derivative Gain
Block
Magnitude
Calculator
W Phase Motor Current
SW 3
Current Limit Level
PI Gain Block
Integral Channel
Proportional Channel
I Limit,
No Bus Reg
Limit
0
SW 1
No Limit
I Limit,
No Bus Reg
Acc/Dec Rate
Jerk
Ramp
Frequency
Ramp
(Integrator)
No Limit
Jerk
Clamp
SW 2
+
Frequency
Reference
+
Bus Reg
Frequency
Limits
+
+
+
SW 5
Frequency Set Point
Output Frequency
Speed
Control
Mode
Maximum Frequency, Minimum Speed, Maximum Speed, Overspeed Limit
Frequency Reference (to Ramp Control, Speed Ref, etc.)
Proportional Channel
Integral Channel
Speed Control (Slip Comp, Process PI, etc)
SW 4
Bus Voltage Regulation Point, Vreg
PI Gain Block
Bus Reg On
Derivative
Gain Block
Bus Voltage (Vbus)
Bus Voltage Regulator
The derivative term senses a rapid rise in the bus voltage and activates the
bus regulator prior to actually reaching the bus voltage regulation set point
Vreg. The derivative term is important since it minimizes overshoot in the
bus voltage when bus regulation begins thereby attempting to avoid an
over-voltage fault. The integral channel acts as the acceleration or
deceleration rate and is fed to the frequency ramp integrator. The
proportional term is added directly to the output of the frequency ramp
integrator to form the output frequency. The output frequency is then
limited to a maximum output frequency.
Bus voltage regulation is the highest priority of the three components of this
controller because minimal drive current will result when limiting the bus
voltage and therefore, current limit will not occur.
2-30
Bus Regulation
!
ATTENTION: The “adjust freq” portion of the bus regulator
function is extremely useful for preventing nuisance overvoltage
faults resulting from aggressive decelerations, overhauling loads,
and eccentric loads. It forces the output frequency to be greater
than commanded frequency while the drive's bus voltage is
increasing towards levels that would otherwise cause a fault;
however, it can also cause either of the following two conditions to
occur.
1. Fast positive changes in input voltage (more than a 10% increase
within 6 minutes) can cause uncommanded positive speed changes;
however an “OverSpeed Limit” fault will occur if the speed
reaches [Max Speed] + [Overspeed Limit]. If this condition is
unacceptable, action should be taken to 1) limit supply voltages
within the specification of the drive and, 2) limit fast positive input
voltage changes to less than 10%. Without taking such actions, if
this operation is unacceptable, the “adjust freq” portion of the bus
regulator function must be disabled (see parameters 161 and 162).
2. Actual deceleration times can be longer than commanded
deceleration times; however, a “Decel Inhibit” fault is generated if
the drive stops decelerating altogether. If this condition is
unacceptable, the “adjust freq” portion of the bus regulator must be
disabled (see parameters 161 and 162). In addition, installing a
properly sized dynamic brake resistor will provide equal or better
performance in most cases.
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:
• off
• frequency regulation
• dynamic braking
• frequency regulation as the primary regulation means with dynamic
braking as a secondary means
• dynamic braking as the primary regulation means with frequency
regulation as a secondary means
The bus voltage regulation setpoint is determined off of bus memory (a
means to average DC bus over a period of time). The following graph and
tables describe the operation.
Table 2.D
Voltage Class
240
480
600
DC Bus Memory
< 342V DC
> 342V DC
< 685 VDC
> 685 VDC
< 856 VDC
> 856 VDC
DB On Setpoint
375V DC
Memory + 33V DC
750V DC
Memory + 65V DC
937V DC
Memory + 81V DC
DB Off Setpoint
On – 4V DC
On – 8V DC
On – 10V DC
Bus Regulation
2-31
880
815
DB Turn On
750
DC Volts
DB Turn Off
685
rn
650
DB
u
On DB T
urn
Off
T
s
Bu
ry
mo
Me
509
453
320
360
460 484
AC Volts
528
576
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. See Table 2.D.
If [Bus Reg Mode A], parameter 161 is set to “Both-Frq 1st”:
Both regulators enabled, the operating point of the Frequency Bus Voltage
Regulator is lower than that of the Dynamic Brake Regulator. The adjust
frequency setpoint follows the “red” (lower) DB turn off curve (Table 2.D).
If [Bus Reg Mode A], parameter 161 is set to “Adjust Freq”:
The Frequency Bus Voltage Regulator is enabled. The adjust frequency
setpoint follows the “red” (lower) DB turn on curve. See Table 2.D.
If [Bus Reg Mode A], parameter 161 is set to “Both-DB 1st”:
Both regulators enabled, the operating point of the Dynamic Brake
Regulator is lower than that of the Frequency Bus Voltage Regulator. The
adjust frequency setpoint follows the “red” (lower) DB turn on curve(Table
2.E).
Table 2.E
Voltage Class
240
DC Bus Memory
< 342V DC
480
> 342V DC
< 685V DC
600
> 685V DC
< 856V DC
> 856V DC
DB On Setpoint
Memory + 50V DC
375V DC
Memory + 33V DC
Memory + 100V DC
750 VDC
Memory + 65V DC
Memory + 125V DC
937 VDC
Memory + 81V DC
DB Off Setpoint
On – 4V DC
On – 8V DC
On – 10V DC
2-32
Cable, Control
Cable, Control
For analog and encoder cable selection, see page 2-15. Digital input cable
selection can be found on page 2-51.
Cable, Motor Lengths
The length of cable between the drive and motor may be limited by various
application parameters. The 2 primary areas of concern are Reflected Wave
and Cable charging.
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. Note that many motors have
inadequate insulation systems to tolerate high peaks. See Reflected Wave on
page 2-132 for more details.
Refer to Figure 2.2 for measuring cable lengths when concerned about
Reflected Wave. The actual lead length for each motor must be measured or
calculated based on the lead length for that motor only. Diagram A shows 2
motors, each 300 feet from the drive. Motor protection decisions are based
on a 300 foot cable length (not 600). If the motors need protection at this
distance, then both motors must be dealt with individually. In some cases, a
single device placed at the drive output or near the motors may protect both
motors. Diagram B shows 1 motor at 50 feet and one at 550 feet. It is likely
that the motor that is close to the drive (50 feet) will not need protection, but
the motor farther from the drive (550 feet) may. Again, each motor must be
considered individually based on its distance from the drive.
Cable charging occurs because of the capacitance, phase-to-phase or
phase-to-ground, inherent in the length of cable. The current that is used to
charge the cable capacitance detracts from the overall current capability of
the drive and reduces the availability of torque producing current for the
motor. This can result in poor motor performance, motor stalls under full
load and nuisance drive overcurrent tripping. In general, shielded cable has
higher cable capacitance and will require higher cable charging current.
Refer to Figure 2.2 for measuring cable lengths when concerned about
cable charging. In this case, it is the total amount of cable connected to the
drive that must be considered. Diagram A shows 2 motors, each 300 feet
from the drive. The drive must be capable of supplying enough current to
charge the total length (600 feet) plus the needed current to produce desired
torque in the motors. If a drive is unable to provide sufficient current for
both cable charging and motor torque, then a larger drive with adequate
current rating should be substituted. Diagram B shows 1 motor at 50 feet
and one at 550 feet. Again, the drive must be capable of supplying enough
current to charge the total length (600 feet), plus the current to produce
desired torque in the motors. In fact, diagrams A, B, C and D will all require
the same cable charging installation guidelines because they all have total
cable lengths of 600 feet.
lists the maximum cable lengths recommended for PowerFlex drives.
Distances listed consider both reflected wave amplitude and cable charging
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
A
B
C
D
15.2 (50)
91.4 (300)
167.6 (550)
91.4 (300)
152.4 (500)
182.9 (600)
15.2 (50)
15.2 (50)
All examples represent motor cable length of 182.9 meters (600 feet).
PowerFlex 700 Maximum Motor Lead Lengths (in Feet)
480V HP
Rating
0.5
1
2
3
5
7.5
10
15
25
Carrier Freq.
(kHz)
4
8
4
8
4
8
4
8
4
8
4
8
4
8
4
8
4
8
1000 volt motor
Shielded
Shielded
50
25
40
20
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
25
25
25
25
NA
NA
NA
NA
NA
NA
NA
NA
20
20
20
20
20
20
20
20
Unshielded
75
75
NA
NA
NA
NA
NA
NA
75
75
NA
NA
NA
NA
40
40
40
40
1200 volt motor
Shielded
Shielded
50
220
40
220
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
40
420
40
420
NA
NA
NA
NA
NA
NA
NA
NA
50
420
40
420
50
620
40
620
Unshielded
320
220
NA
NA
NA
NA
NA
NA
520
275
NA
NA
NA
NA
620
520
620
420
1488 volt motor
NEMA MG1-1998
Shielded
Shielded
220
420
220
420
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
420
620
420
520
NA
NA
NA
NA
NA
NA
NA
NA
420
620
420
520
620
620
620
620
Unshielded
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Notes
–
1000V motor is defined as one assembled without phase paper. 1200V motor is defined as one assembled with phase paper. 1488V motor meets NEMA MG 1-1998
section 31 standard where the insulation can withstand voltage spikes of 3.1 x rated motor voltage due to inverter operation (inverter duty motor). 1600V motor is a
1329R or 1329L. Operation at nominal line voltage. To increase the distance between the drive and the motor, some mitigation device needs to be added to the
system (i.e. an RWR or Terminator).
–
NA = Data Not Available at time of publication.
2-34
Cable, Motor Lengths
PowerFlex 70 Maximum Motor Lead Lengths (in Feet) - No External Devices
480V HP
Rating
0.5
1
2
3
5
7.5
10
15
20
Carrier
Freq.
(kHz)
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
2
4
6
8
10
1000 Volt Motor
Shld. (1) Shld. (2)
NA
60
NA
60
NA
60
NA
60
NA
60
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
70
NA
80
NA
80
NA
80
NA
80
NA
80
NA
50
NA
50
NA
50
NA
50
NA
50
NA
50
NA
50
NA
50
NA
50
NA
50
NA
80
NA
80
NA
80
NA
80
NA
80
NA
70
NA
70
NA
70
NA
70
NA
70
1200 Volt Motor
Un-Shld. Shld. (1) Shld. (2)
40
NA
175
40
NA
175
40
NA
175
40
NA
175
40
NA
175
30
NA
275
30
NA
250
30
NA
250
30
NA
250
30
NA
200
40
NA
275
40
NA
250
40
NA
250
40
NA
240
40
NA
220
40
NA
220
40
NA
220
40
NA
220
40
NA
220
40
NA
220
40
NA
280
40
NA
280
40
NA
280
40
NA
280
40
NA
280
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
40
NA
300
50
NA
600
50
NA
400
50
NA
400
50
NA
400
50
NA
400
50
NA
600
50
NA
400
50
NA
200
50
NA
160
50
NA
160
1488 Volt Motor
NEMA MG1-1998
Un-Shld. Shld. (1) Shld. (2)
60
NA
175
60
NA
175
50
NA
175
50
NA
175
50
NA
175
55
NA
275
55
NA
250
55
NA
250
55
NA
250
55
NA
250
75
NA
275
75
NA
250
75
NA
250
75
NA
250
75
NA
250
75
NA
425
75
NA
400
75
NA
425
75
NA
400
75
NA
400
80
NA
450
80
NA
400
80
NA
400
80
NA
300
80
NA
300
60
NA
400
60
NA
400
60
NA
400
60
NA
400
60
NA
300
60
NA
400
60
NA
400
60
NA
400
60
NA
400
60
NA
300
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
80
NA
600
1600 Volt Motor
1329 R/L
Un-Shld. Shld. (1) Shld. (2)
150
NA
175
130
NA
175
130
NA
175
130
NA
175
130
NA
175
180
NA
275
180
NA
250
170
NA
250
160
NA
250
160
NA
250
500
NA
275
400
NA
250
360
NA
250
260
NA
250
260
NA
250
600
NA
425
520
NA
400
520
NA
425
380
NA
400
380
NA
400
600
NA
450
600
NA
400
560
NA
400
400
NA
300
360
NA
300
600
NA
400
600
NA
400
520
NA
400
400
NA
400
320
NA
300
600
NA
400
600
NA
400
560
NA
400
440
NA
400
380
NA
300
600
NA
600
600
NA
600
600
NA
600
500
NA
600
400
NA
600
600
NA
600
600
NA
600
600
NA
600
600
NA
600
340
NA
600
Un-Shld.
150
150
150
150
150
350
300
280
260
240
500
400
400
400
400
600
600
600
580
550
600
600
600
600
580
600
600
600
560
500
600
600
600
560
520
600
600
600
600
480
600
600
600
600
600
(1) Cable is Belden 295xx series or equivalent.
(2) Cable is Alcatel C1202 or equivalent. Shielded cable with twisted conductors and no filler.
Notes
–
1000V motor is defined as one assembled without phase paper. 1200V motor is defined as one assembled with phase paper. 1488V motor meets NEMA MG 1-1998
section 31 standard where the insulation can withstand voltage spikes of 3.1 x rated motor voltage due to inverter operation (inverter duty motor). 1600V motor is a
1329R or 1329L. Operation at nominal line voltage. To increase the distance between the drive and the motor, some mitigation device needs to be added to the
system (i.e. an RWR or Terminator).
–
Shading indicates limited due to cable charging current.
–
NA = Data Not Available at time of publication.
Cable, Power
2-35
Cable, Power
!
ATTENTION: National Codes and standards (NEC, VDE, BSI
etc.) and local codes outline provisions for safely installing
electrical equipment. Installation must comply with specifications
regarding wire types, conductor sizes, branch circuit protection
and disconnect devices. Failure to do so may result in personal
injury and/or equipment damage.
A variety of cable types are acceptable for drive installations.
Unshielded
For many installations, unshielded cable or loose conductors are adequate,
provided they can be separated from sensitive circuits. As an approximate
guide, allow a minimum spacing of 0.3 meters (1 foot). Avoid long parallel
runs. It is recommended that individual wires have XLPE insulation. As a
minimum, any insulation must be at least 15 mils thick. Wire with PVC
insulation (i.e. THHN, see more below) is acceptable if no moisture is
present and the PVC insulation meets the 15 mil minimum. Recommended
tray cable has XLPE for individual conductors and a PVC outer jacket.
Shielded/Armored
Shielded cable is recommended if sensitive circuits or devices are
connected or mounted to the machinery driven by the motor.
Figure 2.3 Recommended Shielded Power Wire
Location
Rating/Type
Standard
(Option 1)
600V, 90°C (194°F)
XHHW2/RHW-2
Anixter
B209500-B209507,
Belden 29501-29507, or
equivalent
Standard
(Option 2)
Tray rated 600V, 90° C
(194° F) RHH/RHW-2
Anixter OLF-7xxxxx or
equivalent
Description
• Four tinned copper conductors with XLPE insulation.
• Copper braid/aluminum foil combination shield and tinned
copper drain wire.
• PVC jacket.
• Three tinned copper conductors with XLPE insulation.
• 5 mil single helical copper tape (25% overlap min.) with
three bare copper grounds in contact with shield.
• PVC jacket.
Class I & II; Tray rated 600V, 90° C • Three bare copper conductors with XLPE insulation and
Division I & II (194° F) RHH/RHW-2
Anixter 7V-7xxxx-3G or
equivalent
•
•
impervious corrugated continuously welded aluminum
armor.
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.
Flame-retardant heat-resistant thermoplastic insulation is the type of
insulation listed in the NEC code for the THHN wire designation. This type
of insulation is commonly referred to as PVC. In addition to manufacturing
inconsistencies, the physical properties of the cable can change due to
environment, installation and operation, which can also lead to premature
insulation degradation. The following is a summary of our findings:
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). A single IGBT drive output may have reflected wave
transient voltage stresses of up to twice (2 per unit) the DC bus voltage
between its own output wires. Multiple drive output wires in a single
conduit or wire tray further increase output wire voltage stress between
multi-drive output wires that are touching. Drive #1 may have a (+) 2 pu
stress while drive #2 may simultaneously have a (–) 2 pu stress. Wires
with dielectric constants (>4) cause the voltage stress to shift to the air
gap between the wires that are barely touching. This electric field may be
high enough to ionize the air surrounding the wire insulation and cause a
partial discharge mechanism (corona) to occur. The electric field
distribution between wires increases the possibility for corona which
further produces ozone. This attacks the PVC insulation and produces
carbon tracking, leading to the susceptibility of insulation breakdown.
• Due to inconsistencies in manufacturing processes or wire pulling, air
voids can also occur in the THHN wire between the nylon jacket and
PVC insulation. Because the dielectric constant of air is much lower than
the dielectric constant of the insulating material, the transient reflected
wave voltage may appear across the small air void capacitance. The
Corona Inception Voltage (CIV) for the air void may be reached which
further produces ozone, which attacks the PVC insulation and produces
carbon tracking, leading to the susceptibility of insulation breakdown as
in the above case.
• Asymmetrical construction of the insulation has also been observed for
some manufacturers of PVC wire. A wire with a 15 mil specification was
observed to have an insulation thickness of 10 mil at some points. The
smaller the insulation thickness, the less voltage the wire can withstand.
Installation, Operation and Environmental Considerations
• THHN jacket material has a relatively brittle nylon that lends itself to
damage (i.e. nicks and cuts) when pulled through conduit on long wire
runs. This issue is of even greater concern when the wire is being pulled
through multiple 90 degree bends in the conduit. It is these nicks that
may be a starting point for corona that leads to insulation degradation.
• During operation, the conductor heats up and a “coldflow” condition
may occur with PVC insulation at points where the unsupported weight
of the wire may stretch the insulation. This has been observed at right
angle bends where wire is dropped down to equipment from an above
wireway. This “coldflow” condition produces thin spots in the insulation
which lowers the cable’s voltage withstand capability.
• The NEC 1996 code defines “dry, damp and wet” locations (7-31) and
permits the use of heat-resistant thermoplastic wire in both dry and damp
applications (Table 310-13). However, PVC insulation material is more
susceptible to absorbing moisture than XLPE (Cross Linked
Polyethylene) insulation material (XHHN-2) identified for use in wet
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.
Cable Recommendations for New & Existing Installations of IGBT Drives in Wet
Locations
• Belden YR41709 cable is a PVC jacketed, shielded type TC with XLPE
conductor insulation designed to meet NEC code designation XHHW-2
(wet locations per NEC 1996, Table 310-13). Based on Rockwell
Automation research, tests have determined the Belden YR41709 is
notably superior to loose wires in dry, damp and wet applications and
can significantly reduce capacitive coupling and common mode noise.
Other cable types for wet locations include those in the table above
Figure 2.4 summarizes the previous considerations and explanations.
Because applications can vary widely, the information in the flowchart is
intended to be used only as a guideline in the decision-making process.
Figure 2.4 Wire Selection Flowchart
Selecting Wire to Withstand Reflected Wave Voltage for New and Existing Wire Installations
in Conduit or Cable Trays
DRY
(Per NEC 7-31)
Conductor
Environment
Conductor
Insulation
PVC
WET
(Per NEC code Table 7-31)
XLPE (XHHW-2)
Insulation for
<600V AC
System
No RWR or
Terminator
Required
XLPE
Insulation
Thickness
20 mil or > (1)
15 mil
230V
400/460V
Reflected Wave
Reducer?
OK for < 600V AC
System
No RWR or
Terminator required
575V
No RWR or
Terminator
Cable
Length
Reflected Wave
Reducer?
> 50 ft.
# of
Drives in Same
Conduit or Wire
Tray
RWR or
Terminator
< 50 ft.
Single Drive,
Single Conduit
or Wire Tray
Multiple Drives
in Single Conduit
or Wire Tray
No RWR
or Terminator
RWR or
Terminator
15 mil PVC
Not
Recommended
USE XLPE
or > 20 mil
(1) The mimimum wire size for PVC cable with 20 mil or greater insulation is 10 gauge.
15 mil PVC
Not
Recommended
USE XLPE
or > 20 mil
See NEC Guidelines
(70-196 Adjustment Factors) for
Maximum Conductor Derating &
Maximum Wires in Conduit or Tray
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
Conduit must be magnetic steel and be installed so as to provide a
continuous electrical path through the conduit itself.
Care must be taken when pulling wire to avoid nicking the wire.
Nylon-coated wire such as THHN or THWN is subject to insulation
damage when it is pulled through conduit, particularly if 90º bends are
present. Nicking can significantly reduce or remove the insulation. Water
based lubricants should not be used with nylon coated wire such as THHN.
Important: Because of the nature of the drive PWM output and the
reflected wave phenomenon, it is preferable to have each set of
drive motor/power cables in an individual conduit. If this is not
possible, do not route more than 3 sets of drive cables in one
conduit. It is important that the allowable fill rates specified in
the applicable national or local codes Not Be Exceeded.
!
ATTENTION: To avoid a possible shock hazard caused by
induced voltages, unused wires in the conduit must be grounded at
both ends. For the same reason, if a drive sharing a conduit is being
serviced or installed, all drives using this conduit should be
disabled. This will help minimize the possible shock hazard from
“cross coupled” motor leads.
When laying cable in cable trays, do not randomly distribute them. Cables
for each drive should be bundled together and anchored to the tray (see
Figure 2.5). A minimum separation of one cable width should be
maintained between bundles to reduce overheating and cross-coupling.
Current flowing in one set of cables can induce a hazardous voltage and/or
excessive noise on the cable set of another drive, even when no power is
applied to the second drive. Dividers also provide excellent separation.
Figure 2.5 Cable Placement
Random Placement
Not Recommended
or
Bundled & Anchored to Tray
Recommended
For further information, refer to “Wiring and Grounding Guidelines for
PWM AC Drives,” publication DRIVES-IN001A-EN-P.
Carrier (PWM) Frequency
Carrier (PWM)
Frequency
2-39
See page 1-4 for derating guidelines as they relate to carrier 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. Refer to Figure 2.6 and
Figure 2.7. Note the output current at 2 kHz and 4 kHz. The “smoothing” of
the current waveform continues all the way to 10 kHz.
Figure 2.6 Current at 2 kHz PWM Frequency
Figure 2.7 Current at 4 kHz PWM Frequency
The benefits of increased carrier frequency include less motor heating and
lower audible noise. An increase in motor heating is considered negligible
and motor failure at lower switching frequencies is very remote. The higher
switching frequency creates less vibration in the motor windings and
laminations thus, lower audible noise. This may be desirable in some
applications.
Some undesirable effects of higher switching frequencies include derating
ambient temperature vs. load characteristics of the drive, higher cable
charging currents and higher potential for common mode noise.
A very large majority of all drive applications will perform adequately at
2-4 kHz.
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.
CE Declarations of Conformity are available online at:
http://www.ab.com/certification/ce/docs.
Low Voltage Directive (73/23/EEC)
• EN50178 Electronic equipment for use in power installations.
EMC Directive (89/336/EEC)
• EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
• If the adhesive label is removed from the top of the drive, the drive must
be installed in an enclosure with side openings less than 12.5 mm (0.5
in.) and top openings less than 1.0 mm (0.04 in.) to maintain compliance
with the LV Directive.
• The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
• Use of line filters in ungrounded systems is not recommended.
• PowerFlex drives may cause radio frequency interference if used in a
residential or domestic environment. The user is required to take
measures to prevent interference, in addition to the essential
requirements for CE compliance listed below, if necessary.
• Conformity of the drive with CE EMC requirements does not guarantee
an entire machine or installation complies with CE EMC requirements.
Many factors can influence total machine/installation compliance.
• PowerFlex drives can generate conducted low frequency disturbances
(harmonic emissions) on the AC supply system. More information
regarding harmonic emissions can be found in the PowerFlex Reference
Manual.
Essential Requirements for CE Compliance
Conditions 1-6 listed below must be satisfied for PowerFlex drives to meet
the requirements of EN61800-3.
1. Standard PowerFlex CE compatible Drive.
2. Review important precautions/attention statements throughout the User
Manual before installing the drive.
3. Grounding as described on page 2-91.
CE Conformity
2-41
4. Output power, control (I/O) and signal wiring must be braided, shielded
cable with a coverage of 75% or better, metal conduit or equivalent
attenuation.
5. All shielded cables should terminate with the proper shielded connector.
6. Conditions in the appropriate table (2.F, 2.G or 2.H).
Frame
Table 2.F PowerFlex 70 – EN61800-3 EMC Compatibility(1)
A
B
C
D
Drive Description
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Second Environment
Restrict Motor Internal
Cable to
Filter
40 m (131 ft.) Option
✔
–
✔
–
✔
–
✔
✔
✔
✔
✔
✔
✔
–
✔
–
✔
–
✔
–
✔
–
✔
–
External
Filter
✔
✔
✔
–
–
–
–
–
–
–
–
–
Input
Ferrite (2)
–
–
✔
–
–
✔
–
–
✔
–
–
✔
A
B
C
D
First Environment Restricted Distribution
Restrict Motor Restrict Motor Internal
Cable to
Cable to
Filter
External
12 m (40 ft.)
40 m (131 ft.) Option
Filter
–
✔
–
✔
–
✔
–
✔
–
✔
–
✔
✔
–
✔
–
✔
–
✔
–
✔
–
✔
–
✔
–
–
–
✔
–
–
–
✔
–
–
–
✔
–
–
–
✔
–
–
–
✔
–
–
–
Drive Description
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Drive Only
Drive with any Comm Option
Drive with ControlNet
Comm
Common
Cable
Mode
Ferrite (2) Core (3)
–
–
–
–
✔
–
–
–
–
–
✔
–
–
✔
–
✔
✔
✔
–
–
–
–
✔
–
Table 2.H PowerFlex 700 EN61800-3 EMC Compatibility (1)
Frame
Frame
Table 2.G PowerFlex 70 – EN61800-3 First Environment Restricted Distribution (1)
0
1
2
3
Second Environment
First Environment Restricted Distribution
Restrict Motor Cable to 30 m (98 ft.)
Any Drive and Option
Restrict Motor Cable to 150 m (492 ft.)
Any Drive and Option
External Filter Required
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
2-42
Copy Cat
(1) External filters for First Environment installations and increasing motor cable lengths in Second Environment
installations are available. Roxburgh models KMFA (RF3 for UL installations) and MIF or Schaffner FN3258
and FN258 models are recommended.
Refer to the following page and http://www.deltron-emcon.com and http://www.mtecorp.com (USA) or
http://www.schaffner.com, respectively.
(2) Two turns of the blue comm option cable through a Ferrite Core (Frames A, B, C Fair-Rite #2643102002, Frame
D Fair-Rite #2643251002 or equivalent).
(3) Refer to the 1321 Reactor and Isolation Transformer Technical Data publication, 1321-TD001x for 1321-Mxxx
selection information.
Recommended Filters (1)
Manufacturer
Deltron
Drive Type
PowerFlex 70
PowerFlex 700
Schaffner
PowerFlex 70
PowerFlex 700
Frame
A
B w/o Filter
B w/Filter
C
D
D w/o DC CM Capacitor
0
1
2
2 w/o DC CM Capacitor
3
3 w/o DC CM Capacitor
A
B w/o Filter
B w/Filter
C
D
D w/o DC CM Capacitor
0
1
2
2 w/o DC CM Capacitor
3
3 w/o DC CM Capacitor
Manufacturer
Part Number
KMF306A
KMF310A
KMF306A
KMF318A
KMF336A
KMF336A
KMF318A
KMF325A
KMF350A
KMF350A
KMF370A
KMF370A
FN3258-7-45
FN3258-7-45
FN3258-7-45
FN3258-16-45
FN3258-30-47
FN3258-30-47
FN3258-16-45
FN3258-30-47
FN3258-42-47
FN3258-42-47
FN3258-75-52
FN3258-75-52
Class
A
(Meters)
25
50
100
–
150
–
–
–
200
176
150
150
–
100
–
–
0
–
–
–
50
150
100
150
B
(Meters)
25
25
50
150
5
50
100
150
150
150
100
100
50
50
100
150
0
150
150
150
50
150
100
150
Manufacturer
Part Number
–
–
MIF306
–
MIF330
–
MIF316
–
–
–
–
–
–
–
–
–
FN258-30-07
–
–
–
–
–
–
–
Class
A
(Meters)
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
B
(Meters)
–
–
100
–
150
–
150
–
–
–
–
–
–
–
–
–
150
–
–
–
–
–
–
–
(1) Use of these filters assumes that the drive is mounted in an EMC enclosure.
Copy Cat
Some PowerFlex drives have a feature called Copy Cat, which allows the
user to upload a complete set of parameters to the LCD HIM. This
information can then be used as backup or can be transferred to another
drive by downloading the memory.
Generally, the transfer process manages all conflicts. If a parameter from
HIM memory does not exist in the target drive, if the value stored is out of
range for the drive or the parameter cannot be downloaded because the drive
is running, the download will stop and a text message will be issued. The
user than has the option of completely stopping the download or continuing
after noting the discrepancy for the parameter that could not be
downloaded. These parameters can then be adjusted manually.
The LCD HIM will store a number of parameter sets (memory dependant)
and each individual set can be named for clarity.
Current Limit
Current Limit
2-43
[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
• Overload Protection IT
• Heatsink temperature protection
• Thermal Manager
1. Instantaneous Overcurrent - This is a feature that instantaneously trips or
faults the drive if the output current exceeds this value. The value is fixed
by hardware and is typically 250% of drive rated amps. The Fault code
for this feature is F12 “HW Overcurrent.” This feature cannot be
defeated or mitigated.
2. Software Instantaneous Trip - There could be situations where peak
currents do not reach the F12 “HW Overcurrent” value and are sustained
long enough and high enough to damage certain drive components. If
this situation occurs, the drives protection scheme will cause an F36
“SW Overcurrent” fault. The point at which this fault occurs is fixed and
stored in drive memory.
3. Software Current Limit - This is a software feature that selectively faults
the drive or attempts to reduce current by folding back output voltage
and frequency if the output current exceeds this value. The [Current Lmt
Val] parameter is programmable between approximately 25% and 150%
of drive rating. The reaction to exceeding this value is programmable
with [Shear Pin Fault]. Enabling this parameter creates an F63 “Shear
Pin Fault.” Disabling this parameter causes the drive to use Volts/Hz fold
back to try and reduce load.
The frequency adjust or fold back operation consists of two modes. In
the primary mode of current limit operation, motor phase current is
sampled and compared to the Current Limit setting in the [Current Lmt
Val]. If a current “error” exists, error is scaled by an integral gain and fed
to the integrator. The output of this integrator is summed with the
proportional term and the active speed mode component to adjust the
output frequency and the commanded voltage. The second mode of
current limit operation is invoked when a frequency limit has been
reached and current limit continues to be active. At this point, a current
regulator is activated to adjust the output voltage to limit the current.
When the current limit condition ceases or the output voltage of the
current regulator attempts to exceed the open loop voltage commands,
control is transferred to the primary current limit mode or normal ramp
operation.
2-44
Current Limit
4. Overload Protection I2T - 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 I2T value (i.e. 150% for 3 seconds,
etc.). If the IT integrates to maximum, an F64 “Drive Overload” fault
will occur. The approximate integrated value can be monitored via the
[Drive OL Count] parameter.
5. Heatsink Temperature Protection - The drive constantly monitors the
heatsink temperature. If the temperature exceeds the drive maximum, a
“Heatsink OvrTemp” fault will occur. The value is fixed by hardware at a
nominal value of 100 degrees C. This fault is generally not used for
overcurrent protection due to the thermal time constant of the heatsink. It
is an overload protection.
6. Thermal manager (see Drive Overload on page 2-76).
Datalinks
Datalinks
2-45
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. Because each Datalink
consists of a pair of parameters, when enabled, each Datalink occupies two
16 or 32-bit words in both the input and output image tables, depending on
configuration. A user enters a parameter number into the Datalink
parameter. The value that is in the corresponding output data table word in
the controller is then transferred to the parameter whose number has been
placed in the Datalink parameter. The following example demonstrates this
concept. The object of the example is to change Accel and Decel times “on
the fly” under PLC control.
The user makes the following PowerFlex drive parameter settings:
Parameter 300 [Data In A1] = 140 (the parameter number of [Accel Time 1]
Parameter 301 [Data In A2] = 142 (the parameter number of [Decel Time 1]
Programmable
Controller
I/O Image Table
Remote I/O
Communication
Module
Adjustable Frequency
AC Drive
Output Image
Block Transfer
Logic Command
Analog Reference
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
Datalink A
Parameter/Number
Data In A1
Data In A2
300
301
Datalink A
Data Out A1 310
Data Out A2 311
Input Image
Block Transfer
Logic Status
Analog Feedback
WORD 3
WORD 4
WORD 5
WORD 6
WORD 7
In the PLC data Table, the user enters Word 3 as a value of 100 (10.0 Secs)
and word 4 as a value of 133 (13.3 seconds). On each I/O scan, the
parameters in the PowerFlex drive are updated with the value from the data
table:
Accel Time P140 = 10.0 seconds (value from output image table Word 3)
Decel Time P142 = 13.3 seconds (value from output image table Word 4).
Any time these values need to be changed, the new values are entered into
the data table, and the parameters are updated on the next PLC I/O scan.
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. If more than one communications
adapter is connected to a single drive, multiple adapters must not try to
use the same Datalink.
3. Parameter settings in the drive determine the data passed through the
Datalink mechanism
4. When you use a Datalink to change a value, the value is not written to
the Non-Volatile Storage (EEprom memory). The value is stored in
volatile memory (RAM) and lost when the drive loses power.
32-Bit Parameters using 16-Bit Datalinks
To read (and/or write) a 32-bit parameter using 16-bit Datalinks, typically
both Datalinks (A,B,C,D) are set to the 32-bit parameter. For example, to
read Parameter 09 - [Elapsed MWh], both Datalink A1 and A2 are set to
“9.” Datalink A1 will contain the least significant word (LSW) and Datalink
A2 the most significant word (MSW). In this example, the parameter 9
value of 5.8MWh is read as a “58” in Datalink A1
Datalink
A1
A2
Most/Least Significant Word Parameter
LSW
9
MSW
9
Data (decimal)
58
0
Regardless of the Datalink combination, x1 will always contain the LSW
and x2 will always contain the MSW.
In the following examples Parameter 242 - [Power Up Marker] contains a
value of 88.4541 hours.
Datalink
A1
A2
Most/Least Significant Word Parameter
LSW
242
-Not Used0
Data (decimal)
32573
0
Datalink
A1
A2
Most/Least Significant Word Parameter
-Not Used0
MSW
242
Data (decimal)
0
13
Even if non-consecutive Datalinks are used (in the next example, Datalinks
A1 and B2 would not be used), data is still returned in the same way.
Datalink
A2
B1
Most/Least Significant Word Parameter
MSW
242
LSW
242
32-bit data is stored in binary as follows:
MSW
LSW
231 through 216
215 through 20
Example
Parameter 242 - [Power Up Marker] = 88.4541 hours
MSW = 13decimal = 1101binary = 216 + 218 + 219 = 851968
LSW = 32573
851968 + 32573 = 884541
Data (decimal)
13
32573
DC Bus Voltage / Memory
DC Bus Voltage /
Memory
2-47
[DC Bus Voltage] is a measurement of the instantaneous value. [DC Bus
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. Thereafter it is updated by ramping at a
very slow rate toward Vbus. The filtered value ramps at approximately 2.4V
DC per minute (for a 480V AC drive).
Bus memory is used as the base line to sense a power loss condition. If the
drive enters a power loss state, the bus memory will also be used for
recovery (i.e. pre-charge control or inertia ride through upon return of the
power source) upon return of the power source. Update of the bus memory
is blocked during deceleration to prevent a false high value caused by a
regenerative condition.
[Decel Time 1, 2]
Sets the rate at which the drive ramps down its output frequency after a Stop
command or during a decrease in command frequency (speed change). The
rate established is the result of the programmed Decel Time and the
Minimum and Maximum Frequency, as follows:
Maximum Speed
= Decel Rate (Hz/sec)
Decel Time
(1)
(1)
(1)
Two decel times exist to allow the user to change rates “on the fly” via PLC
command or digital input. The selection is made by programming [Decel
Time 1] & [Decel Time 2] and then using one of the digital inputs ([Digital
Inx Sel]) programmed as “Decel 2” (see Table 2.J for further information).
However, if a PLC is used, manipulate the bits of the command word as
shown below.
MO
P
Sp Dec
dR
Sp ef I
d
D
Sp Ref 2
d ID
De Ref 1
ce ID
De l 2 0
ce
Ac l 1
ce
Ac l 2
c
Mo el 1
p
Lo Inc
ca
Re l Co
ve n
Fo rse trl
rw
Cle ard
a
Jo r Fa
g ult
Sta
r
Sto t
p
Decel Time
0 0 0 0 1 1 1 0 1 0 0 0 1 1 0 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
0
0
0
1
0
0
1
0
0
1
0
0
1
0
0
0
1 =Condition True
0 =Condition False
x =Reserved
Accel 1
Accel 2
Decel 1
Decel 2
The effectiveness of these bits or digital inputs can be affected by [Decel
Mask]. See Masks on page 2-97 for more information.
Times are adjustable in 0.1 second increments from 0.0 seconds to 3600.0
seconds.
In its factory default condition, when no decel select inputs are closed and
no time bits are “1,” the default deceleration time is [Decel Time 1] and the
rate is determined as above.
Diagnostics
Diagnostic Parameters – PF700 Vector Control Only
Parameter Name & Description
500 [KI Current Limit]
Related
No.
Group
File
The following parameters can only be viewed when “2, Unused” is selected
in parameter 196, [Param Access Lvl].
Values
Default:
Current Limit Integral gain. This gain is Min/Max:
applied to the current limit error signal to Units:
eliminate steady state current limit error.
A larger value increases overshoot
during a step of motor current/load.
Default:
501 [KD Current Limit]
Current Limit Derivative gain. This gain is Min/Max:
applied to the sensed motor current to
Units:
anticipate a current limit condition. A
larger value reduces overshoot of the
current relative to the current limit value.
Default:
502 [Bus Reg ACR Kp]
This proportional gain, in conjunction
Min/Max:
with P160, adjusts the output frequency Units:
of the drive during a bus limit or inertia
ride through condition. The output
frequency is adjusted in response to an
error in the active, or torque producing,
current to maintain the active bus limit, or
inertia ride through bus reference. A
larger value of gain reduces the dynamic
error of the active current.
Default: 900
503 [Jerk]
UTILITY
Diagnostics
Diag-Motor Cntl
2-48
This parameter allows you to adjust the
amount of S-Curve, or “Jerk” applied to
the Acc/Dec rate. To enable the Jerk
feature, bit 1 of P56 must be set high.
504 [Ln Ls Bus Reg Kp]
Min/Max: 2/30000
Units:
1
Default:
500
This proportional gain adjusts the active Min/Max: 0/10000
current command during an inertia-ride Units:
1
through condition, in response to a bus
error. A larger value of gain reduces the
dynamic error of the bus voltage as
compared to the bus voltage reference.
Default: 500
505 [Ln Ls Bus Reg Kd]
Line Loss Bus Reg Kd is a derivative
Min/Max: 0/10000
gain, which is applied to the sensed bus Units:
1
voltage to anticipate dynamic changes
and minimize them. A larger value
reduces overshoot of the bus voltage
relative to the inertia-ride through bus
voltage reference.
Default: 64
506 [Angl Stblty Gain]
Angle Stability Gain adjusts the electrical Min/Max: 0/32767
angle to maintain stable motor operation. Units:
1
An increase in the value increases the
angle adjustment.
Default: 128
507 [Volt Stblty Gain]
Adjusts the output voltage to maintain
stable motor operation. An increase in
the value increases the output voltage
adjustment.
508 [Stability Filter]
Min/Max: 0/32767
Units:
1
Default:
1750
The Stability Filter coefficient is used to Min/Max: 0/32767
adjust the bandwidth of a low pass filter. Units:
1
The smaller the value of this coefficient,
the lower the bandwidth of the filter.
Parameter Name & Description
509 [Lo Freq Reg KpId]
Values
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.
Default:
510 [Lo Freq Reg KpIq]
The proportional gain adjusts the output Min/Max:
voltage at very low frequency in response Units:
to the active, or q-axis, motor current. A
larger value increases the output voltage
change.
Default: 32767
511 [Cur Reg Ki]
UTILITY
Diag-Motor Cntl
This integral gain adjusts the output
Min/Max: 0/32767
voltage in response to the q and d axis Units:
1
motor currents. A larger value increases
the output voltage change.
Default: 32767
512 [Cur Reg Kp]
This proportional gain adjusts the output Min/Max: 0/32767
voltage in response to the q and d axis Units:
1
motor currents. A larger value increases
the output voltage change.
Default: 95.0%
523 [Bus Utilization]
This value sets the drive output voltage Min/Max: 85.0/100.0%
limit as a percentage of the fundamental Units:
0.1%
output voltage when operating in 6 step
mode. Values above 95% increase
harmonic content and jeopardize control
stability. This output voltage limit is
strictly a function of input line and
resulting bus voltage.
Default:
524 [PWM Type Sel]
Allows selection of the active PWM type. Min/Max:
A value of 0 is default, and results in a
Units:
change of PWM method at approximately
2/3 of rated motor frequency. If this is
unacceptable for harmonic or audible
reasons, a value of 1 disables the
change.
Default:
536 [Flux Brake Ki]
Proportional gain for the Flux Regulator
537 [Flux Brake Kp]
Integral gain for the Flux Regulator
538 [Rec Delay Time]
TBD
513 [PWM DAC Enable]
Diag-DACs
Reserved. Do Not Adjust
514
515
516
517
[DAC47-A]
[DAC47-B]
[DAC47-C]
[DAC47-D]
Min/Max:
Units:
Default:
Min/Max:
Units:
Default: 1000
Min/Max: 1/30000
Units:
1
Default:
Min/Max:
Units:
Default: 0
Min/Max: 0/7432
Units:
1
Reserved. Do Not Adjust
518 [Host DAC Enable]
Reserved. Do Not Adjust
Default:
Min/Max:
Units:
Related
No.
Group
File
Diagnostics
2-49
519
520
521
522
Parameter Name & Description
[DAC55-A]
[DAC55-B]
[DAC55-C]
[DAC55-D]
Values
Default:
Related
No.
Group
Diag-DACs
File
Diagnostics
0
Min/Max: 0/7432
Units:
1
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.
Default: 0
526 [Torq Reg Enable]
Enables or disables the torque regulator Min/Max: 0/1
Units:
1
Default: 32
527 [Torq Reg Kp]
Proportional gain for the torque regulator Min/Max: 0/32767
Units:
1
Default: 512
528 [Torq Reg Ki]
Integral gain for the torque regulator
529 [Torq Reg Trim]
Torque Regulator trim gain. A larger
value increases the developed torque.
Typically used to compensate for losses
between developed and shaft torque.
UTILITY
530 [Slip Reg Enable]
Enables or disables the slip frequency
regulator.
Diag-Vector Cnt
2-50
531 [Slip Reg Kp]
Proportional gain for the slip frequency
regulator.
532 [Slip Reg Ki]
Integral gain for the slip frequency
regulator.
533 [Flux Reg Enable]
Enables or disables the flux regulator.
534 [Flux Reg Kp]
Proportional gain for the flux regulator.
535 [Flux Reg Ki]
Integral gain for the flux regulator.
539 [Freq Reg Kp]
Proportional gain for the Frequency
Regulator
540 [Freq Reg Ki]
Min/Max: 0/32767
Units:
1
Default: 1.0
Min/Max: 0.5/1.5
Units:
0.1
Default:
Min/Max: 0/32767
Units:
1
Default: 64
Min/Max: 0/32767
Units:
1
Default: 0
Min/Max: 0/1
Units:
1
Default: 400
Min/Max: 0/32767
Units:
1
Default: 128
Min/Max: 0/32767
Units:
1
Default:
Min/Max:
Units:
Default:
Integral gain for the Frequency Regulator Min/Max:
Units:
Default:
[Hi Flux Reg Ki]
TBD
[Hi Flux Reg Kp]
TBD
0
Min/Max: 0/1
Units:
1
Default: 160
Min/Max:
Units:
Default:
Min/Max:
Units:
Digital Inputs
Digital Inputs
2-51
Cable Selection
Important points to remember about I/O wiring:
• Always use copper wire.
• Wire with an insulation rating of 600V or greater is recommended.
• Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
Table 2.I Recommended Control Wire for Digital I/O
Type
Wire Type(s)
Unshielded Per US NEC or applicable
national or local code
Shielded
Multi-conductor shielded cable
such as Belden 8770(or equiv.)
Description
–
0.750 mm2 (18AWG), 3
conductor, shielded.
Minimum Insulation
Rating
300V,
60 degrees C
(140 degrees F)
Wiring Examples
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.
There is both hardware and software filtering on these inputs. The hardware
provides an average delay of 12ms from the time the level changes at the
input to the earliest time that the software can detect the change. The actual
time can vary between boards from 7 to 17ms, but any particular board
should be consistent to within 1% of its average value. The amount of
software filtering is not alterable by the user.
PowerFlex 700
Each digital input has a maximum response/pass through/function
execution time of 25ms. This means that, 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.
Digital Input Configuration
Inputs are configured for the required function by setting a [Digital Inx Sel]
parameter (one for each input). These parameters cannot be changed while
the drive is running.
Digital Inputs
PowerFlex 700 Digital Input Selection
361
362
363
364
365
366
[Digital In1 Sel]
[Digital In2 Sel]
[Digital In3 Sel]
[Digital In4 Sel]
[Digital In5 Sel]
[Digital In6 Sel] (11)
Default:
Default:
Default:
Default:
Default:
Default:
Selects the function for the digital inputs. Options:
(1) Speed Select Inputs.
Digital Inputs
3
0
0
0
0
1
1
1
1
INPUTS & OUTPUTS
2-52
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Auto Reference Source
Reference A
Reference B
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
To access Preset Speed 1, set [Speed
Ref x Sel] to “Preset Speed 1”.
Type 2 Alarms - Some digital input
programming may cause conflicts
that will result in a Type 2 alarm.
Example: [Digital In1 Sel] set to “5,
Start” in 3-wire control and [Digital
In2 Sel] set to 7 “Run” in2-wire.
Refer to User Manual for information
on resolving this type of conflict.
(2) Vector Control Option Only.
(3)
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Spd/Trq Mode
Zero Torque
Spd Reg
Torque Reg
Min Spd/Trq
Max Spd/Trq
Sum Spd/Trq
Absolute
Zero Trq
4
5
18
15
16
17
“Stop – CF”
“Start”
“Auto/ Manual”
“Speed Sel 1”
“Speed Sel 2”
“Speed Sel 3”
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15-17
18
19
20
21
22
23
24
25
26
27
28
29
30
31-33
34
“Not Used”
“Enable” (8)(10)
“Clear Faults”(CF) (4)
“Aux Fault”
“Stop – CF” (10)
“Start” (5)(9)
“Fwd/ Reverse” (5)
“Run” (6)(10)
“Run Forward” (6)
“Run Reverse” (6)
“Jog”(5) “Jog1” (2)(5)
“Jog Forward” (6)
“Jog Reverse” (6)
“Stop Mode B”
“Bus Reg Md B”
“Speed Sel 1-3” (1)
“Auto/ Manual” (7)
“Local”
“Acc2 & Dec2”
“Accel 2”
“Decel 2”
“MOP Inc”
“MOP Dec”
“Excl Link”
“PI Enable”
“PI Hold”
“PI Reset”
“Pwr Loss Lvl”
“Precharge En”
“Spd/Trq Sel1-3” (2,3)
“Jog 2” (2)
(4) When [Digital Inx Sel] is set to option 2 “Clear Faults” the Stop button cannot
be used to clear a fault condition.
(5) Typical 3-Wire Inputs - Requires that only 3-wire functions are chosen.
Including 2-wire selections will cause a type 2 alarm.
(6) Typical 2-Wire Inputs - Requires that only 2-wire functions are chosen. Includ-
ing 3-wire selections will cause a type 2 alarm. See User Manual for conflicts.
(7) Auto/Manual - Refer to User Manual for details.
(8) Opening an “Enable” input will cause the motor to coast-to-stop, ignoring any
programmed Stop modes.
(9) A “Dig In ConflictB” alarm will occur if a “Start” input is programmed without a
“Stop” input.
(10) Refer to the Sleep-Wake Mode Attention statement on User Manual .
(11) A dedicated hardware enable input is available via a jumper selection. Refer
to User Manual for further information.
100
156
162
096
140
194
380
384
388
124
Digital Inputs
PowerFlex 70 Digital Input Selection
361 [Digital In1 Sel]
Default:
4
[Digital In2 Sel]
[Digital In3 Sel]
[Digital In4 Sel]
[Digital In5 Sel]
[Digital In6 Sel]
Default:
Default:
Default:
Default:
Default:
5
18
15
16
17
“Stop – CF”
(CF = Clear Fault)
“Start”
“Auto/ Manual”
“Speed Sel 1”
“Speed Sel 2”
“Speed Sel 3”
Selects the function for the digital inputs. Options:
(1) When [Digital Inx Sel] is set to option 2
“Clear Faults” the Stop button cannot
be used to clear a fault condition.
(2) Typical 3-Wire Inputs.
Requires that only 3-wire functions are
chosen. Including 2-wire selections will
cause a type 2 alarm.
(3) Typical 2-Wire Inputs.
Requires that only 2-wire functions are
chosen. Including 3-wire selections will
cause a type 2 alarm.
(4) Speed Select Inputs.
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
“Not Used”
“Enable”(6)
“Clear Faults”(1)
“Aux Fault”
“Stop – CF”(2)
“Start”(2)(7)
“Fwd/ Reverse”(2)
“Run”(3)
“Run Forward”(3)
“Run Reverse”(3)
“Jog”(2)
“Jog Forward”
“Jog Reverse”
“Stop Mode B”
“Bus Reg Md B”
“Speed Sel 1”(4)
“Speed Sel 2”(4)
“Speed Sel 3”(4)
“Auto/ Manual”(5)
“Local”
“Acc2 & Dec2”
“Accel 2”
“Decel 2”
“MOP Inc”
“MOP Dec”
“Excl Link”
“PI Enable”
“PI Hold”
“PI Reset”
Digital Inputs
INPUTS & OUTPUTS (File J)
362
363
364
365
366
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
Auto Reference Source
Reference A
Reference B
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
To access Preset Speed 1, set [Speed
Ref A Sel] or [Speed Ref B Sel] to
“Preset Speed 1”.
Type 2 Alarms
Some digital input programming may
cause conflicts that will result in a Type
2 alarm. Example: [Digital In1 Sel] set
to 5 “Start” in 3-wire control and [Digital
In2 Sel] set to 7 “Run” in 2-wire.
Refer to Alarm Descriptions in the User
Manual for information on resolving
this type of conflict.
(5) Auto/Manual - Refer to User Manual for
details.
(6) Opening an “Enable” input will cause
the motor to coast-to-stop, ignoring
any programmed Stop modes.
(7) A “Dig In ConflictB” alarm will occur if a
“Start” input is programmed without a
“Stop” input.
The available functions are defined in Table 2.J.
100
156
162
096
140
194
380
384
388
124
2-53
2-54
Digital Inputs
Table 2.J Digital Input Function List
Input Function Name
Stop - CF
Run Forward
Run Reverse
Run
Start
Forward/Reverse
Jog
Jog Forward
Jog Reverse
Speed Select 3
Speed Select 2
Speed Select 1
Auto/Manual
Purpose
Stop drive
Clear Faults (open to closed transition)
Run in forward direction (2-wire start mode)
Run in reverse direction (2-wire start mode)
Run in current direction (2-wire start mode)
Start drive (3-wire start mode)
Set drive direction (3-wire mode only)
Jog drive
Jog in forward direction
Jog in reverse direction
Select which Speed reference the drive uses.
Allows terminal block to assume complete control of Speed
Reference.
Accel 2
Select acceleration rate 1 or 2.
Decel 2
Select deceleration rate 1 or 2.
Accel 2 & Decel 2
Select acceleration rate 1 and deceleration rate 1 or
acceleration rate 2 and deceleration rate 2.
MOP Increment
Increment MOP (Motor Operated Pot Function Speed ref)
MOP Decrement
Decrement MOP (Motor Operated Pot Function Speed ref)
Stop Mode B
Select Stop Mode A (open) or B (closed)
Bus Regulation Mode B
Select which bus regulation mode to use
PI Enable
Enable Process PI loop.
PI Hold
Hold integrator for Process PI loop at current value.
PI Reset
Clamp integrator for Process PI loop to 0.
Auxiliary Fault
Open to cause “auxiliary fault” (external string).
Local Control
Allows terminal block to assume complete control of drive
logic.
Clear Faults
Clear faults and return drive to ready status.
Enable
Open input causes drive to coast to stop, disallows start.
Exclusive Link
Exclusive Link – digital input is routed through to digital
output, no other use.
Power Loss Level (PowerFlex 700 only) Selects between using fixed value for power loss level and
getting the level from a parameter
Precharge Enable (PowerFlex 700 only) If common bus configuration, denotes whether drive is
disconnected from DC bus or not. Controls precharge
sequence on reconnection to bus.
Input Function Detailed Descriptions
• Stop - Clear Faults
An open input will cause the drive to stop and become “not ready”. A
closed input will allow the drive to run.
If “Start” is configured, then “Stop - Clear Faults” must also be
configured. Otherwise, a digital input configuration alarm will occur.
“Stop - Clear Faults” is optional in all other circumstances.
An open to closed transition is interpreted as a Clear Faults request. The
drive will clear any existing faults. The terminal block bit must be set in
the [Fault Mask] and [Logic Mask] parameters in order for the terminal
block to clear faults using this input function.
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” input
function is configured and open.
The table below describes the basic action taken by the drive in response
to particular states of these input functions.
Run Forward
Open
Open
Run Reverse
Open
Closed
Closed
Open
Closed
Closed
Action
Drive stops, terminal block relinquishes direction ownership.
Drive runs in reverse direction, terminal block takes direction
ownership.
Drive runs in forward direction, terminal block takes direction
ownership.
Drive continues to run in current direction, but terminal block
maintains direction ownership.
If one of these input functions is configured and the other one isn’t, the
above description still applies, but the unconfigured input function
should be considered permanently open.
The terminal block bit must be set in the [Start Mask], [Direction Mask],
and [Logic Mask] parameters in order for the terminal block to start or
change the direction of the drive using these inputs.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed to control
direction at a time. The terminal block must become
direction “owner” before it can be used to control direction.
If another device is currently the direction owner (as
indicated by [Direction Owner]), it will not be possible to
start the drive or change direction by using the terminal
block digital inputs programmed for both Run and
Direction control (i.e. Run/Fwd).
If one or both of these input functions is configured, it will not be
possible to start or jog the drive from any other control device. This is
true irrespective of the state of the [Start Mask], [Direction Mask], and
[Logic Mask] parameters.
• Run
An open to closed transition on this input while drive is stopped will
cause the drive to run in the currently selected direction unless the “Stop
- Clear Faults” input function is configured and open.
If this input is open, then the drive will stop.
The purpose of this input function is to allow a 2-wire start while the
direction is being controlled by some other means.
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. This is true irrespective of
the state of the [Start Mask], [Direction Mask], and [Logic Mask]
parameters.
The Effects of 2-Wire Start Modes on Other DPI Devices
The “Run/Stop” and “Run Fwd/Rev” start modes are also called
“2-wire” start modes, because they allow the drive to be started and
stopped with only a single input and two wires. When a “2-wire”
terminal block start mode is put into effect by the user, the drive can no
longer be started or jogged from any other control device (i.e. HIM,
network card, etc.). This restriction persists as long as one or more of
“Run”, “Run Forward”, and “Run Reverse” are configured. This is true
even if the configuration is otherwise illegal and causes a configuration
alarm. See page 2-94 for typical 2 and 3-wire configurations.
• Start
An open to closed transition while the drive is stopped will cause the
drive to run in the current direction, unless the “Stop – Clear Faults”
input function is open.
The terminal block bit must be set in the [Start Mask] and [Logic Mask]
parameters in order for the terminal block to start or change the direction
of the drive using these inputs.
If “Start” is configured, then “Stop - Clear Faults” must also be
configured.
• Forward/Reverse
This function is one of the ways to provide direction control when the
Start / Stop / Run functions of the drive are configured as 3 – wire
control.
An open input sets direction to forward. A closed input sets direction to
reverse. If state of input changes and drive is running or jogging, drive
will change direction.
The terminal block bit must be set in the [Direction Mask] and [Logic
Mask] parameters in order for the terminal block to select the direction
of the drive using this input function.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed to control
direction at a time. The terminal block must become
direction “owner” before it can be used to control direction.
If another device is currently the direction owner (as
indicated by [Direction Owner]), it will not be possible to
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. In order for the terminal block to actually gain
ownership, the masks must be set up correctly (see above) and
no other device can currently have direction ownership. Once
the terminal block gains direction ownership, it will retain it
until shutdown, until the [Direction Mask] or [Logic Mask] bits
for the terminal block are cleared, or until this input function is
no longer configured
• Jog
Jog is essentially a non-latched “run/start” command. An open to closed
transition while drive is stopped causes drive to start (jog) in the current
direction. When the input opens while drive is running (jogging), the
drive will stop.
The drive will not jog while running or while the “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. The drive will not stop, but may change speed and/or
change direction.
The terminal block bit must be set in the [Jog Mask] and [Logic Mask]
parameters in order for the terminal block to cause the drive to jog using
this input function.
• Jog Forward, Jog Reverse
An open to closed transition on one input or both inputs while drive is
stopped will cause the drive to jog unless the “Stop - Clear Faults” input
function is configured and open. The table below describes the actions
taken by the drive in response to various states of these input functions.
Jog Forward Jog Reverse Action
Open
Open
Drive will stop if already jogging, but can be started by other
means. Terminal block relinquishes direction ownership.
Open
Closed
Drive jogs in reverse direction. Terminal block takes direction
ownership.
Closed
Open
Drive jogs in forward direction. Terminal block takes direction
ownership.
Closed
Closed
Drive continues to jog in current direction, but terminal block
maintains direction ownership.
If one of these input functions is configured and the other one isn’t, the
above description still applies, but the unconfigured input function
should be considered permanently open.
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. The drive will not stop, but may change speed and/or
change direction.
The terminal block bit must be set in the [Jog Mask], [Direction Mask],
and [Logic Mask] parameters in order for the terminal block to cause the
drive to jog using these input functions.
Important: Direction control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed to control
direction at a time. The terminal block must become
direction “owner” before it can be used to control direction.
If another device is currently the direction owner (as
indicated by [Direction Owner]), it will not be possible to
jog the drive or change direction by using the terminal
block digital inputs programmed for both Run and
Direction control (i.e. Run/Fwd).
If another device is not currently the direction owner (as indicated by
[Direction Owner]) and the terminal block bit is set in the [Direction
Mask] and [Logic Mask] parameters, the terminal block becomes
direction owner as soon as one (or both) of the “Jog Forward” or “Jog
Reverse” input functions is closed.
• Speed select 1, 2, and 3
One, two, or three digital input functions can be used to select the speed
reference used by the drive, and they are called the Speed Select input
functions. The current open/closed state of all Speed Select input
functions combine to select which source is the current speed reference.
There are 8 possible combinations of open/closed states for the three
input functions, and thus 8 possible parameters can be selected. The 8
parameters are: [Speed Ref A Sel], [Speed Ref B Sel], and [Preset Speed
2] through [Preset Speed 7].
If the Speed Select input functions select [Speed Ref A Sel] or [Speed
Ref B Sel], then the value of that parameter further selects a reference
source. There are a large number of possible selections, including all 7
presets.
If the input functions directly select one of the preset speed parameters,
then the parameter contains a frequency that is to be used as the
reference.
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). This means that only one
control device (terminal block, DPI device, HIM, etc.) at a
time is allowed to select the reference source. The terminal
block must become direction “owner” before it can be used
to control direction. If another device is currently the
reference owner (as indicated by [Reference Owner]), it will
not be possible to select the reference by using the terminal
block digital inputs, and the Speed Select Inputs will have
no effect on which reference the drive is currently using.
Because any combination of open/closed conditions (or unwired
condition) commands a reference source, terminal block seeks
ownership of reference selection as soon as any of these input functions
are configured, which may happen at power-up. In order for the terminal
block to actually gain ownership, the masks must be set up correctly (see
above) and no other device can currently have reference ownership.
Once the terminal block gains reference ownership, it will retain it until
shutdown, until the [Reference Mask] or [Logic Mask] bits for the
terminal block are cleared, or until none of the digital inputs are
configured as Speed Select input functions.
The Speed Select input function configuration process involves
assigning the functionality of the three possible Speed Select input
functions to physical digital inputs. The three Speed Select inputs
functions are called “Speed Select 1”, “Speed Select 2”, and “Speed
Select 3”, and they are assigned to physical inputs using the [Digital Inx
Sel] parameters.
The table below describes the various reference sources that can be
selected using all three of the Speed Select input functions.
Speed Select 3
Open
Open
Open
Open
Closed
Closed
Closed
Closed
Speed Select 2
Open
Open
Closed
Closed
Open
Open
Closed
Closed
Speed Select 1
Open
Closed
Open
Closed
Open
Closed
Open
Closed
Parameter that determines Reference
[Speed Ref A Sel]
[Speed Ref B Sel]
[Preset Speed 2]
[Preset Speed 3]
[Preset Speed 4]
[Preset Speed 5]
[Preset Speed 6]
[Preset Speed 7]
If any of the three Reference Select input functions are not configured,
then the software will still follow the table, but will treat the
unconfigured inputs as if they are permanently open.
As an example, the table below describes what reference selections can
be made if “Speed Select 1” is the only configured input function. This
2-60
Digital Inputs
configuration allows a single input to choose between [Speed Ref A Sel]
and [Speed Ref B Sel].
Speed Select 1
Open
Closed
Selected Parameter that determines Reference
[Speed Ref A Sel]
[Speed Ref B Sel]
As another example, describes what reference selections can be made if
the “Speed Select 3” and “Speed Select 2” input functions are
configured, but “Speed Select 1” is not.
Speed Select 3
Open
Open
Closed
Closed
Speed Select 2
Open
Closed
Open
Closed
Selected Parameter that determines reference
[Speed Ref A Sel]
[Preset Speed 2]
[Preset Speed 4]
[Preset Speed 6]
• Auto/Manual
The Auto/Manual facility is essentially a higher priority reference select.
It allows a single control device to assume exclusive control of reference
select, irrespective of the reference select digital inputs, reference select
DPI commands, the reference mask, and the reference owner.
If the “Auto/Manual” input function is closed, then the drive will use one
of the analog inputs (defined by [TB Man Ref Sel]) as the reference,
ignoring the normal reference selection mechanisms. This mode of
reference selection is called “Terminal Block Manual Reference
Selection Mode”.
If this input function is open, then the terminal block does not request
manual control of the reference. If no control device (including the
terminal block) is currently requesting manual control of the reference,
then the drive will use the normal reference selection mechanisms. This
is called “Automatic Reference Selection” mode.
The drive arbitrates among manual reference requests from different
control devices, including the terminal block.
• Accel 2 / Decel 2
The Acceleration/Deceleration Rate Control input functions (Acc/Dec
input functions for short) allow the rate of acceleration and deceleration
for the drive to be selected from the terminal block. The rates themselves
are contained in [Accel Time 1], [Decel Time 1], [Accel Time 2], and
[Decel Time 2]. The Acc/Dec input functions are used to determine
which of these acceleration and deceleration rates are in effect at a
particular time.
The terminal block bit must be set in the [Accel Mask] and [Logic Mask]
parameters in order for the acceleration rate selection to be controlled
from the terminal block. The terminal block bit must be set in the [Decel
Mask] and [Logic Mask] parameters in order for the deceleration rate
selection to be controlled from the terminal block.
There are two different schemes for using the Acc/Dec input functions.
Each one will be described in its own section.
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].
Important: Acc/Dec Control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed to select
the Acc/Dec rates. The terminal block must become Acc/
Dec “owner” before it can be used to control ramp rates. If
another device is currently the reference owner (as indicated
by [Reference Owner]), it will not be possible to select the
reference by using the terminal block digital inputs, and the
Speed Select Inputs will have no effect on which reference
the drive is currently using.
Because any combination of open / closed conditions (or unwired
condition) commands a reference source, the terminal block seeks accel
ownership as soon as the “Accel 2” input function is configured, which
may happen at power-up. In order for the terminal block to actually gain
ownership, the masks must be set up correctly (see above) and no other
device can currently have accel ownership. Once the terminal block
gains accel ownership, it will retain it until shutdown, until the [Accel
Mask] or [Logic Mask] bits for the terminal block are cleared, or until
“Accel 2” is unconfigured.
For the “Decel 2” input function, deceleration rate selection ownership is
handled in a similar fashion to acceleration rate selection ownership.
• Acc2 & Dec2
In the second scheme, the “1” rates are combined (Acc and Dec) and the
“2” rates are combined. A single input function is used to select between
[Accel Time 1]/[Decel Time 1] and [Accel Time 2]/[Decel Time 2]. This
input function is called “Acc 2 & Dec 2”.
If function is open, then drive will use [Accel Time 1] as the acceleration
rate and [Decel Time 1] as the deceleration rate. If function is closed,
then drive will use [Accel Time 2] as the acceleration rate and [Decel
Time 2] as the deceleration rate.
The same ownership rules as above apply.
• MOP Increment, MOP Decrement
These inputs are used to increment and decrement the Motor Operated
Potentiometer (MOP) value inside the drive. The MOP is a reference
setpoint (called the “MOP Value”) that can be incremented and
decremented by external devices. The MOP value will be retained
through a power cycle.
While the “MOP Increment” input is closed, MOP value will increase at
rate contained in [MOP Rate]. Units for rate are Hz per second.
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.
In order for the drive to use the MOP value as the current speed
reference, either [Speed Ref A Sel] or [Speed Ref B Sel] must be set to
“MOP.”
• Stop Mode B
This digital input function selects between two different drive stop
modes. See also Stop Modes on page 2-174.
If the input is open, then [Stop Mode A] selects which stop mode to use.
If the input is closed, then [Stop Mode B] selects which stop mode to
use. If this input function is not configured, then [Stop Mode A] always
selects which stop mode to use.
• Bus Regulation Mode B
This digital input function selects how the drive will regulate excess
voltage on the DC bus. See also Bus Regulation.
If the input is open, then [Bus Reg Mode A] selects which bus regulation
mode to use. If the input is closed, then [Bus Reg Mode B] selects which
bus regulation mode to use. If this input function is not configured, then
[Bus Reg Mode A] always selects which bus regulation mode to use.
• PI Enable
If this input function is closed, the operation of the Process PI loop will
be enabled.
If this input function is open, the operation of the Process PI loop will be
disabled. See Process PI Loop on page 2-121.
• PI Hold
If this input function is closed, the integrator for the Process PI loop will
be held at the current value, which is to say that it will not increase.
If this input function is open, the integrator for the Process PI loop will
be allowed to increase. See Process PI Loop on page 2-121.
• PI Reset
If this input function is closed, the integrator for the Process PI loop will
be reset to 0.
If this input function is open, the integrator for the Process PI loop will
integrate normally. See Process PI Loop on page 2-121.
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” (F2) fault code.
If the “Aux Fault” input function is assigned to a physical digital input,
that input will be active regardless of any drive control masks. Also, the
input will be active even if a device other than the terminal block gains
complete local control of drive logic. See Local Control.
If this input function is not configured, then the fault will not occur.
• Local Control
The “Local Control” input function allows exclusive control of all drive
logic functions from the terminal block. If this input function is closed,
the terminal block has exclusive control (disabling all the DPI devices)
of drive logic, including start, reference selection, acceleration rate
selection, etc. The exception is the stop condition, which can always be
asserted from any connected control device.
The drive must be stopped in order for the terminal block to gain
complete local control.
Important: Local Control is an “Exclusive Ownership” function (see
Owners). This means that only one control device (terminal
block, DPI device, HIM, etc.) at a time is allowed take local
control. If another device is not currently the local owner (as
indicated by [Local Owner]) and the terminal block bit is set
in the [Local Mask] and [Logic Mask] parameters, the
terminal block becomes local owner as soon as the “Local
Control” input function is closed.
• Clear Faults
The “Clear Faults” digital input function allows an external device to
reset drive faults through the terminal block. An open to closed transition
on this input will cause the current fault (if any) to be reset.
If this input is configured at the same time as “Stop - Clear Faults”, then
only the “Clear Faults” input can actually cause faults to be reset.
The terminal block bit must be set in the [Fault Mask] and [Logic Mask]
parameters in order for faults to be reset from the terminal block.
• Enable
If this input is closed, then the drive can run (start permissive). If open,
the drive will not start.
If the drive is already running when this input is opened, the drive will
coast and indicate “not enabled” on the HIM (if present). This is not
considered a fault condition, and no fault will be generated.
2-64
Digital Inputs
This input is not used for a fast output power removal. The drive will not
stop running until the software detects the open state of this input
function.
If multiple “Enable” inputs are configured, then the drive will not run if
any of the inputs are open.
• Exclusive Link
This input function is used to activate the state of the input to control one
of the drive’s digital outputs. See Digital Outputs.
If an Input is so configured, no function exists for the input until
complementary Digital Output programming is done. If no outputs are
programmed (linked), the input has no function.
This choice is made when the user wishes to link the input to the output,
but desires that no other functionality be assigned to the input.
The state of any digital input can be “passed through” to a digital output
by setting the value of a digital output configuration parameter ([Digital
Outx Sel]) to “Input n Link”. The output will then be controlled by the
state of the input, even if the input is being used for a second function. If
the input is configured as “Not used” input function, the link to the input
is considered non-functional.
• Power Loss Level (PowerFlex 700 only)
When the DC bus level in the drive falls below a certain level, a “power
loss” condition is created in the drive logic. This input allows the user to
select between two different “power loss” detection levels dynamically.
If the physical input is closed, then the drive will take its power loss level
from [Power Loss Level]. If the physical input is open (de-energized),
then the drive will use a power loss level designated by internal drive
memory, typically 82% of nominal.
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.
• Precharge Enable (PowerFlex 700 only)
This input function is used to manage disconnection from a common DC
bus.
If the physical input is closed, this indicates that the drive is connected to
common DC bus and normal precharge handling can occur, and that the
drive can run (start permissive). If the physical input is open, this
indicates that the drive is disconnected from the common DC bus, and
thus the drive should enter the precharge state (precharge relay open) and
initiate a coast stop immediately in order to prepare for reconnection to
the bus.
If this input function is not configured, then the drive assumes that it is
always connected to the DC bus, and no special precharge handling will
be done. This input function is used in PowerFlex 700 drive only. In
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. As long as the Digital Input Conflict exists, the drive will not
start. These alarms will be automatically cleared by the drive as soon as the
user changes the parameters so that there is an internally consistent digital
input configuration.
Examples of configurations that cause an alarm are:
• User tries to configure both the “Start” input function and the “Run
Forward” input function at the same time. “Start” is only used in
“3-wire” start mode, and “Run Forward” is only used in “2-wire” run
mode, so they should never be configured at the same time
• User tries to assign a toggle input function (for instance “Forward/
Reverse”) to more than one physical digital input simultaneously.
• These alarms, called Type 2 Alarms, are different from other alarms in
that it will not be possible to start the drive while the alarm is active. It
should not be possible for any of these alarms to occur while drive is
running, because all configuration parameters are only changeable while
drive is stopped. Whenever one or more of these alarms is asserted, the
drive ready status will become “not ready” and the HIM will reflect a
message signaling the conflict. In addition, the drive status light will be
flashing yellow.
There are three different digital input configuration alarms. They appear to
the user (in [Drive Alarm 2]) as “DigIn CflctA”, “DigIn CflctB”, and “DigIn
CflctC”.
“DigIn CflctA” indicates a conflict between different input functions that
are not specifically associated with particular start modes.
The table below defines which pairs of input functions are in conflict.
Combinations marked with a “ ” will cause an alarm.
Important: There are combinations of input functions in Table 2.K that
will produce other digital input configuration alarms. “DigIn
CflctA” alarm will also be produced if “Start” is configured and
“Stop – Clear Faults” is not.
Table 2.K Input function combinations that produce “DigIn CflctA” alarm
Acc2/Dec2
Acc2 / Dec2
Accel 2
Decel 2
Jog
Jog Fwd
Jog Rev
Fwd / Rev
Accel 2
Decel 2
Jog
Jog Fwd
Jog Rev
Fwd/Rev
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
Start Stop–CF
Run Run Fwd
Run Rev Jog
Fwd/
Jog Fwd Jog Rev Rev
Start
Stop–CF
Run
Run Fwd
Run Rev
Jog
Jog Fwd
Jog Rev
Fwd / Rev
“Digin CflctC” indicates that more than one physical input has been
configured to the same input function, and this kind of multiple
configuration isn’t allowed for that function. Multiple configuration is
allowed for some input functions and not allowed for others.
The input functions for which multiple configuration is not allowed are:
Forward/Reverse
Speed Select 1
Speed Select 2
Speed Select 3
Run Forward
Run Reverse
Jog Forward
Jog Reverse
Run
Stop Mode B
Bus Regulation Mode B
Accel2 & Decel2
Accel 2
Decel 2
There is one additional alarm that is related to digital inputs: the “Bipolar
Cflct” alarm occurs when there is a conflict between determining motor
direction using digital inputs on the terminal block and determining it by the
polarity of an analog speed reference signal.
Note that the drive will assert an alarm when the user sets up a illegal
configuration rather than refusing the first parameter value that results in
such a configuration. This is necessary because the user may have to change
several parameters one at a time in order to get to a new desired
configuration, and some of the intermediate configurations may actually be
illegal. Using this scheme, the user or a network device can send parameter
updates in any order when setting up the digital input configuration.
The “Bipolar Cflct” alarm occurs when there is a conflict between
determining motor direction using digital inputs on the terminal block and
determining it by some other means.
When [Direction Mode] is “Bipolar”, the drive uses the sign of the
reference to determine drive direction; when [Direction Mode] is “Reverse
Dis”, then the drive never permits the motor to run in the reverse direction.
In both of these cases, the terminal block inputs cannot be used to set
Digital Inputs
2-67
direction, so this alarm is asserted if any digital input function that can set
motor direction is configured.
The “Bipolar Cflct” alarm will be asserted if both of the following are true:
• One or more of the following digital input functions are configured:
“Forward/Reverse”, “Run Forward”, “Run Reverse”, “Jog Forward”,
“Jog Reverse”.
• [Direction Mode] is set to “Bipolar” or “Reverse Dis”.
Digital In Status
This parameter represents the current state of the digital inputs. It contains
one bit for each input. 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.
Figure 2.8 Typical digital input configuration with “3-wire” start
Internal Power Source
Digital In1 = Stop
Digital In2 = Start
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Speed Select 1
Digital In6 = Enable
24V Common
Digital In Common
24V
External Power Source
+24V Common
Digital In1 = Stop
Digital In2 = Start
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Speed Select 1
Digital In6 = Enable
24V Common
Digital In Common
24V
Figure 2.9 represents a typical digital input configuration that includes
“2-wire” start. The digital input configuration parameters should be set up
as shown
Figure 2.9 Typical digital input configuration with “Run Fwd/Rev” start
Internal Power Source
Digital In1 = Run
Digital In2 = Clear Faults
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Auxiliary Fault
Digital In6 = Enable
24V Common
Digital In Common
24V
External Power Source
+24V Common
Digital In1 = Run
Digital In2 = Clear Faults
Digital In3 = Forward/Reverse
Digital In4 = Jog
Digital In5 = Auxiliary Fault
Digital In6 = Enable
24V Common
Digital In Common
24V
Digital Outputs
Each drive provides digital (relay) outputs for external annunciation of a
variety of drive conditions. 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.
Rated Voltage
Maximum Current
Maximum Power
Minimum DC Current
Switching Time
Initial State
Number of relays
(Standard I/O)
PowerFlex 70
Resistive Load
250V AC
220V DC
3A
AC - 50 VA
DC - 60 W
10 µA
8 ms
De-energized
2
PowerFlex 700
Resistive Load Inductive Load
240V AC
240V AC
30V DC
30V DC
5A
3.5 A
1200 VA
840 VA
150W
105W
10 mA
10 ms
De-energized
2 - Standard Control
3 - Vector Control
Inductive Load
250V AC
220V DC
1.5 A
AC - 25 VA
DC - 30 W
Configuration
The outputs may be independently configured via the following parameters
to switch for various states of the drive.
PowerFlex 700 Digital Output Selection
380 [Digital Out1 Sel]
384 [Digital Out2 Sel]
388
[Digital Out3 Sel]
Vector
Default:
Selects the drive status that will energize Options:
a (CRx) output relay.
(1)Contacts shown in User Manual are in
drive powered state with condition
present. Refer to “Fault” and “Alarm”
information.
Digital Outputs
Digital Outputs
INPUTS & OUTPUTS
2-68
(2)Vector Control Option Only.
1
4
4
“Fault”
“Run”
“Run”
381
385
389
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2126
27
28
29
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed”
“At Freq”
“At Current”
“At Torque”
“At Temp”
“At Bus Volts”
“At PI Error”
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1-6 Link”
382
386
390
383
“PI Enable”(2)
“PI Hold”(2)
“PI Reset”(2)
002
001
003
004
218
012
137
157
147
053
048
184
Digital Outputs
2-69
PowerFlex 70 Digital Output Selection
380 [Digital Out1 Sel]
384 [Digital Out2 Sel]
Default:
Selects the drive status that will energize Options:
a (CRx) output relay.
Digital Outputs
INPUTS & OUTPUTS (File J)
(1) Contacts shown on page 1-14 of the
User Manual are in drive powered
state with condition not present. For
functions such as “Fault” and “Alarm”
the normal relay state is energized and
N.O. / N.C. contact wiring may have to
be reversed.
1
4
“Fault”
“Run”
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
“Fault”(1)
“Alarm”(1)
“Ready”
“Run”
“Forward Run”
“Reverse Run”
“Auto Restart”
“Powerup Run”
“At Speed”
“At Freq”
“At Current”
“At Torque”
“At Temp”
“At Bus Volts”
“At PI Error”
“DC Braking”
“Curr Limit”
“Economize”
“Motor Overld”
“Power Loss”
“Input 1 Link”
“Input 2 Link”
“Input 3 Link”
“Input 4 Link”
“Input 5 Link”
“Input 6 Link”
381
385
389
382
386
390
383
002
001
003
004
218
012
137
157
147
053
048
184
The selections can be divided into three types of annunciation.
1. The relay changes state due to a particular status condition in the drive.
The following drive conditions or status can be selected to cause the
relay activation:
Condition
Fault
Alarm
Ready
Run
Description
A drive Fault has occurred and stopped the drive
A Drive Type 1 or Type 2 Alarm condition exists
The drive is powered, Enabled and no Start Inhibits exist. It is “ready” to run
The drive is outputting Voltage and frequency to the motor (indicates 3–wire
control, either direction)
Forward Run The drive is outputting Voltage and frequency to the motor (indicates 2–wire
control in Forward)
Reverse Run The drive is outputting Voltage and frequency to the motor (indicates 2–wire
control in Reverse)
Reset/Run
The drive is currently attempting the routine to clear a fault and restart the drive
Powerup Run The drive is currently executing the Auto Restart or “Run at Power Up” function
DC Braking
The drive is currently executing either a “DC Brake” or a “Ramp to Hold” Stop
command and the DC braking voltage is still being applied to the motor.
Current Limit The drive is currently limiting output current
Economize
The drive is currently reducing the output voltage to the motor to attempt to
reduce energy costs during a lightly loaded situation.
Mtr Overload The drive output current has exceeded the programmed [Motor NP FLA] and the
electronic motor overload function is accumulating towards an eventual trip.
Power Loss
The drive has monitored DC bus voltage and sensed a loss of input AC power
that caused the DC bus voltage to fall below the fixed monitoring value (82% of
[DC bus Memory]
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
At Speed
Description
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. The limit is set into one of two parameters: [Dig Out1
Level] and [Dig Out2 Level] depending on the output being used. If the
value for the specified function (frequency, current, etc.) exceeds the user
programmed limit, the relay will activate. If the value falls back below
the limit, the relay will deactivate.
381 [Dig Out1 Level]
385 [Dig Out2 Level]
389
[Dig Out3 Level]
Vector
Default:
0.0
0.0
Min/Max: 0.0/819.2
Sets the relay activation level for options Units:
0.1
10 – 15 in [Digital Outx Sel]. Units are
assumed to match the above selection
(i.e. “At Freq” = Hz, “At Torque” = Amps).
380
384
388
Notice that the [Dig Outx Level] parameters do not have units. The drive
assumes the units from the selection for the annunciated value. For
example, if the chosen “driver” is current, the drive assumes that the
entered value for the limit [Dig Outx Level] is% rated Amps. If the
chosen “driver” is Temperature, the drive assumes that the entered value
for the limit [Dig Outx Level] is degrees C. No units will be reported to
LCD HIM users, offline tools, devices communicating over a network,
PLC’s, etc.
The online and offline limits for the digital output threshold parameters
will be the minimum and maximum threshold value required for any
output condition.
If the user changes the currently selected output condition for a digital
output, then the implied units of the corresponding threshold parameter
will change with it, although the value of the parameter itself will not.
For example, if the output is set for “At Current” and the threshold for
100, drive current over 100% will activate the relay. If the user changes
the output to “At Temp”, the relay will deactivate (even if current >
100%) because the drive is cooler than 100 degrees C.
The following values can be annunciated
Value
At Freq
At Current
At Torque
At Temp
At Bus Volts
At PI Error
Description
The drive output frequency equals or exceeds the programmed Limit
The drive total output current exceeds the programmed Limit
The drive output torque current component exceeds the programmed Limit
The drive operating temperature exceeds the programmed Limit
The drive bus voltage exceeds the programmed Limit
The drive Process PI Loop error exceeds the programmed Limit
3. The relay changes state because a Digital Input link has been established
and the Input is closed.
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:
– The Input is configured for any choice other than “Unused”
– The Output is configured for the appropriate “Input x Link”
Note that the output will continue to track or be controlled by the state of
the input, even if the input has been assigned a function (i.e. Start, Jog)
Output Time Delay
Each digital output has two user-controlled timers associated with it.
One timer (the ON timer) defines the delay time between a FALSE to TRUE
transition (condition appears) on the output condition and the corresponding
change in state of the digital output.
The second timer (the OFF timer) defines the delay time between a TRUE
to FALSE transition (condition disappears) on the output condition and the
corresponding change in the state of the digital output.
382 [Dig Out1 OnTime]
386 [Dig Out2 OnTime]
390
[Dig Out3 OnTime]
Vector
Sets the “ON Delay” time for the digital
outputs. This is the time between the
occurrence of a condition and activation
of the relay.
383 [Dig Out1 OffTime]
387 [Dig Out2 OffTime]
391
[Dig Out3 OffTime]
Vector
Sets the “OFF Delay” time for the digital
outputs. This is the time between the
disappearance of a condition and
de-activation of the relay.
Default:
0.00 Secs
0.00 Secs
Min/Max: 0.00/600.00 Secs
Units:
0.01 Secs
Default:
0.00 Secs
0.00 Secs
Min/Max: 0.00/600.00 Secs
Units:
0.01 Secs
380
384
388
380
384
388
Either timer can be disabled by setting the corresponding delay time to “0.”
Important: Whether a particular type of transition (False-True or
True-False) on an output condition results in an energized or
de-energized output depends on the output condition.
If a transition on an output condition occurs and starts a timer, and the
output condition goes back to its original state before the timer runs out,
then the timer will be aborted and the corresponding digital output will not
change state.
Relay Activates
CR1 On Delay = 2 Seconds
Current Limit Occurs
0
5
10
Relay Does Not Activate
CR1 On Delay = 2 Seconds
Cyclic Current Limit
(every other second)
0
5
10
2-72
Direction Control
Direction Control
Direction control of the drive is an exclusive ownership function. This
means that only one device can be commanding/controlling direction at a
time and that device can only command one direction or the other, not both.
Direction is defined as the forward (+) or reverse (–) control of the drive
output frequency, not motor rotation. Motor wiring and phasing determines
its CW or CCW rotation. The direction of the drive is controlled in one of
four ways:
1. 2-Wire digital input selection such as Run Forward or Run Reverse
(Figure 2.9 on page 2-67).
2. 3-Wire digital input selection such as Forward/Reverse, Forward or
Reverse (Figure 2.8 on page 2-67).
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.
Direction commands by various devices can be controlled using the
[Direction Mask]. See page 2-97 for details on masks.
Refer to Digital Inputs on page 2-51 and Analog Inputs on page 2-6 for
more detail on the configuration and operating rules for direction control.
DPI
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. SCANport and DPI both provide two basic message types
called Client/Server (C/S) and Producer/Consumer (P/C). Client/Server
messages are used to transfer parameter and configuration information in
the background (relative to other message types). Producer/Consumer
messages are used for control and status information. DPI adds a higher
baud rate, brand specific enabling, Peer-to-Peer (P/P) communication, and
Flash Memory programming support. PowerFlex drives support the existing
SCANport and Drive Peripheral Interface (DPI) communication protocols.
Multiple devices of each type (SCANport or DPI) can be attached to and
communicate with the drive at the same time. This communication interface
is the primary way to interact with, and control the drive.
Client/Server
Client/Server messages operate in the background (relative to other
message types) and are used for non-control purposes. The Client/Server
messages are based on a 10ms “ping” event that allows peripherals to
perform a single transaction (i.e. one C/S transaction per peripheral per time
period). Message fragmentation (because the message transaction is larger
than the standard CAN message of eight data bytes) is automatically
handled by Client/Server operation. The following types of messaging are
covered:
•
•
•
•
•
•
•
Logging in peripheral devices
Read/Write of parameter values
Access to all parameter information (limits, scaling, default, etc.)
User set access
Fault/Alarm queue access
Event notification (fault, alarm, etc.)
Access to all drive classes/objects (e.g. Device, Peripheral, Parameter,
etc.)
Producer/Consumer operation overview
Producer/Consumer messages operate at a higher priority than Client/
Server messages and are used to control/report the operation of the drive
(e.g. start, stop, etc.). A P/C status message is transmitted every 5ms (by the
drive) and a command message is received from every change of state in
any attached DPI peripheral. Change of state is a button being pressed or
error detected by a DPI peripheral. SCANport devices are slightly different
in that those peripherals transmit command messages upon reception of a
drive status message rather than on detection of a change of state. Producer/
2-74
DPI
Consumer messages are of fixed size, so support of message fragmentation
is not required. The following types of messaging are covered:
•
•
•
•
•
Drive status (running, faulted, etc.)
Drive commands (start, stop, etc.)
Control logic parsing operations (e.g., mask and owner parameters)
Entering Flash programming mode
“Soft” login and logout of peripheral devices (enabling/disabling of
peripheral control)
Peer-to-Peer operation
Peer-to-Peer messaging allows two devices to communicate directly rather
than through the master or host (i.e. drive). They are the same priority as C/
S messages and will occur in the background. In the PowerFlex 70 drive,
the only Peer-to-Peer functionality supports proxy operations for the LED
HIM. Since the PowerFlex 700 drive does not support an LED HIM, it will
not support Peer-to-Peer proxy operations. The Peer-to-Peer proxy
operation is only used so that the LED HIM can access parameters that are
not directly part of the regulator board (e.g. DeviceNet baud rate, etc.). The
LED HIM is not attached to a drive through a CAN connection (as normal
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). Because the PowerFlex 70 supports the LED
HIM, only 4 communication ports can be used. PowerFlex 700 drives can
use all 6 communication ports because Peer-to-Peer proxy operations are
not needed. All Peer-to-Peer operations occur without any intervention
from the user (regardless whether proxy or normal P/P operation), no setup
is required. No Peer-to-Peer proxy operations are required while the drive is
in Flash mode.
All the timing requirements specified in the DPI and SCANport System,
Control, and Messaging specifications are supported. Peripheral devices
will be scanned (“pinged”) at a 10ms rate. Drive status messages will be
produced at a 5ms rate, while peripheral command messages will be
accepted (by the drive) as they occur (i.e. change of state). Based on these
timings, the following worst case conditions can occur (independent of the
baud rate and protocol):
• Change of peripheral state (e.g. Start, Stop, etc.) to change in the drive –
10ms
• Change in reference value to change in drive operation – 10ms
• Change in Datalink data value to change in the drive – 10ms
• Change of parameter value into drive – 20ms times the number of
attached peripherals
The maximum time to detect the loss of communication from a peripheral
device is 500ms.
DPI
2-75
Table 2.M Timing specifications contained in DPI and SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
SCANport
DPI
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). DPI allows minimum 5ms status at 125k and
1ms status at 500k.
Host status messages only go out to peripherals once they log in. Peripherals time out
if >500ms. If Peripheral receives incorrect status message type, Peripheral generates
an error. Actual time dependent on number of peripherals attached. SCANport allows
minimum rate of 5ms.
Host determines MUT based on number of attached peripherals. Range of values
from 2 to 125ms. Minimum goal time of 5ms. DPI allows 2ms min at 500k and 5ms min
at 125k.
No MUT.
Peripheral command messages (including Datalinks) generated on change-of-state,
but not faster than Host MUT and at least every 250ms. Host will time out if >500ms.
Command messages produced as a result of Host status message. If no command
response to Host status within 3 status scan times, Host will time out on that
peripheral.
Peer messages requests cannot be sent any faster than 2x of MUT.
No Peer message support
Host must ping every port at least every 2 sec. Peripherals time out if >3 sec. Host will
wait maximum of 10ms (125k) or 5ms (500k) for peripheral response to ping.
Peripherals typical response time is 1ms. Peripherals only allow one pending explicit
message (i.e. ping response or peer request) at a time.
Host waits at least 10ms for response to ping. Host cannot send more than 2 event
messages (including ping) to a peripheral within 5ms. Peripherals typical response
time is 1ms.
Response to an explicit request or fragment must occur within 1 sec or device will time
out (applies to Host or Peripheral). Time-out implies retry from beginning. Maximum
number of fragments per transaction is 16. Flash memory is exception with 22
fragments allowed.
Assume same 1 sec time-out. Maximum number of fragments is 16
During Flash mode, host stops ping, but still supports status/command messages at a
1 – 5 sec rate. Drive will use 1 sec rate. Data transfer occurs via explicit message as
fast as possible (i.e. peripheral request, host response, peripheral request, etc.) but
only between two devices.
No Flash mode support
The Minimum Update Time (MUT), is based on the message type only. A
standard command and Datalink command could be transmitted from the
same peripheral faster than the MUT and still be O.K. Two successive
Datalink commands or standard commands will still have to be separated by
the MUT, however.
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.
The purpose of is to protect the power structure from abuse. Any protection
for the motor and associated wiring is provided by a Motor Thermal
Overload feature.
The drive will monitor the temperature of the power module based on a
measured temperature and a thermal model of the IGBT. As the temperature
rises the drive may lower the PWM frequency to decrease the switching
losses in the IGBT. If the temperature continues to rise, the drive may
reduce current limit to try to decrease the load on the drive. If the drive
temperature becomes critical the drive will generate a fault.
If the drive is operated in a low ambient condition the drive may exceed
rated levels of current before the monitored temperature becomes critical.
To guard against this situation the drive thermal overload also includes an
inverse time algorithm. When this scheme detects operation beyond rated
levels, current limit may be reduced or a fault may be generated.
Operation
The drive thermal overload has two separate protection schemes, an overall
RMS protection based on current over time, and an IGBT junction thermal
manager based on measured power module temperature and operating
conditions. The drive may fold back current limit when either of these
methods detects a problem.
Overall RMS Protection
The overall RMS protection makes sure the current ratings of the drive are
not exceeded. The lower curve in Figure 2.10 shows the boundary of
normal-duty operation. In normal duty, the drive is rated to produce 110%
of rated current for 60 seconds, 150% of rated current for three seconds, and
165% of rated current for 100 milliseconds. The maximum value for current
limit is 150% so the limit of 165% for 100 milliseconds should never be
crossed. If the load on the drive exceeds the level of current as shown on the
upper curve, current limit may fold back to 100% of the drive rating until
the 10/90 or 5/95 duty cycle has been achieved. For example, 60 seconds at
110% will be followed by 9 minutes at 100%, and 3 seconds at 150% will
be followed by 57 seconds at 100%. With the threshold for where to take
action slightly above the rated level the drive will only fold back when drive
ratings are exceeded.
If fold back of current limit is not enabled in [Drive OL Mode], the drive
will generate a fault when operation exceeds the rated levels. This fault can
not be disabled. If current limit fold back is enabled then a fault is generated
when current limit is reduced.
Drive Overload
2-77
Current Level (Per Normal)
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. In heavy duty, the drive is rated to produce 150% of rated current
for 60 seconds, 200% for three seconds, and 220% for 100 milliseconds.
The maximum value for current limit is 200% so the limit of 220% for 100
milliseconds should never be crossed. If the load on the drive exceeds the
level of current as shown on the upper curve, current limit may fold back to
100% of the drive rating until the 10/90 or 5/95 duty cycle has been
achieved. For example, 60 seconds at 150% will be followed by 9 minutes
at 100%, and 3 seconds at 200% will be followed by 57 seconds at 100%.
With the threshold for where to take action slightly above the rated level the
drive will only fold back when drive ratings are exceeded.
Again, if fold back of current limit is not enabled in the [Drive OL Mode],
the drive will generate a fault when operation exceeds the rated levels. This
fault can not be disabled. If current limit fold back is enabled then a fault is
generated when current limit is reduced.
Figure 2.11 Heavy Duty Boundary of Operation
2.50
2.25
Current Level (Per Normal)
2.00
1.75
1.50
1.25
1.00
0.75
0.50
0.25
0.00
1.00
10.00
100.00
Time (Seconds)
1000.00
10000.00
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.
Figure 2.12 Thermal Manager Inputs/Outputs
DTO Select
(Off,PWM,ILmt,Both)
DTO Fault
(On,Off)
PWM Frequency
(2 - 12 kHz)
Active PWM Frequency
(2 - 12 kHz)
Current Limit
(0 - 200%)
Active Current Limit
(0 - 200%)
Temperature Analog Input
(Volts)
I_total
(Amps)
V_dc
(Volts)
Output Frequency
(0-400 Hz)
Drive
Thermal
Overload
Drive Temperature
(x deg C)
IGBT Temperature
(x deg C)
KHz Alarm
(On, Off)
ILmt Alarm
(On, Off)
EE Power Board Data
The following is a generalization of the calculations done by the thermal
manager. The IGBT junction temperature TJ is calculated based on the
measured drive temperature TDrive, and a temperature rise that is a function
of operating conditions. When the calculated junction temperature reaches a
maximum limit the drive will generate a fault. This fault can not be
disabled. This maximum junction temperature is stored in EE on the power
board along with other information to define the operation of the drive
thermal overload function. These values are not user adjustable. In addition
to the maximum junction temperature there are thresholds that select the
point at which the PWM frequency begins to fold back, and the point at
which current limit begins to fold back. As TJ increases the thermal
manager may reduce the PWM frequency. If TJ continues to rise current
limit may be reduced, and if TJ continues to rise the drive generates a fault.
The calculation of the reduced PWM frequency and current limit is
implemented with an integral control.
PWM Frequency
PWM Frequency as selected by the user can be reduced by the thermal
manager. The resulting Active PWM Frequency may be displayed in a test
point parameter.
The active PWM frequency will change in steps of 2 kHz. It will always be
less than or equal to the value selected by the user, and will not be less than
the drives minimum PWM frequency. When drive temperature reaches the
level where PWM frequency would be limited, the Drv OL Lvl 1 Alarm is
turned on. This alarm will be annunciated even if the reduced PWM
frequency is not enabled.
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. When drive
temperature reaches the level where current limit would be clamped, the
Drv OL Lvl 2 Alarm is turned on. This alarm will be annunciated even if
reduced current limit is not enabled.
The active current limit is used during normal operation and during DC
injection braking. Any level of current requested for DC injection braking is
limited by the Active Current Limit.
Configuration
The [Drive OL Mode] allows the user to select the action(s) to perform with
increased current or drive temperature. When this parameter is “Disabled,”
the drive will not modify the PWM frequency or current limit. When set to
“Reduce PWM” the drive will only modify the PWM frequency. “Reduce
CLim” will only modify the current limit. Setting this parameter to
“Both-PWM 1st” the drive will modify the PWM frequency and the current
limit.
DTO Fault
For all possible settings of [Drive OL Mode], the drive will always monitor
the Tj and TDrive and generate a fault when either temperature becomes
critical. If TDrive is less than –20° C, a fault is generated. With these
provisions, a DTO fault is generated if the NTC ever malfunctions.
Temperature Display
The Drive’s temperature is measured (NTC in the IGBT module) and
displayed as a percentage of drive thermal capacity in [Drive Temp]. This
parameter is normalized to the thermal capacity of the drive (frame
dependent) and displays thermal usage in % of maximum (100% = drive
Trip). A test point, “Heatsink temperature” is available to read temperature
directly in degrees C, but cannot be related to the trip point since
“maximums” are only given in %. The IGBT temperature shown in Figure
2.12 is used only for internal development and is not provided to the user.
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.
When the drive is in current limit the output frequency is reduced to try to
reduce the load. This works fine for a variable torque load, but for a constant
torque load reducing the output frequency does not lower the current (load).
Lowering current limit on a CT load will push the drive down to a region
where the thermal issue becomes worse. In this situation the thermal
manager will increase the calculated losses in the power module to track the
worst case IGBT. For example, if the thermal manager normally provides
150% for 3 seconds at high speeds, it may only provide 150% for one
second before generating a fault at low speeds.
If operating at 60Hz 120%, lowering the current limit may cause a fault
sooner than allowing the drive to continue to operate. In this case the user
may want to disable current limit fold back.
Drive Ratings (kW,
Amps, Volts)
Refer to Fuses and Circuit Breakers on page 2-87.
Economizer
(Auto-Economizer)
Refer to Torque Performance Modes on page 2-178.
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.
Reduced load commands a reduction in motor flux current. The flux current
is reduced as long as the total drive output current does not exceed 75% of
motor rated current as programmed in [Motor NP FLA], parameter 42. The
flux current is not allowed to be less than 50% of the motor flux current as
programmed in [Flux Current Ref], parameter 63. During acceleration and
deceleration, the economizer is inactive and sensorless vector motor control
performs normally.
Maximum Voltage
Motor Nameplate Voltage
Increasing
Load
Rated Flux Current
Vtotal
Reduced Flux Current,
minimum of 50% of Rated Flux Current
Ir Voltage
0
0
Frequency
Motor Nameplate
Frequency
Maximum
Frequency
Efficiency
Efficiency
2-81
The following chart shows typical efficiency for PWM variable frequency
drives, regardless of size. Drives are most efficient at full load and full
speed.
100
vs. Speed
% Efficiency
95
vs. Load
90
85
80
75
10
Fan Curve
20
30
40 50 60 70
% Speed/% Load
80
90
100
When torque performance (see page 2-178) 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. At low speed the fan
curve can be offset by the run boost parameter to provide extra starting
torque if needed. No extra parameters are needed for fan/pump curve.
The pattern matches the speed vs. load characteristics of a centrifugal fan or
pump and optimizes the drive output to those characteristics.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
Base Frequency
(Nameplate)
Fan
See Fan Curve above.
Maximum
Frequency
2-82
Faults
Faults
Faults are events or conditions occurring within and/or outside of the drive.
Theses events or conditions are (by default) considered to be of such
significant magnitude that drive operation should or must be discontinued.
Faults are annunciated to the user via the HIM, communications and/or
contact outputs. The condition that caused the fault determines the user
response.
Once a fault occurs, the fault condition is latched, requiring the user or
application to perform a fault reset action to clear the latched condition. If
the condition that caused fault still exists when the fault is reset, the drive
will fault again and the fault will be latched again.
When a Fault Occurs
1. The drive is set as faulted, causing the drive output to be immediately
disabled and a “coast to stop” sequence to occur
2. The fault code is entered into the first buffer of the fault queue (see
“Fault Queue” below for rules).
3. Additional data on the status of the drive at the time that the fault
occurred is recorded. Note that there is only a single copy of this
information which is always related to the most recent fault queue entry
[Fault 1 Code], parameter 243. When another fault occurs, this data is
overwritten with the new fault data. The following data/conditions are
captured and latched into non-volatile drive memory:
– [Status 1 @ Fault], parameter 227 (drive condition at the time of the
fault).
– [Status 2 @ Fault], parameter 228 (drive condition at the time of the
fault).
– Alarm 1 @ Fault], parameter 229 (alarm condition at the time of the
fault).
– Alarm 2 @ Fault], parameter 230 (alarm conditions at the time of the
fault).
– Fault Frequency (drive output frequency at time of fault).
– Fault Motor Amps: (motor amps at time of fault).
– Fault Bus Volts: (unfiltered DC Bus volts at time of fault.)
Fault Queue
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
queue.
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. Only faults that actually trip the drive will be logged. No fault that
occurs while the drive is already faulted will be logged.
The fault queue will be a first-in, first-out (FIFO) queue. Fault queue entry
#1 will always be the most-recent entry (newest). Entry 4 (8) will always be
the oldest. As a new fault is logged, each existing entry will be shifted up by
one (i.e. previous entry #1 will move to entry #2, previous entry #2 will
move to entry #3, etc.). If the queue is full when a fault occurs, the oldest
entry will be discarded.
The fault queue will be saved in nonvolatile storage at power loss, thus
retaining its contents through a power off - on cycle.
Fault Code/Text [Fault Code 1-x]
The fault code for each entry can be read in its respective read-only
parameter. When viewed with a HIM, only the fault code is displayed. If
viewed via a DPI peripheral (communications network), the queue is not
accessed through parameters, and a text string of up to 16 characters is also
available.
Fault Time [Fault 1-8 Time]
PowerFlex drives have an internal drive-under-power-timer. The user has no
control over the value of this timer, which will increment in value over the
life of the drive and saved in nonvolatile storage. Each time the drive is
powered down and then repowered, the value of this timer is written to
[Power Up Marker], parameter 242.
The time is presented in xxx.yyyy hours (4 decimal places). Each increment
of 1 represents approximately 0.36 seconds. Internally it will be
accumulated in a 32-bit unsigned integer with a resolution of 0.35 seconds,
resulting in a rollover to zero every 47.66 years.
The time stamp value recorded in the fault queue at the time of a fault is the
value of internal drive under power timer. By comparing this value to the
[PowerUp Marker], it is possible to determine when the fault occurred
relative to the last drive power-up.
The time stamp for each fault queue entry can be read via the corresponding
parameter. Time comparisons of one fault to the next and/or with [PowerUp
Marker] are only meaningful if they occur less than or equal to the rollover
range.
Resetting or Clearing a Fault
A latched fault condition can be cleared by the following:
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. Cycling power to the drive such that the control board goes through a
power-up sequence.
Resetting faults will clear the faulted status indication. If any fault condition
still exists, the fault will relatch and another entry made in the fault queue.
Clearing the Fault Queue
Performing a fault reset does not clear the fault queue. Clearing the fault
queue is a separate action.
Fault Configuration
The drive can be configured such that some fault conditions do not trip the
drive. Configurable faults include those that are user inputs.
[Fault Config 1] is a bit-mapped 16 bit word enabling or disabling certain
fault conditions (see below). Disabling a fault removes the effect of the fault
condition and makes the event unknown to the user. If the bit is on, the fault
is enabled. If the bit is off, the fault is not enabled.
De
c
Au el Inh
tR ib
Sh st Tr t
ea ies
Mo r Pi
tor n
Ov
erL
Un
d
de
r
Po Vo
we lta
r L ge
os
s
2-84
x x x x x x x x x 1 0 0 1 x 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
Factory Default Bit Values
1 =Enabled
0 =Disabled
x =Reserved
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. If the drive is started in this mode
with the motor already spinning, large currents will be generated. An
overcurrent trip may result if the current limiter cannot react quickly
enough. The likelihood of an overcurrent trip is further increased if there is
a residual flux (back emf) on the spinning motor when the drive starts. Even
if the current limiter is fast enough to prevent an overcurrent trip, it will take
an unacceptable amount of time for synchronization to occur and for the
motor to reach its desired frequency. In addition, larger mechanical stress is
placed on the application, increasing downtime and repair costs while
decreasing productivity.
In Flying Start mode, the drive’s response to a start command will be to
identify the motor’s speed and apply a voltage that is synchronized in
frequency, amplitude and phase to the back emf of the spinning motor. The
motor will then accelerate to the desired frequency. This process will
prevent an overcurrent trip and significantly reduce the time for the motor to
reach its desired frequency. Since the motor is “picked up “smoothly at its
rotating speed and ramped to the proper speed, little or no mechanical stress
is present.
Configuration
Flying Start is activated by setting the [Flying Start En] parameter to
“Enable”
169 [Flying Start En]
Default:
0
“Disabled”
Enables/disables the function which
Options:
reconnects to a spinning motor at actual
RPM when a start command is issued.
0
1
“Disabled”
“Enabled”
170
The gain can be adjusted to increase responsiveness. Increasing the value in
[Flying StartGain] increases the responsiveness of the Flaying Start Feature
Restart Modes
Flying Start
2-85
170 [Flying StartGain]
Sets the response of the flying start
function.
Default:
4000
169
Min/Max: 20/32767
Display: 1
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.
This operation can be very hard on the mechanics of the system including
fans, belts and other coupling devices.
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
Fuses and Circuit Breakers
Fuses and Circuit
Breakers
2-87
Tables 2.N through 2.R provide drive ratings (including continuous, 1
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. N.E.C. Other country, state or local codes may
require different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the
recommended types listed below. If available amp ratings do not match the
tables provided, the closest fuse rating that exceeds the drive rating should
be chosen.
• IEC – BS88 (British Standard) Parts 1 & 2(1) , EN60269-1, Parts 1 & 2,
type gG or equivalent should be used.
• UL – UL Class CC, T, RK1 or J must be used.
Circuit Breakers
The “non-fuse” listings in the following tables include both circuit breakers
(inverse time or instantaneous trip) and 140M Self-Protecting Motor
Starters. If one of these is chosen as the desired protection method, the
following requirements apply.
• IEC and UL – Both types of devices are acceptable for IEC and UL
installations.
(1) Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED,
EFS, EF, FF, FG, GF, GG, GH.
2-88
Fuses and Circuit Breakers
Drive
Catalog
Number
Frame
Table 2.N PF70 208/240 Volt AC Input Recommended Protection Devices
HP
Rating
ND HD
Dual
Input
Element Time Non-Time
Ratings
Output Amps
Delay Fuse
Delay Fuse
Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2)
Motor
Circuit Circuit
Breaker Protector
(3)
(4)
Amps
Amps
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
208 Volt AC Input
20AB2P2
20AB4P2
20AB6P8
20AB9P6
20AB015
20AB022
20AB028
A
A
B
B
C
D
D
0.5
1
2
3
5
7.5
10
0.33
0.75
1.5
2
3
5
7.5
2.9
5.6
10
14
16
23.3
29.8
1.1
2
3.6
5.1
5.8
8.3
10.7
2.5
4.8
7.8
11
17.5
25.3
32.2
2.7
5.5
10.3
12.1
19.2
27.8
37.9
3.7
7.4
13.8
16.5
26.6
37.9
50.6
6
10
15
20
20
30
40
6
10
15
25
35
50
70
6
10
15
20
20
30
40
10
17.5
30
40
70
100
125
15
15
30
40
70
100
125
7
7
15
30
30
30
50
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C20
140M-C2E-C25
–
140M-D8E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C20
140M-D8E-C25
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C20
140M-F8E-C25
140M-F8E-C32
–
–
–
–
–
140M-CMN-2500
140M-CMN-4000
0.33
0.75
1.5
2
3
5
7.5
2.5
4.8
8.7
12.2
13.9
19.9
25.7
1.1
2
3.6
5.1
5.8
8.3
10.7
2.2
4.2
6.8
9.6
15.3
22
28
2.4
4.8
9
10.6
17.4
24.4
33
3.3
6.4
12
14.4
23.2
33
44
3
6
15
20
20
25
35
4.5
9
15
20
30
45
60
3
6
15
20
20
25
35
8
15
25
35
60
80
110
15
15
25
35
60
80
110
3
7
15
15
30
30
50
140M-C2E-B25
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-C2E-C20
–
140M-D8E-B25
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-D8E-C20
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C16
140M-F8E-C20
140M-F8E-C32
–
–
–
–
–
–
140M-CMN-4000
240 Volt AC Input
20AB2P2
20AB4P2
20AB6P8
20AB9P6
20AB015
20AB022
20AB028
A
A
B
B
C
D
D
0.5
1
2
3
5
7.5
10
Drive
Catalog
Number
Frame
Table 2.O PF70 400/480 Volt AC Input Recommended Protection Devices
kW
(400V)
HP (480V) Input
Rating
Ratings
Output Amps
ND HD Amps kVA Cont. 1 Min. 3 Sec.
Dual
Element Time Non-Time
Delay Fuse
Delay Fuse
Min. (1) Max. (2) Min. (1) Max. (2)
Motor
Circuit Circuit
Breaker Protector
(3)
(4)
Amps
Amps
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
400 Volt AC Input
20AC1P3
20AC2P1
20AC3P5
20AC5P0
20AC8P7
20AC011
20AC015
20AC022
20AC030
A
A
A
B
B
C
C
D
D
0.37
0.75
1.5
2.2
4
5.5
7.5
11
15
0.25
0.55
1.1
1.5
3
4
5.5
7.5
11
1.6
2.5
4.3
6.5
11.3
11
15.1
21.9
30.3
1.1
1.8
3
4.5
7.8
7.6
10.4
15.2
21
1.3
2.1
3.5
5
8.7
11.5
15.4
22
30
1.4
2.4
4.5
5.5
9.9
13
17.2
24.2
33
1.9
3.2
6
7.5
13.2
17.4
23.1
33
45
3
4
6
10
15
15
20
30
40
3
6
6
10
17.5
25
30
45
60
3
4
6
10
15
15
20
30
40
5
8
12
20
30
45
60
80
120
15
15
15
20
30
40
60
80
120
3
7
7
15
15
15
20
30
50
140M-C2E-B16
140M-C2E-B25
140M-C2E-B40
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-C2E-C16
140M-C2E-C25
–
–
140M-D8E-B25
140M-D8E-B40
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-D8E-C16
140M-D8E-C25
–
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C16
140M-F8E-C16
140M-F8E-C25
140M-F8E-C32
–
–
–
–
–
–
–
140M-CMN-2500
140M-CMN-4000
0.33
0.75
1.5
2
3
5
7.5
10
15
1.3
2.4
3.8
5.6
9.8
9.5
12.5
19.9
24.8
1.1
2
3.2
4.7
8.4
7.9
10.4
16.6
20.6
1.1
2.1
3.4
5
8
11
14
22
27
1.2
2.4
4.5
5.5
8.8
12.1
16.5
24.2
33
1.6
3.2
6
7.5
12
16.5
22
33
44
3
3
6
10
15
15
20
25
35
3
6
6
10
15
20
30
45
60
3
3
6
10
15
15
20
25
35
4
8
12
20
30
40
50
80
100
15
15
15
20
30
40
50
80
100
3
3
7
15
15
15
20
30
50
140M-C2E-B16
140M-C2E-B25
140M-C2E-B40
140M-C2E-C63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-C2E-C20
–
–
140M-D8E-B25
140M-D8E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-D8E-C20
–
–
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C16
140M-F8E-C20
140M-F8E-C25
–
–
–
–
–
–
–
–
140M-CMN-2500
480 Volt AC Input
20AD1P1
20AD2P1
20AD3P4
20AD5P0
20AD8P0
20AD011
20AD014
20AD022
20AD027
A
A
A
B
B
C
C
D
D
0.5
1
2
3
5
7.5
10
15
20
Drive
Catalog
Number
Frame
Table 2.P PF70 600 Volt AC Input Recommended Protection Devices
Dual
HP
Input
Element Time Non-Time
Rating
Ratings
Output Amps
Delay Fuse
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2)
Motor
Circuit Circuit
Breaker Protector
(3)
(4)
Amps
Amps
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
15
15
15
15
20
35
40
60
80
3
3
7
7
15
15
15
30
30
140M-C2E-B16
140M-C2E-B25
140M-C2E-B40
140M-C2E-C63
140M-C2E-C10
140M-C2E-C10
140M-C2E-C16
140M-C2E-C20
140M-C2E-C25
600 Volt AC Input
20AE0P9
20AE1P7
20AE2P7
20AE3P9
20AE6P1
20AE9P0
20AE011
20AE017
20AE022
A
A
A
B
B
C
C
D
D
0.5
1
2
3
5
7.5
10
15
20
0.33
0.75
1.5
2
3
5
7.5
10
15
1.3
1.9
3
4.4
7.5
7.7
9.8
15.3
20
1.3
2
3.1
4.5
7.8
8
10.1
15.9
20.8
0.9
1.7
2.7
3.9
6.1
9
11
17
22
1.1
2
3.6
4.3
6.7
9.9
13.5
18.7
25.5
1.4
2.6
4.8
5.9
9.2
13.5
18
25.5
34
3
3
4
6
10
10
15
20
25
3
6
6
8
12
20
20
35
45
3
3
4
6
10
10
15
20
25
See page 2-91 for Notes.
3.5
6
10
15
20
35
40
60
80
–
140M-D8E-B25
140M-D8E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C10
140M-D8E-C16
140M-D8E-C20
140M-D8E-C25
–
–
–
–
140M-F8E-C10
140M-F8E-C10
140M-F8E-C16
140M-F8E-C20
140M-F8E-C25
–
–
–
–
–
–
–
–
140M-CMN-2500
Fuses and Circuit Breakers
2-89
Drive
Catalog
Number
Frame
Table 2.Q PF700 208/240 Volt AC Input Recommended Protection Devices
HP
Rating
ND HD
Motor
Circuit Circuit
Breaker Protector
Dual
Input
Element Time Non-Time
Ratings
Output Amps
Delay Fuse
Delay Fuse
Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2)
(3)
(4)
Amps
Amps
1.9
3.7
6.8
9.5
15.7
23.0
29.6
44.5
51.5
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
208 Volt AC Input
20BB2P2
20BB4P2
20BB6P8
20BB9P6
20BB015
20BB022
20BB028
20BB042
20BB052
20BB070
20BB080
20BB104
20BB130
20BB154
20BB192
0
0
1
1
1
1
2
3
3
4
4
5
0.5
1
2
3
5
7.5
10
15
20
25
30
–
40
5 –
50
6 60
6 75
0.33
0.75
1.5
2
3
5
7.5
10
15
20
25
30
–
40
–
50
60
84.7
113
98
122
0.7
1.3
2.4
3.4
5.7
8.3
10.7
16.0
17.1
2.5
4.8
7.8
11
17.5
25.3
32.2
48.3
56
78.2
92
28 92
37.5 120
32.4 104
40.6 130
154
192
2.8
5.6
10.4
12.1
19.3
27.8
38
53.1
64
86
117.3
138
132
156
143
3.8
7.0
13.8
17
26.3
38
50.6
72.5
86
117.3
156.4
175
175
175
175
3
6
10
12
20
30
40
60
80
6
10
15
20
35
50
70
100
125
3
6
10
12
20
30
40
60
80
10
17.5
30
40
70
100
125
175
200
15
15
30
40
70
100
125
175
200
3
7
15
15
30
30
50
70
100
140M-C2E-B25
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C20
140M-C2E-C25
–
–
140M-D8E-B25
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C20
140M-D8E-C25
–
–
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C20
140M-F8E-C25
140M-F8E-C32
140M-F8E-C45
–
–
–
–
–
–
140M-CMN-2500
140M-CMN-4000
140M-CMN-6300
140M-CMN-6300
125
150
125
175
200
250
225
275
125
150
125
175
350
475
400
500
300
350
300
375
150
150
150
250
–
–
–
–
–
–
–
–
–
–
–
–
140M-CMN-9000
–
–
–
0.7
1.4
2.4
3.4
5.7
8.3
10.7
16.0
18.2
2.4
4.8
9
10.6
16.8
24.2
33
46.2
63
78
105
120
115
156
143
3.3
6.4
12
14.4
23
33
44
63
80
105
136
160
175
175
175
3
5
10
12
20
25
35
50
60
6
8
15
20
30
50
60
90
100
3
5
10
12
20
25
35
50
60
10
15
25
35
60
80
100
150
200
15
15
25
35
60
80
100
150
200
3
7
15
15
30
30
50
50
100
140M-C2E-B25
140M-C2E-B63
140M-C2E-C10
140M-C2E-C10
140M-C2E-C16
140M-C2E-C25
–
–
–
140M-D8E-B25
140M-D8E-B63
140M-D8E-C10
140M-D8E-C10
140M-D8E-C16
140M-D8E-C25
–
–
–
–
–
140M-F8E-C10
140M-F8E-C10
140M-F8E-C16
140M-F8E-C25
140M-F8E-C32
140M-F8E-C45
–
–
–
–
–
–
140M-CMN-2500
140M-CMN-4000
140M-CMN-6300
140M-CMN-6300
100
125
125
175
175
225
225
275
100
125
125
175
300
400
400
500
300
300
300
375
100
150
150
250
–
–
–
–
–
–
–
–
–
–
–
–
140M-CMN-9000
–
–
–
240 Volt AC Input
20BB2P2
20BB4P2
20BB6P8
20BB9P6
20BB015
20BB022
20BB028
20BB042
20BB052
20BB070
20BB080
20BB104
20BB130
20BB154
20BB192
0
0
1
1
1
1
2
3
3
4
4
5
0.5
1
2
3
5
7.5
10
15
20
25
30
–
40
5 –
50
6 60
6 75
0.33
0.75
1.5
2
3
5
7.5
10
15
20
25
30
–
40
–
50
60
1.7
3.3
5.9
8.3
13.7
19.9
25.7
38.5
47.7
73
98
98
122
2.2
4.2
6.8
9.6
15.3
22
28
42
52
70
80
28 80
37.3 104
37.3 104
47 130
154
192
See page 2-91 for Notes.
2-90
Fuses and Circuit Breakers
Drive
Catalog
Number
Frame
Table 2.R PF700 400/480 Volt AC Input Recommended Protection Devices
Dual
kW
Input
Element Time Non-Time
Rating
Ratings
Output Amps
Delay Fuse
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2)
Motor
Circuit Circuit
Breaker Protector
(3)
(4)
Amps
Amps
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
400 Volt AC Input
20BC1P3
20BC2P1
20BC3P5
20BC5P0
20BC8P7
20BC011
20BC015
20BC022
20BC030
20BC037
20BC043
20BC056
20BC072
20BC085 (8
0
0
0
0
0
0
1
1
2
2
3
3
3
4
20BC105
5
20BC125
5
20BC140
6
20BC170
6
)
20BC205 (9 6
)
0.37
0.75
1.5
2.2
4
5.5
7.5
11
15
18.5
22
30
37
–
45
–
55
–
55
–
75
–
90
–
110
0.25
0.55
0.75
1.5
2.2
4
5.5
7.5
11
15
18.5
22
30
37
–
45
–
45
–
55
–
75
–
90
–
1.1
1.8
3.2
4.6
7.9
10.8
14.4
20.6
28.4
35.0
40.7
53
68.9
68.9
81.4
81.4
100.5
91.9
121.1
101
136
136
164
164
199
0.77
1.3
2.2
3.2
5.5
7.5
10.0
14.3
19.7
24.3
28.2
36.7
47.8
47.8
56.4
56.4
69.6
63.7
83.9
76
103
103
126
126
148
1.3
2.1
3.5
5.0
8.7
11.5
15.4
22
30
37
43
56
72
72
85
85
105
96
125
105
140
140
170
170
205
1.4
2.4
4.5
5.5
9.9
13
17.2
24.2
33
45
56
64
84
108
94
128
116
144
138
158
154
210
187
255
220
1.9
3.2
6.0
7.5
13.2
17.4
23.1
33
45
60
74
86
112
144
128
170
158
168
163
210
210
280
255
313
289
3
3
6
6
15
15
20
30
35
45
60
70
90
110
110
110
125
125
150
150
200
200
250
250
275
3
6
7
10
17.5
25
30
45
60
80
90
125
150
175
175
175
225
200
275
225
300
300
375
375
450
3
3
6
6
15
15
20
30
35
45
60
70
90
110
110
110
125
125
150
150
200
200
250
250
275
6
8
12
20
30
45
60
80
120
125
150
200
250
300
300
300
400
375
500
400
550
550
600
600
600
15
15
15
20
30
45
60
80
120
125
150
200
250
300
300
300
300
375
375
300
400
400
500
500
600
3
3
7
7
15
15
20
30
50
50
60
100
100
150
150
150
150
150
250
150
250
250
250
250
400
140M-C2E-B16
140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C20
140M-C2E-C25
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
140M-D8E-B25
140M-D8E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C20
140M-D8E-C25
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C20
140M-F8E-C25
140M-F8E-C32
140M-F8E-C45
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
0.33
0.75
1.5
2
3
5
7.5
10
15
20
25
30
40
50
–
60
–
75
–
100
–
125
–
0.9
1.6
2.6
3.9
6.9
9.5
12.5
19.9
24.8
31.2
36.7
47.7
59.6
59.6
72.3
72.3
90.1
90.1
117
131
147
147
169
0.7
1.4
2.2
3.2
5.7
7.9
10.4
16.6
20.6
25.9
30.5
39.7
49.6
49.6
60.1
60.1
74.9
74.9
97.6
109
122
122
141
1.1
2.1
3.4
5.0
8.0
11
14
22
27
34
40
52
65
65
77
77
96
96
125
125
156
156
180
1.2
2.4
4.5
5.5
8.8
12.1
16.5
24.2
33
40.5
51
60
78
98
85
116
106
144
138
188
172
234
198
1.6
3.2
6.0
7.5
12
16.5
22
33
44
54
68
80
104
130
116
154
144
168
163
250
234
312
270
3
3
4
6
10
15
17.5
25
35
40
50
60
75
100
100
100
125
125
150
175
200
200
225
3
6
8
10
15
20
30
50
60
70
90
110
125
170
170
170
200
200
250
250
350
350
400
3
3
4
6
10
15
17.5
25
35
40
50
60
75
100
100
100
125
125
150
175
200
200
225
6
8
12
20
30
40
50
80
100
125
150
200
250
300
300
300
350
350
500
500
600
600
600
15
15
15
20
30
40
50
80
100
125
150
200
250
300
300
300
350
350
375
375
450
450
500
3
3
7
7
15
15
20
30
50
50
50
70
100
100
100
100
125
125
150
250
250
250
250
140M-C2E-B16
140M-C2E-B25
140M-C2E-B40
140M-C2E-C63
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-C2E-C25
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
140M-D8E-B40
140M-D8E-B63
140M-D8E-C10
140M-D8E-C16
140M-D8E-C16
140M-D8E-C25
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
140M-F8E-C10
140M-F8E-C16
140M-F8E-C16
140M-F8E-C25
140M-F8E-C32
140M-F8E-C45
140M-F8E-C45
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
140-CMN-2500
140-CMN-4000
140-CMN-4000
140-CMN-4000
140M-CMN-6300
140M-CMN-9000
140M-CMN-9000
140M-CMN-9000
140M-CMN-9000
–
–
–
–
–
–
–
480 Volt AC Input
20BD1P1
20BD2P1
20BD3P4
20BD5P0
20BD8P0
20BD011
20BD014
20BD022
20BD027
20BD034
20BD040
20BD052
20BD065
20BD077
0
0
0
0
0
0
1
1
2
2
3
3
3
4
20BD096
5
20BD125
5
20BD156
6
20BD180
6
0.5
1
2
3
5
7.5
10
15
20
25
30
40
50
–
60
–
75
–
100
–
125
–
150
See page 2-91 for Notes.
Grounding, General
2-91
Drive
Catalog
Number
Frame
Table 2.S PF700 600 Volt AC Input Recommended Protection Devices
Dual
HP
Input
Element Time Non-Time
Rating
Ratings
Output Amps
Delay Fuse
Delay Fuse
ND HD Amps kVA Cont. 1 Min. 3 Sec. Min. (1) Max. (2) Min. (1) Max. (2)
Motor
Circuit Circuit
Breaker Protector
(3)
(4)
Amps
Amps
40
60
80
100
125
150
200
15
20
30
50
50
50
100
140M Motor Starter with Adjustable Current Range (5)(6)
Available Catalog Numbers (7)
600 Volt AC Input
20BE011
20BE017
20BE022
20BE027
20BE032
20BE041
20BE052
20BE062
20BE077
1
1
2
2
3
3
3
4
5
10
15
20
25
30
40
50
60
75
7.5
10
15
20
25
30
40
50
60
9.9
15.4
20.2
24.8
29.4
37.6
47.7
10.2
16.0
21.0
25.7
30.5
39.1
49.6
11
17
22
27
32
41
52
62
77
13.5
18.7
25.5
33
40.5
48
61.5
18
25.5
34
44
54
64
82
15
20
30
35
40
50
60
25
40
50
60
70
90
110
15
20
30
35
40
50
60
40
60
80
100
125
150
200
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Notes:
(1) Minimum protection device size is the lowest rated device that supplies maximum protection without nuisance tripping.
(2) Maximum protection device size is the highest rated device that supplies drive protection. For US NEC, minimum size is 125% of motor FLA. Ratings shown are
maximum.
(3) Circuit Breaker - inverse time breaker. For US NEC, minimum size is 125% of motor FLA. Ratings shown are maximum.
(4) Motor Circuit Protector - instantaneous trip circuit breaker. For US NEC minimum size is 125% of motor FLA. Ratings shown are maximum.
(5) Bulletin 140M with adjustable current range should have the current trip set to the minimum range that the device will not trip.
(6) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/ 347. Not UL listed for use on
480V or 600V Delta/Delta systems.
(7) The AIC ratings of the Bulletin 140M Motor Protector may vary. See publication 140M-SG001B-EN-P.
(8) 20BC085 current rating is limited to 45 degrees C ambient.
(9) 20BC205 current rating is limited to 40 degrees C ambient.
Grounding, General
Refer to “Wiring and Grounding Guidelines for PWM AC Drives,”
publication DRIVES-IN001A-EN-P.
2-92
HIM Memory
HIM Memory
See 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. Press Enter to select the desired language. To switch to an
alternate language, follow the steps below.
Step
1. Press ALT and then the Up Arrow (Lang).
The Language screen will appear.
Key(s)
ALT +
2. Press the Up Arrow or Down Arrow to scroll
through the languages.
Example Displays
Speak English?
Parlez Francais?
Spechen Duetsch?
Plare Italiano?
3. Press Enter to select a language.
Using Passwords
By default the password is set to 00000 (password protection disabled).
Logging in to the Drive
Step
1. Press the Up or Down Arrow to enter your
password. Press Sel to move from digit to
digit.
Key(s)
Example Displays
Login: Enter
Password 9999
2. Press Enter to log in.
Logging Out
Step
Key(s)
You are automatically logged out when the User
Display appears. If you want to log out before
that, select “log out” from the Main Menu.
Example Displays
To change a password
Step
Key(s)
1. Use the Up Arrow or Down Arrow to scroll to
Operator Intrfc. Press Enter.
2. Select “Change Password” and press Enter.
3. Enter the old password. If a password has
not been set, type “0.” Press Enter.
4. Enter a new password (1- 65535). Press
Enter and verify the new password. Press
Enter to save the new password.
Example Displays
Operator Intrfc:
Change Password
User Display
Parameters
Password:
Old Code: 0
New Code: 9999
Verify: 9999
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.
Input Devices
2-93
Setting the User Display
Step
Key(s)
1. Press the Up Arrow or Down Arrow to scroll
to Operator Intrfc. Press Enter.
2. Press the Up Arrow or Down Arrow to scroll
to User Display. Press Enter.
3. Select the desired user display. Press Enter.
Scroll to the parameter that the user display
will be based on.
Example Displays
Operator Intrfc:
Change Password
User Display
Parameters
Sel
4. Press Enter. Set a scale factor.
5. Press Enter to save the scale factor and
move to the last line.
6. Press the Up Arrow or Down Arrow to
change the text.
7. Press Enter to save the new user display.
Setting the Properties of the User Display
The following HIM parameters can be set as desired:
• User Display - Enables or disables the user display.
• User Display 1 - Selects which user display parameter appears on the top
line of the user display.
• User Display 2 - Selects which user display parameter appears on the
bottom line of the user display.
• User Display Time - Sets how many seconds will elapse after the last
programming key is touched before the HIM displays the user display.
Input Devices
Contactors
See Motor Start/Stop Precautions on page 2-105
Circuit Breakers / Fuses
See Fuses and Circuit Breakers on page 2-87
Filters, EMC
Refer to CE Conformity on page 2-40.
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:
2-Wire Control
This input mode is so named
because it only utilizes one
device and 2 wires to control both
the Start (normally referred to as
“RUN” in 2-wire) and Stop
functions in an application.
• A maintained contact device,
PWR
such as a thermostat, for
example, closes its contact to
Run the drive and opens to
Stop the drive
STS
Run/Stop
PORT
MOD
NET A
NET B
• In other applications, the
maintained device (such as a
limit switch), can directly
control both Run/Stop and
direction control . . .
PWR
STS
Run Forward
PORT
MOD
NET A
NET B
Run Reverse
• Or, a combination of the two
PWR
may be desirable.
STS
Run
PORT
MOD
NET A
NET B
Forward/Reverse
3-Wire Control
This input mode utilizes 2 devices
requiring 3 wires to control the
Start (proper term for 3-wire) and
Stop functions in an application.
In this case, momentary contact
devices, such as pushbuttons are
used.
• A Start is issued when the
Start button is closed, but
unlike 2-wire circuits, the
drive does not Stop when the
Start button is released.
Instead, 3-wire control
requires a Stop input to Stop
the drive
• Direction control is
accomplished either with
momentary inputs . . .
PWR
STS
Start
PORT
MOD
NET A
NET B
Stop
Start
PWR
STS
Stop
Forward
PORT
MOD
NET A
NET B
Reverse
• Or, with a maintained input.
PWR
STS
Start
Stop
PORT
MOD
NET A
NET B
Forward/Reverse
Input Power Conditioning
Input Power
Conditioning
Refer to Chapter 2 of “Wiring and Grounding Guidelines for PWM AC
Drives,” publication DRIVES-IN001A-EN-P.
Jog
Also refer to Jog on page 2-57.
2-95
When a JOG command is issued by any of the controlling devices (terminal
block digital input, communications adapter or HIM), the drive ouputs
voltage and frequency to the motor as long as the command is present.
When the command is released, the drive output stops.
Whenever a jog command is present, the value programmed in parameter
100, [Jog Speed] becomes the active speed reference. Regardless of the
[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.
If [Direction Mode] = “Unipolar” the drive will jog using the Jog reference
parameter value and will use the direction currently selected via the DPI
commanded direction. When [Direction Mode] = “Bipolar” and a Jog
command (with no direction) is asserted, the drive will jog using the Jog
reference parameter (which is always positive or forward). To accommodate
jogging with direction while in Bipolar mode (such as from a terminal
block), the drive will allow Jog Fwd and Jog Rev to be configured as
terminal block inputs. When these inputs are asserted, the drive will jog the
requested direction. This still implies that a HIM can only jog in the
forward direction when in Bipolar mode since they only transmit a Jog
command with no direction via DPI.
For PowerFlex 700 drives with Vector Control, 2 independent Jog Speeds
(1 and 2) are provided. The jog reference is signed and limited between
Minimum Speed or Reverse Speed Limit (whichever is programmed)) and
Maximum Speed. In this control, the jog reference controls both speed and
direction of the jog operation. If the programmed Jog Speed is negative the
drive will jog in the reverse direction: if the Jog Speed value is positive, the
drive will jog in the forward direction.
When a jog command is issued, exclusive control of speed and direction is
given to the Jog function. If the master speed reference is bipolar and
commanding reverse direction but the programmed Jog Speed is a positive
value, the drive will jog in the forward direction, overriding the direction
control of a bipolar speed reference.
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:
• On initial drive power-up, a language choice screen appears.
• The language choice screen can also be recalled at any time to change to
a new language. This is accomplished by pressing the “Alt” key followed
by the “Lang” key.
• The language can also be changed by selecting the [Language]
parameter (201). Note that this parameter is not functional when using
an LED HIM.
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.
276 [Logic Mask]
DP
I
DP Port
5
I
DP Port
4
I
DP Port
IP 3
DP ort
IP 2
Dig ort
ita 1
l In
288
Determines which adapters can control the drive. If the bit for an adapter is set to thru
297
“0,” the adapter will have no control functions except for stop.
x x x x x x x x x x 1 1 1 1 1 1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Control Permitted
0 =Control Masked
x =Reserved
Bit #
Factory Default Bit Values
277 [Start Mask]
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
See [Logic Mask].
288
thru
297
288
thru
297
Controls which adapters can issue start
commands.
278 [Jog Mask]
Controls which adapters can issue jog
commands.
Masks & Owners
279 [Direction Mask]
COMMUNICATION
Masks
2-97
Controls which adapters can issue
forward/reverse direction commands.
280 [Reference Mask]
Controls which adapters can select an
alternate reference; [Speed Ref A, B Sel]
or [Preset Speed 1-7].
281 [Accel Mask]
Controls which adapters can select
[Accel Time 1, 2].
282 [Decel Mask]
Controls which adapters can select
[Decel Time 1, 2].
283 [Fault Clr Mask]
Controls which adapters can clear a fault.
284 [MOP Mask]
See [Logic Mask].
Controls which adapters can issue MOP
commands to the drive.
285 [Local Mask]
Controls which adapters are allowed to
take exclusive control of drive logic
commands (except stop). Exclusive
“local” control can only be taken while the
drive is stopped.
See [Logic Mask].
288
thru
297
Example: A customer's process is normally controlled by a remote PLC,
but the drive is mounted on the machine. The customer does not want
anyone to walk up to the drive and reverse the motor because it would
damage the process. The local HIM (drive mounted Adapter 1) is
configured with an operator's panel that includes a “REV” Button. To assure
that only the PLC (connected to Adapter 2) has direction control, the
[Direction Mask] can be set as follows:
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.
MOP
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
• [Save MOP Ref] parameter
• [MOP Frequency] parameter
MOP increment input
MOP decrement input
The MOP reference rate is defined in [MOP rate]. The MOP function is
defined graphically below
MOP dec
MOP inc
MOP reference
MOP rate is defined in Hz/sec. The MOP reference will increase/decrease
linearly at that rate as long as the MOP inc or dec is asserted via TB or DPI
port (the MOP inputs are treated as level sensitive).
Both the MOP inc and dec will use the same rate (i.e. they can not be
separately configured). The MOP rate is the rate of change of the MOP
reference. The selected active MOP reference still feeds the ramp function
to arrive at the present commanded speed/frequency (eg. is still based on the
accel/decel rates). Asserting both MOP inc and dec inputs simultaneously
will result in no change to the MOP reference.
[Save MOP Ref] is a packed boolean parameter with two bits used as
follows:
Bit 0
0 = Don’t save MOP reference on power-down (default)
1 = Save MOP reference on power-down
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. The MOP save reference parameter and the MOP rate
parameter can be changed while the drive is running.
Bit 1
0 = Reset MOP reference when STOP edge is asserted
1 = Don’t reset MOP reference when STOP is asserted (default)
2-100
MOP
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.
In order to change the MOP reference (increment or decrement) a given DPI
port must have the MOP mask asserted (and the logic mask asserted). In the
case of the terminal block, if the MOP increment or MOP decrement
function is assigned to a digital input, then the act of asserting either of
those inputs will cause the TB to try and gain ownership of the MOP inc/
dec reference change.
Ownership of the MOP function can be obtained even if the MOP reference
is not being used to control the drive. If ownership is granted, the owner has
the right to inc/dec the MOP reference. Whether this reference is the active
speed reference for the drive is separately selected via TB reference select,
or Ref A/B select through DPI.
The MOP Frequency parameter is an output which shows the active value of
the MOP reference in Hz x 10.
MOP handling with Direction Mode
If the Direction Mode is configured for “Unipolar,” then the MOP
decrement will clamp at zero not allowing the user to generate a negative
MOP reference that is clamped off by the reference generation. When
Direction Mode = “Bipolar” the MOP reference will permit the decrement
function to produce negative values. If the drive is configured for Direction
Mode = “Bipolar” and then is changed to “Unipolar”, the MOP reference
will also be clamped at zero if it was less than zero.
Motor Nameplate
Motor Nameplate
2-101
[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. It is used in the motor thermal
overload, and in the calculation of slip.
[Motor NP Hz]
The motor nameplate base frequency defines the output frequency, when
operating at rated voltage, rated current, rated speed, and rated temperature.
[Motor NP RPM]
The motor nameplate RPM defines the rated speed, when operating at
motor nameplate base frequency, rated current, base voltage, and rated
temperature. This is used to calculate slip.
[Motor NP Power]
The motor nameplate power is used together with the other nameplate
values to calculate default values for motor parameters to and facilitate the
commissioning process. This may be entered in horsepower or in kilowatts
as selected in the previous parameter or kW for certain catalog numbers and
HP for others.
[Motor NP Pwr Units]
The rated power of the motor may be entered in horsepower or in kilowatts.
This parameter determines the units on the following parameter.
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.
Motor Overload Curve
100000
Trip Time (Seconds)
2-102
10000
Cold
Hot
1000
100
10
100
125
150
175
200
Full Load Amps (%)
225
250
Motor nameplate FLA programming is used to set the overload feature.
This parameter, which is set in the start up procedure, is adjustable from 0 200% of drive rating and should be set for the actual motor FLA rating.
Setting the correct bit in [Fault Config x] to zero disables the motor thermal
overload. Most multimotor applications (using one drive and more than one
motor) will require the MTO to be disabled since the drive would be unable
to distinguish each individual motor’s current and provide protection.
Operation of the overload is based on three parameters; [Motor NP FLA],
[Motor OL Factor] and [Motor OL Hertz].
1. [Motor NP FLA] is the base value for motor protection.
2. [Motor OL Factor] is used to adjust for the service factor of the motor.
Within the drive, motor nameplate FLA is multiplied by motor overload
factor to select the rated current for the motor thermal overload. This can
be used to raise or lower the level of current that will cause the motor
thermal overload to trip without the need to adjust the motor FLA. For
example, if motor nameplate FLA is 10 Amps and motor overload factor
is 1.2, then motor thermal overload will use 12 Amps as 100%.
Motor Overload
2-103
Changing Overload Factor
140
Continuous Rating
120
100
80
OL % = 1.20
OL % = 1.00
OL % = 0.80
60
40
20
0
10
20
30
40
50
60
70
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. This parameter defines the frequency
where derating the motor overload capacity should begin. As shown
here, the motor overload capacity is reduced when operating below the
motor overload Hz. For all settings of overload Hz other than zero, the
overload capacity is reduced to 70% when output frequency is zero.
During DC injection the motor current may exceed 70% of FLA, but this
will cause the Motor Thermal Overload to trip sooner than when
operating at base speed. At low frequencies, the limiting factor may be
the Drive Thermal Overload.
Changing Overload Hz
Continuous Rating
120
100
80
OL Hz = 10
OL Hz = 25
OL Hz = 50
60
40
20
0
10
20
30
40
50
60
% of Base Speed
70
80
90 100
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. If operating continuous at 100%
FLA, and the load increases to 150% FLA for 59 seconds and then returns
to 100%FLA, the load must remain at 100% FLA for 20 minutes to reach
steady state.
1 Minute
1 Minute
150%
100%
20 Minutes
The ratio of 1:20 is the same for all durations of 150%. When operating
continuous at 100%, if the load increases to 150% for 1 second the load
must then return to 100% for 20 seconds before another step to 150%
FLA%
105
110
115
120
125
130
135
140
145
150
Cold Trip
Time
6320
1794
934
619
456
357
291
244
209
180
Hot Trip
Time
5995
1500
667
375
240
167
122
94
74
60
FLA%
155
160
165
170
175
180
185
190
195
200
Cold Trip
Time
160
142
128
115
105
96
88
82
76
70
Hot Trip
Time
50
42
36
31
27
23
21
19
17
15
FLA%
205
210
215
220
225
230
235
240
245
250
Cold Trip
Time
66
62
58
54
51
48
46
44
41
39
Hot Trip
Time
14
12
11
10
10
9
8
8
7
7
Motor Start/Stop Precautions
Motor Start/Stop
Precautions
2-105
Input Contactor 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. If an
input device is used, operation must not exceed one cycle per
minute or drive damage will occur.
ATTENTION: The drive start/stop/enable control circuitry
includes solid state components. If hazards due to accidental
contact with moving machinery or unintentional flow of liquid, gas
or solids exist, an additional hardwired stop circuit may be
required to remove the AC line to the drive. An auxiliary braking
method may be required.
Output Contactor Precaution
!
Mounting
ATTENTION: To guard against drive damage when using output
contactors, the following information must be read and
understood. One or more output contactors may be installed
between the drive and motor(s) for the purpose of disconnecting or
isolating certain motors/loads. If a contactor is opened while the
drive is operating, power will be removed from the respective
motor, but the drive will continue to produce voltage at the output
terminals. In addition, reconnecting a motor to an active drive (by
closing the contactor) could produce excessive current that may
cause the drive to fault. If any of these conditions are determined to
be undesirable or unsafe, an auxiliary contact on the output
contactor should be wired to a drive digital input that is
programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is
opened.
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.
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. One or more output contactors may be installed
between the drive and motor(s) for the purpose of disconnecting or
isolating certain motors/loads. If a contactor is opened while the
drive is operating, power will be removed from the respective
motor, but the drive will continue to produce voltage at the output
terminals. In addition, reconnecting a motor to an active drive (by
closing the contactor) could produce excessive current that may
cause the drive to fault. If any of these conditions are determined to
be undesirable or unsafe, an auxiliary contact on the output
contactor should be wired to a drive digital input that is
programmed as “Enable.” This will cause the drive to execute a
coast-to-stop (cease output) whenever an output contactor is
opened.
Cable Termination
Voltage doubling at motor terminals, known as reflected wave phenomenon,
standing wave or transmission line effect, can occur when using drives with
long motor cables.
Inverter duty motors with phase-to-phase insulation ratings of 1200 volts or
higher should be used to minimize effects of reflected wave on motor insulation life.
Applications with non-inverter duty motors or any motor with exceptionally
long leads may require an output filter or cable terminator. A filter or terminator will help limit reflection to the motor, to levels which are less than the
motor insulation rating.
Cable length restrictions for unterminated cables are discussed on
page 2-32. Remember that the voltage doubling phenomenon occurs at different lengths for different drive ratings. If your installation requires longer
motor cable lengths, a reactor or cable terminator is recommended.
Optional Output Reactor
Bulletin 1321 Reactors can be used for drive input and output. These
reactors are specifically constructed to accommodate IGBT inverter applications with switching frequencies up to 20 kHz. They have a UL approved
dielectric strength of 4000 volts, opposed to a normal rating of 2500 volts.
The first two and last two turns of each coil are triple insulated to guard
against insulation breakdown resulting from high dv/dt. When using motor
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.
Output Frequency
[Output Frequency]
This parameter displays the actual output frequency of the drive. The output
frequency is created by a summation of commanded frequency and any
active speed regulator such as slip compensation, PI Loop, bus regulator.
The actual output may be different than the commanded frequency.
Output Power
This parameter displays the output kW of the drive. The output power is a
calculated value and tends to be inaccurate at lower speeds. It is not
recommended for use as a process variable to control a process.
Output Voltage
[Output Voltage]
This parameter displays the actual output voltage at the drive output
terminals. The actual output voltage may be different than that determined
by the sensorless vector or V/Hz algorithms because it may be modified by
features such as the Auto-Economizer.
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.
Figure 2.13 illustrates a typical Custom V/Hz profile. Minimum Speed
determines the lower speed reference limit during normal operation.
Maximum Speed determines the upper speed reference limit. The two
“Speed” parameters only limit the speed reference and not the output
frequency.
The actual output at maximum speed reference is the sum of the speed
reference plus “speed adder” components from functions such as slip
compensation, encoder feedback or process trim.
The Overspeed Limit is added to Maximum Speed and the sum of the two
(Speed Limit) limits is output. This sum (Speed Limit) is compared to
Maximum Frequency and an alarm is initiated which prevents operation if
the Speed Limit exceeds Maximum Frequency.
Figure 2.13 Typical V/Hz Curve for Full Custom (with Speed/Frequency Limits
Allowable Output Frequency Range Bus Regulation or Current Limit
Allowable Output Frequency Range - Normal Operation 1
Allowable Speed Reference Range
Maximum
Voltage
Motor NP
Voltage
Output Voltage
2-108
Frequency Trim
due to Speed
Control Mode
Overspeed
Limit
Break
Voltage
Start
Boost
Run
Boost
0
Minimum
Break
Speed Frequency
Motor NP Hz
Maximum
Speed
Frequency
Note 1: The lower limit on this range can be 0 depending on the value of Speed Adder
Output
Maximum
Frequency Frequency
Limit
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. Ownership falls into two categories;
Exclusive
Only one adapter at a time can issue the command and only one bit in the
parameter will be high.
For example, it is not allowable to have one Adapter command the drive to
run in the forward direction while another Adapter is issuing a command to
make the drive run in reverse. Direction Control, therefore, is exclusive
ownership.
Non Exclusive
Multiple adapters can simultaneously issue the same command and multiple
bits may be high.
288 [Stop Owner]
Read Only
276
thru
285
DP
I
DP Port
IP 5
DP ort
4
I
DP Port
IP 3
DP ort
2
I
Dig Port
ita 1
l In
Adapters presently issuing a valid stop command.
x x x x x x x x x x 0 0 0 0 0 1
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
1 =Issuing Command
0 =No Command
x =Reserved
Bit #
289 [Start Owner]
Adapters that are presently issuing a valid start
command.
290 [Jog Owner]
See [Stop Owner]
276
thru
285
See [Stop Owner]
276
thru
285
See [Stop Owner]
276
thru
285
See [Stop Owner]
276
thru
285
See [Stop Owner]
140
276
thru
285
142
276
thru
285
276
thru
285
276
thru
285
Adapters that are presently issuing a
valid jog command.
291 [Direction Owner]
Adapter that currently has exclusive
control of direction changes.
292 [Reference Owner]
Masks & Owners
COMMUNICATIONS
Owners
2-109
Adapter that has the exclusive control of
the command frequency source
selection.
293 [Accel Owner]
Adapter that has exclusive control of
selecting [Accel Time 1, 2].
294 [Decel Owner]
See [Stop Owner]
Adapter that has exclusive control of
selecting [Decel Time 1, 2].
295 [Fault Clr Owner]
See [Stop Owner]
Adapter that is presently clearing a fault.
296 [MOP Owner]
See [Stop Owner]
Adapters that are currently issuing
increases or decreases in MOP
command frequency.
297 [Local Owner]
Adapter that has requested exclusive
control of all drive logic functions. If an
adapter is in local lockout, all other
functions (except stop) on all other
adapters are locked out and
non-functional. Local control can only be
obtained when the drive is not running.
See [Stop Owner]
276
thru
285
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. The operator needs to determine why the
drive will not restart.
The operator first views the Start owner to be certain that the Start button on
the HIM is issuing a command.
Start Owner
0 0 0 0 0 0 0 0
Adapter #
X 6 5 4 3 2 1 0
When the local Start button is pressed, the display indicates that the
command is coming from the HIM.
Start Owner
0 0 0 0 0 0 1 0
Adapter #
X 6 5 4 3 2 1 0
The [Start Owner] indicates that there is not any maintained Start
commands causing the drive to run.
Stop Owner
0 0 0 0 0 0 0 1
Adapter #
X 6 5 4 3 2 1 0
The operator then checks the Stop Owner. Notice that bit 0 is a value of “1,”
indicating that the Stop device wired to the Digital Input terminal block is
open, issuing a Stop command to the drive.
Until this device is reclosed, a permanent Start Inhibit condition exists and
the drive will not restart.
Also refer to Start Inhibits and Start Permissives.
Parameter Access Level
Parameter Access
Level
2-111
The PowerFlex 70 allows the user to restrict the number of parameters that
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.
If you are trying to gain access to a particular parameter and the HIM skips
over it, you must change the parameter view from “Basic” to “Advanced.”
This can be accomplished in two different ways:
• Press “Alt” and then “View” from the HIM and change the view.
or
• Reprogram Parameter 196 [Param Access Lvl] to “Advanced”.
PET
Pulse Elimination Technique – See Reflected Wave on page 2-132.
2-112
Power Loss
Power Loss
Some processes or applications cannot tolerate drive output interruptions
caused by momentary power outages. When AC input line power is
interrupted to the drive, user programming can determine the drive’s
reaction.
Terms
The following is a definition of terms. Some of these values are drive
parameters and some are not. The description of how these operate is
explained below
Term
Vbus
Vmem
Vslew
Vrecover
Vtrigger
Definition
The instantaneous DC bus voltage.
The average DC bus voltage. A measure of the “nominal” bus voltage determined by
heavily filtering bus voltage. Just after the pre-charge relay is closed during the initial
power-up bus pre-charge, bus memory is set equal to bus voltage. Thereafter it is
updated by ramping at a very slow rate toward Vbus. The filtered value ramps at 2.4VDC
per minute (for a 480VAC drive). An increase in Vmem is blocked during deceleration to
prevent a false high value due to the bus being pumped up by regeneration. Any change
to Vmem is blocked during inertia ride through.
The rate of change of Vmem in volts per minute.
The threshold for recovery from power loss.
The threshold to detect power loss.
PowerFlex 700
The level is adjustable. The default is the value in the PF700 Bus Level table. If “Pwr Loss
Lvl” is selected as an input function AND energized, Vtrigger is set to Vmem minus
[Power Loss Level].
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.
Vinertia
Vclose
Vopen
Vmin
Voff
WARNING:
When using a value of Parameter #186 [Power Loss Level] larger than default, the
customer must provide a minimum line impedance to limit inrush current when the power
line recovers. The input impedance should be equal or greater than the equivalent of a
5% transformer with a VA rating 5 times the drive’s input VA rating.
The software regulation reference for Vbus during inertia ride through.
The threshold to close the pre-charge contactor.
The threshold to open the pre-charge contactor.
The minimum value of Vopen.
The bus voltage below which the switching power supply falls out of regulation.
Table 2.T PF70 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1
Vtrigger2
Vopen
Vmin
Voff 3
200/240 VAC
1.2 VDC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
204 VDC
?
400/480 VAC
2.4 VDC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
407 VDC
300 VDC
600/690 VAC
3.0 VDC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
509 VDC
?
Power Loss
Line Loss Mode = Decel
700
Line Loss Mode = Coast
700
Recover
Close
Trigger
Open
650
600
DC Bus Volts
DC Bus Volts
650
550
Recover
Close
Trigger
Open
600
550
500
500
450
450
400
2-113
400
350
400
AC Input Volts
450
350
400
AC Input Volts
450
Table 2.U PF700 Bus Levels
Class
Vslew
Vrecover
Vclose
Vtrigger1,2
Vtrigger1,3
Vopen
Vopen4
Vmin
Voff 5
200/240V AC
1.2 VDC
Vmem – 30V
Vmem – 60V
Vmem – 60V
Vmem – 90V
Vmem – 90V
153 VDC
153 VDC
–
400/480V AC
2.4 VDC
Vmem – 60V
Vmem – 120V
Vmem – 120V
Vmem – 180V
Vmem – 180V
305 VDC
305 VDC
200 VDC
600/690V AC
3.0 VDC
Vmem – 75V
Vmem – 150V
Vmem – 150V
Vmem – 225V
Vmem – 225V
382 VDC
382 VDC
–
Note 1:Vtrigger is adjustable, these are the standard values.
Line Loss Mode = Coast
Line Loss Mode = Decel
700
650
Recover
Close
Trigger
Open
650
600
550
DC Bus Volts
DC Bus Volts
600
700
500
450
500
450
400
350
350
300
350
400
AC Input Volts
450
Line Loss Mode = Continue
700
650
600
DC Bus Volts
550
400
300
Recover
Close
Trigger
Open
Recover
Close
Trigger
Open
550
500
450
400
350
300
350
400
AC Input Volts
450
350
400
AC Input Volts
450
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” state if:
3 wire mode – it is not faulted and if all Enable and Not Stop inputs are
energized.
2 wire mode – it is not faulted and if all Enable, Not Stop, and Run inputs
are energized.
Power Loss Actions
The drive is designed to operate at a nominal bus voltage. When Vbus falls
below this nominal value by a significant amount, action can be taken to
preserve the bus energy and keep the drive logic alive as long as possible.
The drive will have three methods of dealing with low bus voltages:
• “Coast” – Disable the transistors and allow the motor to coast.
• “Decel” – Decelerate the motor at just the correct rate so that the energy
absorbed from the mechanical load balances the losses.
• “Continue” – Allow the drive to power the motor down to half bus
voltage.
184 [Power Loss Mode]
Power Loss
2-114
Default:
0
“Coast”
Sets the reaction to a loss of input power. Options:
Power loss is recognized when:
• DC bus voltage is ≤ 73% of [DC Bus
Memory] and [Power Loss Mode] is
set to “Coast”.
• DC bus voltage is ≤ 82% of [DC Bus
Memory] and [Power Loss Mode] is
set to “Decel”.
0
1
2
3
4
“Coast”
“Decel”
“Continue”
“Coast Input”
“Decel Input”
013
185
Coast
This is the default mode of operation.
The drive determines a power loss has occurred if the bus voltage drops
below Vtrigger. If the drive is running the inverter output is disabled and the
motor coasts.
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.
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.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls
below Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes
if the bus voltage rises above Vclose
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. The drive then accelerates at the programmed
rate to the set speed.
680V
620V
560V
500V
Bus Voltage
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 2.U for further information.
Decel
This mode of operation is useful if the mechanical load is high inertia and
low friction. By recapturing the mechanical energy, converting it to
electrical energy and returning it to the drive, the bus voltage is maintained.
As long as there is mechanical energy, the ride through time is extended and
the motor remains fully fluxed up. If AC input power is restored, the drive
can ramp the motor to the correct speed without the need for reconnecting.
The drive determines a power loss has occurred if the bus voltage drops
below Vtrigger.
If the drive is running, the inertia ride through function is activated.
The load is decelerated at just the correct rate so that the energy absorbed
from the mechanical load balances the losses and bus voltage is regulated to
the value Vinertia.
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.
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.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls
below Vmin and the UnderVoltage bit in [E238 Fault Config 1] is set.
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. The power loss alarm is cleared.
If the drive is still in inertia ride through operation, the drive immediately
accelerates at the programmed rate to the set speed. If the drive is coasting
and it is in a “run permit” state, the reconnect algorithm is run to match the
speed of the motor. The drive then accelerates at the programmed rate to the
set speed.
680V
620V
560V
500V
Bus Voltage
407V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 2.U for further information.
Half Voltage
This mode provides the maximum power ride through. In a typical
application 230VAC motors are used with a 480VAC drive, the input
voltage can then drop to half and the drive is still able to supply full power
to the motor.
!
ATTENTION: To guard against drive damage, a minimum line
impedance must be provided to limit inrush current when the
power line recovers. The input impedance should be equal or
greater than the equivalent of a 5% transformer with a VA rating
6 times the drive’s input VA rating.
The drive determines a power loss has occurred if the bus voltage drops
below Vtrigger.
If the drive is running the inverter output is disabled and the motor coasts.
If the bus voltage drops below Vopen/Vmin (In this mode of operation
Vopen and Vmin are the same value) or if the Enable input is de-energized,
the inverter output is disabled and the motor coasts. If the Not Stop or Run
inputs are de-energized, the drive stops in the programmed manner.
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.
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.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls
below Vmin and the UnderVoltage bit in [Fault Config 1] is set.
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 coasting and if it is in a “run permit” state, the reconnect
algorithm is run to match the speed of the motor. The drive then accelerates
at the programmed rate to the set speed.
680V
620V
560V
Bus Voltage
365V
305V
Motor Speed
Power Loss
Output Enable
Pre-Charge
Drive Fault
480V example shown, see Table 2.U for further information.
Coast Input (PowerFlex700 Only)
This mode can provide additional ride through time by sensing the power
loss via an external device that monitors the power line and provides a
hardware power loss signal. This signal is then connected to the drive
through the “pulse” input (because of its high-speed capability). Normally
this hardware power loss input will provide a power loss signal before the
bus drops to less than Vopen.
The drive determines a power loss has occurred if the “pulse” input is
de-energized OR the bus voltage drops below Vopen. If the drive is running,
the inverter output is disabled.
The Power Loss alarm in [Drive Alarm 1] is set and the power loss timer
starts.
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.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls
below Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes
if the bus voltage rises above Vclose.
If the “pulse” input is re energized and the pre-charge relay is closed, 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. The drive then accelerates at the programmed
rate to the set speed.
Decel Input (PF700 only)
This mode can provide additional ride through time by sensing the power
loss via an external device that monitors the power line and provides a
hardware power loss signal. This signal is then connected to the drive
through the “pulse” input (because of its high-speed capability). Normally
this hardware power loss input will provide a power loss signal before the
bus drops to less than Vopen.
The drive determine a power loss has occurred if the “pulse” input is
de-energized or the bus voltage drops below Vopen.
If the drive is running, the inertia ride through function is activated. The
load is decelerated at just the correct rate so that the energy absorbed from
the mechanical load balances the losses and bus voltage is regulated to the
value Vmem.
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 inverter
output is disabled and the motor coasts.
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.
The drive faults with a F003 – Power Loss fault if the power loss timer
exceeds [Power Loss Time] and the Power Loss bit in [E238 Fault Config 1]
is set.
The drive faults with a F004 – UnderVoltage fault if the bus voltage falls
below Vmin and the UnderVoltage bit in [Fault Config 1] is set.
The pre-charge relay opens if the bus voltage drops below Vopen and closes
if the bus voltage rises above Vclose.
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.
If the drive is in a “run permit” state, the reconnect algorithm is run to
match the speed of the motor. The drive then accelerates at the programmed
rate to the set speed.
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. Preset
frequencies have a range of plus/minus [Maximum Speed].
Process PI Loop
Process PI Loop
2-121
[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. The function is designed to be used
in applications that require simple control of a process without external
control devices. The PI function allows the microprocessor to follow a
single process control loop.
The PI function reads a process variable input to the drive and compares it
to a desired setpoint stored in the drive. The algorithm will then adjust the
output of the PI regulator, changing drive output frequency to try and make
the process variable equal the setpoint.
Proportional control (P) adjusts output based on size of the error (larger
error = proportionally larger correction). If the error is doubled, then the
output of the proportional control is doubled and, conversely, if the error is
cut in half then the output of the proportional output will be cut in half. With
proportional control there is always an error, so the feedback and the
reference are never equal.
Integral control (I) adjusts the output based on the duration of the error.
(The longer the error is present, the harder it tries to correct). The integral
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).
Derivative Control (D) adjusts the output based on the rate of change of the
error and, by itself, tends to be unstable. The faster that the error is
changing, the larger change to the output. Derivative control is generally not
required and, when it is used, is almost always combined with proportional
and integral control (PID).
The PI function can perform a combination of proportional and integral
control. It does not perform derivative control, however, the accel / decel
control of the drive can be considered as providing derivative control.
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.
The selection between these two modes of operation is done in the [PI
Configuration] parameter.
Process Trim
Process Trim takes the output of PI regulator and sums it with a master
speed reference to control the process. In the following example, the master
speed reference sets the wind/unwind speed and the dancer pot signal is
used as a PI Feedback to control the tension in the system. An equilibrium
point is programmed as PI Reference, and as the tension increases or
decreases during winding, the master speed is trimmed to compensate and
maintain tension near the equilibrium point.
0 Volts
Equilibrium Point
[PI Reference Sel]
Dancer Pot
[PI Feedback Sel]
10 Volts
Master Speed Reference
When the PI is disabled the commanded speed is the ramped speed
reference.
Slip
Comp
+
Slip Adder
+
Spd Ref
PI Ref
PI Fbk
Open
Loop
Linear Ramp
& S-Curve
Spd Cmd
+
Process PI
Controller
PI Disabled
+
Process
PI
Speed Control
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
+
Spd Ref
PI Ref
PI Fbk
Open
Loop
Linear Ramp
& S-Curve
Spd Cmd
+
Process PI
Controller
PI Enabled
+
Process
PI
Speed Control
Exclusive Control
Process Control takes the output of PI regulator as the speed command. No
master speed reference exists and the PI Output directly controls the drive
output.
In the pumping application example below, the reference or setpoint is the
required pressure in the system. The input from the transducer is the PI
feedback and changes as the pressure changes. The drive output frequency
is then increased or decreased as needed to maintain system pressure
regardless of flow changes. With the drive turning the pump at the required
speed, the pressure is maintained in the system.
Pump
Motor
PI Feedback
Pressure
Transducer
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.
When the PI is disabled the commanded speed is the ramped speed
reference.
2-124
Process PI Loop
Slip
Comp
+
Slip Adder
+
Linear Ramp
& S-Curve
Spd Ref
Open
Loop
Spd Cmd
Process
PI
PI Ref
PI Fbk
Process PI
Controller
Speed Control
PI Disabled
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.
+
Slip Adder
+
Linear Ramp
& S-Curve
Spd Ref
Slip
Comp
Open
Loop
Spd Cmd
Process
PI
PI Ref
PI Fbk
Process PI
Controller
PI Enabled
Speed Control
Configuration
To operate the drive in PI regulator Mode, the speed regulation mode must
be changed by selecting “Process PI” through the [Speed Control]
parameter.
Three parameters are used to configure, control, and indicate the status of
the logic associated with the Process PI controller; [PI Configuration], [PI
Control], and [PI Status]. Together these three parameters define the
operation of the PI logic.
1. [PI Configuration] is a set of bits that select various modes of operation.
The value of this parameter can only be changed while the drive is
stopped.
• Exclusive Mode - see page 2-123.
• Invert Error - This feature changes the “sign” of the error, creating a
decrease in output for increasing error and an increase in output for
decreasing error. An example of this might be an HVAC system with
thermostat control. In Summer, a rising thermostat reading commands
an increase in drive output because cold air is being blown. In Winter,
a falling thermostat commands an increase in drive output because
warm air is being blown.
The PI has the option to change the sign of PI Error. This is used
when an increase in feedback should cause an increase in output.
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 Fdbk Sel
PI Error
–
PI_Config
.Sqrt
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. Refer to diagram 2 below.
If PI is not enabled the PI Integrator may be initialized to the PI
Pre-load Value or the current value of the commanded speed. The
operation of Preload is selected in the PI Configuration parameter.
PI_Config
.PreloadCmd
PI_Status
.Enabled
Preload Value
PI Integrator
Spd Cmd
By default, Pre-load Command is off and the PI Load Value is zero,
causing a zero to be loaded into the integrator when the PI is disabled.
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. This may result in the PI reaching
steady state sooner, however if the step is too large the drive may go
into current limit which will extend the acceleration.
PI Enabled
PI Pre-load Value
PI Output
Spd Cmd
PI Pre-load Value = 0
PI Pre-load Value > 0
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.
PI Enabled
Start at Spd Cmd
PI Output
Spd Cmd
Pre-load to Command Speed
When the PI is configured to have exclusive control of the
commanded speed and the drive is in current limit or voltage limit the
integrator is preset to the commanded speed so that it knows where to
resume when no longer in limit.
• Ramp Ref - The PI Ramp Reference feature is used to provide a
smooth transition when the PI is enabled and the PI output is used as a
speed trim (not exclusive control),.
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. After the PI reference reaches the selected value the
ramp is bypassed until the PI is disabled and enabled again. S-curve is
not available as part of the PI linear ramp.
• Zero Clamp - This feature limits the possible drive action to one
direction only. Output from the drive will be from zero to maximum
frequency forward or zero to maximum frequency reverse. This
removes the chance of doing a “plugging” type operation as an
attempt to bring the error to zero.
The PI has the option to limit operation so that the output frequency
will always have the same sign as the master speed reference. The
zero clamp option is selected in the PI Configuration parameter. Zero
clamp is disabled when PI has exclusive control of speed command.
For example, if master speed reference is +10 Hz and the output of
the PI results in a speed adder of –15 Hz, zero clamp would limit the
output frequency to not become less than zero. Likewise, if master
speed reference is –10 Hz and the output of the PI results in a speed
adder of +15 Hz, zero clamp would limit the output frequency to not
become greater than zero.
Process PI Loop
≥0
Spd Ref
Linear
Ramp
& S-Curve
Spd Ramp
+32K
PI_Config
.ZeroClamp
+
2-127
0
0
Spd Cmd
-32K
+
+32K
PI Output
PI Ref
Process PI
Controller
-32K
PI Fbk
• Feedback Square Root - This feature uses the square root of the
feedback signal as the PI feedback. This is useful in processes that
control pressure, since centrifugal fans and pumps vary pressure with
the square of speed.
The PI has the option to take the square root of the selected feedback
signal. This is used to linearize the feedback when the transducer
produces the process variable squared. The result of the square root is
normalized back to full scale to provide a consistent range of
operation.
The option to take the square root is selected in the PI Configuration
parameter.
Normalized SQRT(Feedback)
100.0
75.0
50.0
25.0
0.0
-25.0
-50.0
-75.0
-100.0
-100.0
-75.0
-50.0
-25.0
0.0
25.0
50.0
75.0
100.0
Normalized Feedback
• Stop Mode (PF700 Only). When Stop Mode is set to “1” and a Stop
command is issued to the drive, the PI loop will continue 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. This bit is active in Trim mode only.
• Anti-Wind Up (PF700 Only). When Anti-Windup is set to “1” the
PI loop will automatically prevent the integrator from creating an
excessive error that could cause loop instability. The integrator will be
automatically controlled without the need for PI Reset or PI Hold
inputs.
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.
• PI Enable - The PI loop can be enabled/disabled. The Enabled status
of the PI loop determines when the PI regulator output is part or all of
the commanded speed. The logic evaluated for the PI Enabled status
is shown in the following ladder diagram.
The drive must be in run before the PI Enabled status can turn on. The
PI will remain disabled when the drive is jogged. The PI is disabled
when the drive begins a ramp to stop, except in the PowerFlex 700
when it is in Trim mode and the Stop mode bit in [PI Configuration]
is on.
When a digital input is configured as “PI Enable,” the PI Enable bit of
[PI Control] must be turned on for the PI loop to become enabled.
If a digital input is not configured as “PI Enable” and the PI Enable
bit in [PI Control] is turned on, then the PI loop may become enabled.
If the PI Enable bit of [PI Control] is left continuously, then the PI
may become enabled as soon as the drive goes into run. If analog
input signal loss is detected, the PI loop is disabled.
Running
Stopping
DigInCfg
.PI_Enable
DigInCfg
.PI_Enable
DigIn
.PI_Enable
PI_Control
.PI_Enable
Signal Loss
PI_Status
.Enabled
PI_Control
.PI_Enable
• PI Hold - The Process PI Controller has the option to hold the
integrator at the current value so if some part of the process is in limit
the integrator will maintain the present value to avoid windup in the
integrator.
The logic to hold the integrator at the current value is shown in the
following ladder diagram. There are three conditions under which
hold will turn on.
– If a digital input is configured to provide PI Hold and that digital
input is turned on then the PI integrator will stop changing. Note that
when a digital input is configured to provide PI Hold that takes
precedence over the PI Control parameter.
– If a digital input is not configured to provide PI Hold and the PI Hold
bit in the PI Control parameter is turned on then the PI integrator will
stop changing.
Process PI Loop
2-129
– If the current limit or voltage limit is active then the PI is put into
hold.
DigInCfg
.PI_Hold
DigInCfg
.PI_Hold
DigIn
.PI_Hold
PI_Status
.Hold
PI_Control
.PI_Hold
Current Lmt
or Volt Lmt
• PI Reset – This feature holds the output of the integral function at
zero. The term “anti windup” is often applied to similar features. It
may be used for integrator preloading during transfer and can be used
to hold the integrator at zero during “manual mode”. Take the
example of a process whose feedback signal is below the reference
point, creating error. The drive will increase its output frequency in an
attempt to bring the process into control. If, however, the increase in
drive output does not zero the error, additional increases in output will
be commanded. When the drive reaches programmed Maximum
Frequency, it is possible that a significant amount of integral value
has been “built up” (windup). This may cause undesirable and sudden
operation if the system were switched to manual operation and back.
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.
3. [PI Status] parameter is a set of bits that indicate the status of the
process PI controller
• Enabled – The loop is active and controlling the drive output.
• Hold – A signal has been issued and the integrator is being held at its
current value.
• Reset – A signal has been issued and the integrator is being held at
zero.
• In Limit – The loop output is being clamped at the value set in [PI
Upper/Lower Limit].
PI Reference and Feedback
The selection of the source for the reference signal is entered in the PI
Reference Select parameter. The selection of the source for the feedback
signal is selected in the PI Feedback Select parameter. The reference and
feedback have the same limit of possible options.
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. The value used for feedback is displayed in PI Feedback as a
read only parameter. These displays are active independent of PI Enabled.
Full scale is displayed as 100.00.
Refer to Analog Input Configuration on page 2-6.
PI Setpoint
This parameter can be used as an internal value for the setpoint or reference
for the process. If [PI Reference Sel] points to this Parameter, the value
entered here will become the equilibrium point for the process.
PI Output
The PI Error is then sent to the Proportional and Integral functions, which
are summed together.
PI Gains
The PI Proportional Gain and the PI Integral Gain parameters determine the
response of the PI.
The PI Proportional Gain is unitless and defaults to 1.00 for unit gain. With
PI Proportional Gain set to 1.00 and PI Error at 1.00% the PI output will be
1.00% of maximum frequency.
The PI Integral Gain is entered in seconds. If the PI Integral Gain is set to
2.0 seconds and PI Error is 100.00% the PI output will integrate from 0 to
100.00% in 2.0 seconds.
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. If the integrator
reaches the limit the value is clamped and the InLimit bit is set in the PI
Status parameter to indicate this condition.
The limits are entered in the range of 100.00.
PI Positive Limit must always be greater than PI Negative Limit.
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.
PI PosLmt
PI NegLmt
PI Kp
+
PI Error
PI Output
*
+
PI_Status
.Hold
*
+
+
In Limit
PI Ki
-1
Z
Output Scaling
The output value produced by the PI is displayed as ±100.00. Internally this
is represented by ±32767 which corresponds to maximum frequency.
Figure 2.14 Process PI Block Diagram
PI_Config
.ZeroClamp
PI_Config
.Exclusive
PI_Status
.Enabled
Linear Ramp
& S-Curve
Spd Ref
+32K
+
Spd Cmd
Spd Ramp
+
-32K
PI Pos Limit
+32K
PI Neg Limit
0
0
PI Kp
PI ExcessErr
abs
*(PI Ref Sel)
PI Ref
Linear
Ramp
PI Cmd
+
≥
≥0
PI XS Error
-
+
+
*
+
PI_Config
.RampCmd
In Limit
-1
z
0
*(PI Fbk Sel)
PI Fbk
PI_Config
.Sqrt
PI_Config
.Invert
PI Ki
PI_Status
.Hold
Preload Value
Spd Cmd
Spd Cmd
PI_Config
.PreloadCmd
PI_Config
.Exclusive
PI_Status
.Enabled
Current Limit
or Volt Limit
PI Output
*
-
PI_Status
.Enabled
Zclamped
+
PI Error
-32K
2-132
Reflected Wave
Reflected Wave
[Compensation]
The pulses from a Pulse Width Modulation (PWM) inverter using IGBTs
are very short in duration (50 nanoseconds to 1 millisecond). These short
pulse times combined with the fast rise times (50 to 400 nanoseconds) of
the IGBT, will result in excessive over-voltage transients at the motor.
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. The minimum
time between PWM pulses is 10 microseconds. The modifications to the
PWM modulator limit the over-voltage transient to 2.25 per unit volts
line-to-line peak at 600 feet of cable.
400 V Line = 540V DC bus x 2.25 = 1215V
480 V Line = 650V DC bus x 2.25 = 1463V
600 V Line = 810V DC bus x 2.25 = 1823 V
The software is standard and requires no special parameters or settings.
500
V/div
Inverter
<Tα
0
1670 Vpk
Motor
500
V/div
0
0
5
10
15
20
25
30
35
40
45
50
Time ( sec)
The above figure shows the inverter line-to-line output voltage (top trace)
and the motor line-to-line voltage (bottom trace) for a 10 HP, 460V AC
inverter, and an unloaded 10 HP AC induction motor at 60 Hz operation.
500 ft. of #12 AWG cable connects the drive to the motor.
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. Thus, the second pulse arrives at a
point in the motor terminal voltage's natural response and excites a motor
over-voltage transient greater than 2 pu. The amplitude of the double pulsed
motor over-voltage is determined by a number of variables. These include
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. The output line-to-line voltage was measured at the motor
terminals in 100 feet increments.
No Correction vs Correction Method at 4 kHz and 8 kHz Carrier
Frequencies - Vbus = 650, fe = 60 Hz
2.6
No Correction 4 kHz Carrier
Corrected 4 kHz Carrier
No Correction 8 kHz Carrier
Corrected 8 kHz Carrier
2.5
per Unit Vout/Vbus
2.4
2.3
2.2
2.1
2
1.9
1.8
1.7
1.6
0
100
200
300
400
Cable Length (Feet)
500
600
Without the correction, the overvoltage increases to unsafe levels with
increasing cable length for both carrier frequencies.
The patented modulation correction code reduces the overvoltage for both
carrier frequencies and maintains a relatively flat overvoltage level for
increasing cable lengths beyond 300 feet.
To determine the maximum recommended motor cable lengths for a
particular drive refer to Cable, Motor Lengths on page 2-32.
Refer to: www.ab.com/drives/techpapers/menu for detailed technical papers.
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]
Resets selected meters to zero.
Default:
0
“Ready”
Options:
0
1
2
“Ready”
“MWh”
“Elapsed Time”
0 = Ready
1 = Reset kW Hour Meter
2 = Reset Elapsed Time Meter
Reset Run
Refer to Auto Restart (Reset/Run) on page 2-25.
RFI Filter Grounding
Refer to “Wiring and Grounding Guidelines for PWM AC Drives,”
publication DRIVES-IN001A-EN-P.
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. By adjusting the percentage of S
Curve applied to the normal accel / decel ramps, the ramp takes the shape of
an “S”. This allows a smoother transition that produces less mechanical
stress and smoother control for light loads.
Linear Accel & Decel
Acceleration is defined as moving away from zero; deceleration is defined
as moving toward zero. The linear acc / dec ramp is active when the S
curve% is set to zero. The accel time and maximum frequency determine
the ramp rate for speed increases while decel time and maximum frequency
determine the ramp rate for speed decreases. Separate times can be set for
accel and decel. In addition, a second set of accel and decel times is
available. In this example Ta = 1.0 sec, Td = 2.0 sec and Maximum
Frequency is set to 60.0 Hz.
80.0
60.0
40.0
Hz
20.0
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
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%. The other lines show 25%, 50%, and 100%
S-curve. At 25% S-curve acceleration time is extended by 0.5 seconds (2.0
* 25%). Note that the linear portion of this line has the same slope as when
s-curve is set to zero.
70.0
60.0
50.0
Hz
S Curve
2-135
40.0
30.0
20.0
10.0
0.0
0.0
0.5
1.0
1.5
2.0
Seconds
2.5
3.0
3.5
4.0
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
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
Seconds
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.
70.0
60.0
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
0.5
1.0
1.5
Seconds
2.0
2.5
3.0
Crossing Zero Speed
When the commanded frequency passes through zero the frequency will
S-curve to zero and then S-curve to the commanded frequency.
80.0
60.0
40.0
20.0
Hz
2-136
0.0
-20.0
-40.0
-60.0
-80.0
0.0
1.0
2.0
3.0
Seconds
4.0
5.0
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.
70.0
60.0
Hz
50.0
40.0
30.0
20.0
10.0
0.0
0.0
1.0
2.0
3.0
Seconds
Scaling Blocks
See Scaling Blocks on page 2-9 and page 2-20.
4.0
5.0
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. By programming the drive current limit value and
enabling the electronic shear pin, current to the motor is limited, and if
excess current is demanded by the motor, the drive will fault.
Configuration
The Shear Pin Fault is activated by setting Bit 4 of [Fault Config 1] to “1.”
238 [Fault Config 1]
Enables/disables annunciation of the listed faults.
De
c
Au el Inh
tR ib
Sh st Tr t
ea ie
Mo r Pi s
tor n
Ov
erL
Un
d
de
Po rVo
we lta
r L ge
os
s
Shear Pin Fault
1 =Enabled
0 =Disabled
x =Reserved
x x x x x x x x x 1 0 0 1 x 1 0
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Bit #
Factory Default Bit Values
The programmable current limit [Current Lmt Sel] should also set to
identify the source of the current limit value. If “Cur Lim Val” is selected,
then [Current Lmt Val] should be set to the required limit value.
DYNAMIC CONTROL
2-138
147 [Current Lmt Sel]
Default:
0
“Cur Lim Val”
Selects the source for the adjustment of Options:
current limit (i.e. parameter, analog input,
etc.).
0
1
2
“Cur Lim Val”
“Analog In 1”
“Analog In 2”
146
149
A separate fault (Shear Pin Fault, F63) dedicated to the Shear Pin feature,
will be generated if the function is activated.
Application Example
In some applications, mechanical hardware can be damaged if the motor is
allowed to develop excess torque. If a mechanical jam should occur,
shutting down the system may be the only way to prevent damage. For
example, a chain conveyor may be able to “hook” itself, causing a jam on
the conveyor. Excess torque from the motor could cause chain or other
mechanical damage.
By programming the Shear Pin feature, the user can cause the drive to fault,
stopping the excess torque before mechanical damage occurs.
Skip Frequency
Skip Frequency
2-139
Figure 2.15 Skip Frequency
Frequency
Command
Frequency
Drive Output
Frequency
(A)
(A)
Skip + 1/2 Band
35 Hz
Skip Frequency
30 Hz
Skip – 1/2 Band
(B)
25 Hz
(B)
Time
Some machinery may have a resonant operating frequency that must be
avoided to minimize the risk of equipment damage. To assure that the motor
cannot continuously operate at one or more of the points, skip frequencies
are used. Parameters 084-086, ([Skip Frequency 1-3]) are available to set
the frequencies to be avoided.
The value programmed into the skip frequency parameters sets the center
point for an entire “skip band” of frequencies. The width of the band (range
of frequency around the center point) is determined by parameter 87, [Skip
Freq Band]. The range is split, half above and half below the skip frequency
parameter.
If the commanded frequency of the drive is greater than or equal to the skip
(center) frequency and less than or equal to the high value of the band (skip
plus 1/2 band), the drive will set the output frequency to the high value of
the band. See (A) in Figure 2.15.
If the commanded frequency is less than the skip (center) frequency and
greater than or equal to the low value of the band (skip minus 1/2 band), the
drive will set the output frequency to the low value of the band. See (C) in
Figure 2.15.
2-140
Skip Frequency
Skip Frequency Examples
The skip frequency will have
hysteresis so the output does not
toggle between high and low
values. Three distinct bands can
be programmed. If none of the
skip bands touch or overlap, each
band has its own high/low limit.
Max. Frequency
Skip Frequency 1
Skip Band 1
Skip Frequency 2
Skip Band 2
0 Hz
If skip bands overlap or touch, the
center frequency is recalculated
based on the highest and lowest
band values.
400 Hz.
Skip Frequency 1
Skip Frequency 2
Adjusted
Skip Band
w/Recalculated
Skip Frequency
0 Hz
If a skip band(s) extend beyond
the max frequency limits, the
highest band value will be
clamped at the max frequency
limit. The center frequency is
recalculated based on the
highest and lowest band values.
400 Hz.
Max.Frequency
Skip
Adjusted
Skip Band
w/Recalculated
Skip Frequency
0 Hz
If the band is outside the limits,
the skip band is inactive.
400 Hz.
Skip Frequency 1
Inactive
Skip Band
60 Hz. Max.
Frequency
0 Hz
Acceleration and deceleration are not affected by the skip frequencies.
Normal accel/decel will proceed through the band once the commanded
frequency is greater than the skip frequency. See (A) & (B) in Figure 2.15.
This function affects only continuous operation within the band.
Sleep Mode
Sleep Mode
2-141
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]. Setting [Sleep-Wake Mode] to
“Direct” enables the sleep wake function.
Requirements
In addition to enabling the sleep function with [Sleep-Wake Mode], at least
one of the following assignments must be made to a digital input: Enable,
Stop-CF, Run, Run Fwd or Run Rev, and the input must be closed. All
normal Start Permissives must also be satisfied (Not Stop, Enable, Not
Fault, Not Alarm, etc.).
Conditions to Start/Restart
!
ATTENTION: Enabling the Sleep-Wake function can cause
unexpected machine operation during the Wake mode. Equipment
damage and/or personal injury can result if this parameter is used
in an inappropriate application. Do Not use this function without
considering the table below and applicable local, national &
international codes, standards, regulations or industry guidelines.
Table 2.V Conditions Required to Start Drive (1)(2)(3)
Input
After Power-Up
Stop
Stop Closed
Wake Signal
Enable
Enable Closed
Wake Signal (4)
Run
Run Closed
Run For. Wake Signal
Run Rev.
After a Drive Fault
Reset by Stop-CF,
HIM or TB
Stop Closed
Wake Signal
New Start or Run Cmd.(4)
Enable Closed
Wake Signal
New Start or Run Cmd.(4)
New Run Cmd.(5)
Wake Signal
After a Stop Command
Reset by Clear HIM or TB
Faults (TB)
Stop Closed Stop Closed
Wake Signal Analog Sig. > Sleep Level (6)
New Start or Run Cmd.(4)
Enable Closed Enable Closed
Wake Signal Analog Sig. > Sleep Level (6)
New Start or Run Cmd.(4)
Run Closed
New Run Cmd.(5)
Wake Signal Wake Signal
(1) When power is cycled, if all conditions are present after power is restored, restart will occur.
(2) If all conditions are present when [Sleep-Wake Mode] is “enabled,” the drive will start.
(3) The active speed reference is determined as explained in the User Manual. The Sleep/Wake function and the
speed reference may be assigned to the same input.
(4) Command must be issued from HIM, TB or network.
(5) Run Command must be cycled.
(6) Signal does not need to be greater than wake level.
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). On power up, timers are initialized to
the state that does not permit a start condition. When the analog signal
satisfies the level requirement, the timers start counting.
Interactive functions
Separate start commands are also honored (including a digital input “start”),
but only when the sleep timer is not satisfied. Once the sleep timer times
out, the sleep function acts as a continuous stop. There are two exceptions
to this, which will ignore the Sleep/Wake function:
1. When a device is commanding “local” control
2. When a jog command is being issued.
When a device is commanding “local” control, the port that is commanding
it has exclusive start control (in addition to ref select), essentially overriding
the Sleep/Wake function, and allowing the drive to run in the presence of a
sleep situation. This holds true even for the case of Port 0, where a digital
input start or run will be able to override a sleep situation.
Sleep / Wake Levels
Normal operation will require that [Wake Level] be set greater than or equal
to [Sleep Level]. However, there are no limits that prevent the parameter
settings from crossing, but the drive will not start until such settings are
corrected. These levels are programmable while the drive is running. If
[Sleep Level] is made greater than [Wake Level] while the drive is running,
the drive will continue to run as long as the analog input remains at a level
that doesn’t trigger the sleep condition. Once the drive goes to sleep in this
situation, it will not be allowed to restart until the level settings are
corrected (increase wake, or decrease sleep). If however, the levels are
corrected prior to the drive going to sleep, normal Sleep/Wake operation
will continue.
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.
Also, [Analog In x Hi] and [Analog In x Lo] parameters have no affect on
the function. However, the factory calibrated result will be used. In addition,
the absolute value of the calibrated result will be used, thus making the
function useful for bipolar direction applications. The analog in loss
function is unaffected and therefore operational with the Sleep/Wake
function, but not tied to the sleep or wake levels.
Figure 2.16 Sleep/Wake Function
Drive
Run
Sleep-Wake
Function
Wake Up
Go to Sleep
Start
Stop
Sleep Timer
Satisfied
Sleep Level
Satisfied
Wake Timer
Satisfied
Wake Level
Satisfied
Wake
Time
Wake Level
Sleep Level
Analog Signal
Example Conditions
Wake Time = 3 Seconds
Sleep Time = 3 Seconds
Sleep
Time
Wake
Time
Sleep
Time
2-144
Speed Control Speed Mode Speed Regulation
Speed Control
Speed Mode
Speed Regulation
The purpose of speed regulation is to allow the drive to adjust certain
operating conditions, such as output frequency, to compensate for actual
motor speed losses in an attempt to maintain motor shaft speed within the
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):
• Open Loop - No speed control is offered
• Slip Comp - Slip Compensation is active – approximately 5% regulation
• Process PI – The PI Loop sets the actual speed based on process
variables
080
Vector
[Feedback Select]
Selects the source for motor speed
feedback.
Default:
0
“Open Loop”
Options:
0
1
2
3
4
5
“Open Loop”
“Slip Comp”
“Reserved”
“Encoder”
“Encdless/Db”
“Simulator”
0
“Open Loop”
0
1
2
“Open Loop”
“Slip Comp”
“Process PI”
“Open Loop” (0) - no encoder is present,
and slip compensation is not needed.
“Slip Comp” (1) - tight speed control is
needed, and encoder is not present.
“Encoder” (3) - an encoder is present.
“Encdless/Db” (4), Encoderless w/
Deadband - no encoder and operation
below 1Hz/30 RPM is required. This will
limit drive operation below a reference of
1Hz/30 RPM (clamping the speed and
torque regulators to zero).
“Simulator” (5) - Simulates a motor for
testing drive operation and interface
checkout.
Default:
Standard [Speed Mode]
Sets the method of speed regulation.
Options:
Open Loop
As the load on an induction motor increases, the rotor speed or shaft speed
of the motor decreases, creating additional slip (and therefore torque) to
drive the larger load. This decrease in motor speed may have adverse effects
on the process. If the [Speed Mode] parameter is set to “Open Loop,” no
speed control will be exercised. Motor speed will be dependent on load
changes and the drive will make no attempt to correct for increasing or
decreasing output frequency due to load.
Slip Compensation
As the load on an induction motor increases, the rotor speed or shaft speed
of the motor decreases, creating additional slip (and therefore torque) to
drive the larger load. This decrease in motor speed may have adverse effects
on the process. If speed control is required to maintain proper process
control, the slip compensation feature of the PowerFlex drives can be
enabled by the user to more accurately regulate the speed of the motor
without additional speed transducers.
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]. During drive commissioning this parameter
is set to the RPM that the motor will slip when operating with Full Load
Amps. The user may adjust this parameter to provide more or less slip.
As mentioned above, induction motors exhibit slip which is the difference
between the stator electrical frequency, or output frequency of the drive, and
the induced rotor frequency.
The slip frequency translates into a slip speed resulting in a reduction in
rotor speed as the load increases on the motor. This can be easily seen by
examining Figure 2.17.
Rotor Speed
Figure 2.17 Rotor Speed with/without Slip Compensation
Slip Compensation
Inactive
Slip Compensation
Active
Load
Applied
Load
Applied
No Load
0.5 p.u. Load
1.0 p.u. Load
1.5 p.u. Load
1.5 p.u. Load
1.0 p.u. Load
0.5 p.u. Load
Slip Compensation
Active
Load
Removed
Slip @
F.L.A.
0
0
Time
Without slip compensation active, as the load increases from no load to
150% of the motor rating, the rotor speed decreases approximately
proportional to the load.
With slip compensation, the correct amount of slip compensation is added
to the drive output frequency based on motor load. Thus, the rotor speed
returns to the original speed. Conversely, when the load is removed, the
rotor speed increases momentarily until the slip compensation decays to
zero.
Motor nameplate data must be entered by the user in order for the drive to
correctly calculate the proper amount of slip compensation. The motor
nameplate reflects slip in the rated speed value at rated load. The user can
enter the Motor Nameplate RPM, Motor Nameplate Frequency, the Motor
Nameplate Current, Motor Nameplate Voltage, and Motor Nameplate HP/
kW and during commissioning the drive calculates the motor rated slip
frequency and displays it in [Slip RPM @ FLA]. The user can adjust the
slip compensation for more accurate speed regulation, by increasing or
decreasing [Slip RPM @ FLA] value.
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. The drive
scales the amount of slip compensation to the motor rated current. The
amount of slip frequency added to the frequency command is then scaled by
the sensed torque current (indirect measurement of the load) and displayed.
Slip compensation also affects the dynamic speed accuracy (ability to
maintain speed during “shock” loading). The effect of slip compensation
during transient operation is illustrated in Figure 2.18. Initially, the motor is
operating at some speed and no load. At some time later, an impact load is
applied to the motor and the rotor speed decreases as a function of load and
inertia. And finally, the impact load is removed and the rotor speed
increases momentarily until the slip compensation is reduced based on the
applied load.
When slip compensation is enabled the dynamic speed accuracy is
dependent on the filtering applied to the torque current. The filtering delays
the speed response of the motor/drive to the impact load and reduces the
dynamic speed accuracy. Reducing the amount of filtering applied to the
torque current can increase the dynamic speed accuracy of the system.
However, minimizing the amount of filtering can result in an unstable
motor/drive. The user can adjust the Slip Comp Gain parameter to decrease
or increase the filtering applied to the torque current and improve the
system performance.
Figure 2.18 Rotor Speed Response Due to Impact Load and Slip Com Gain
Impact Load
Removed
Increasing Slip
Comp Gain
Impact Load
Applied
Speed
2-146
Rotor Speed
Increasing Slip
Comp Gain
Reference
0
0
Time
Application Example - Baking Line
The diagram below shows a typical application for the Slip Compensation
feature. The PLC controls the frequency reference for all four of the drives.
Drive #1 and Drive #3 control the speed of the belt conveyor. Slip
compensation will be used to maintain the RPM independent of load
changes caused by the cutter or dough feed. By maintaining the required
RPM, the baking time remains constant and therefore the end product is
consistent.
With the Slip Compensation feature, the process will only require a new
speed reference when the product is changed. The user will not have to tune
the drive due to a different load characteristic.
Speed Control Speed Mode Speed Regulation
Dough Stress
Relief
2-147
Cookie Line
CUTTERS
OVEN
5/40
PowerFlex
Drive
PowerFlex
Drive
PowerFlex
Drive
PowerFlex
Drive
#1
#2
#3
#4
Process PI – See 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.
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)
Analog Input
Preset Speed Parameter
Jog Speed Parameter
Communications Adapter
Process PI Loop
Digital Input MOP
Selection
Binary Logic
Some references can be selected by binary logic, through digital inputs to
the terminal block or bit manipulation of the Logic Command Word in a
communications adapter. These sources are used when the drive is in
“Auto” mode. The default reference is from the source selected in [Speed
Ref A Sel], parameter 90. This parameter can be set to any one of the 22
choices. If the binary logic selection is zero, this will be the active speed
reference.
Auto/Manual
Many applications require a “manual mode” where adjustments can be
made and setup can be done by taking local control of the drive speed.
Typically, these adjustments would be made via a “local” HIM mounted on
the drive. When all setup is complete, control of the drive frequency
command is turned over to automatic control from a remote source such as
a PLC, analog input etc.
The source of the speed reference is switched to one of two “manual”
sources when the drive is put into manual mode:
1. Local HIM
2. Analog Input to terminal block
If the selection is the HIM, then the digital or analog speed control on the
HIM provides the reference.
If the switch to manual mode was made via a digital input, (parameters
361-366 set to “18, Auto/Manual”) then the source for the reference is
defined in [TB Man Ref Sel], parameter 96. This can be either of the 2
analog inputs or the digital MOP.
When the drive is returned to automatic mode, the speed reference returns
to the source selected by the binary logic. Also see Auto/Manual on
page 2-23.
Speed Reference
2-149
Jog
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.
Figure 2.19 Speed Reference Selection
= Default
Auto Speed Ref Options
Trim
[Digital Inx Select]:
Speed Sel 3 2 1
0
0
0
0
1
1
1
1
Speed Ref A Sel, Parameter 090
Speed Ref B Sel, Parameter 093
Preset Speed 2, Parameter 102
Preset Speed 3, Parameter 103
Preset Speed 4, Parameter 104
Preset Speed 5, Parameter 105
Preset Speed 6, Parameter 106
Preset Speed 7, Parameter 107
DPI Port Ref 1-6, See Parameter 209
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
PI Exclusive Mode
[PI Configuration]:
Bit 0, Excl Mode = 0
Drive Ref Rslt
Mod Functions
(Skip, Clamp,
Direction, etc.)
Auto
Min/Max Speed
Commanded
Frequency
DPI Command
Acc/Dec Ramp
and
S Curve
Manual Speed Ref Options
HIM Requesting Auto/Manual
TB Man Ref Sel, Parameter 096
Jog Speed, Parameter 100
Speed Adders
PI Output
Slip Compensation
None
Pure Reference
to follower drive for
Frequency Reference
Man
Digital Input
Jog Command
Post Ramp
to follower drive for
Frequency Reference
[Speed Mode]:
2 "Process Pi"
1 "Slip Comp"
0 "Open Loop"
Output Frequency
Scaling
Scaling applies only to references from analog inputs and reference sources
selected in [Speed Ref x Sel], parameters 90/93.
Each analog input has its own set of scale parameters:
• [Analog In x Hi] sets the maximum level on input to be seen (i.e. 10
Volts).
• [Analog In x Lo] sets the minimum level on input to be seen (i.e. 0
Volts).
Each [Speed Ref x Sel] parameter has an additional set of scale parameters:
• [Speed Ref x Hi] selects the reference value for the maximum input
specified in [Analog In x Hi].
• [Speed Ref x Lo] selects the reference value for the minimum input
specified in [Analog In x Lo].
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. See
additional examples under Analog Inputs on page 2-9.
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
speed reference by a programmable amount. The source of the trim signal is
made via [Trim In Sel], parameter 117 and can be any of the sources that are
also used as references. [Trim Out Select], parameter 118 selects which of
the references, A/B will be trimmed.
If the trim source is an analog input, two additional scale parameters are
provide to scale the trim signal.
Figure 2.20 Trim
Trim Enable Select
A
Trim
B
Both
None
Reference A
Reference B
+
+
Trimmed
Reference A
+
+
Trimmed
Reference B
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. This is due to the positive and negative minimum speeds.
If the reference is positive and less than the positive minimum, it is set to the
positive minimum. If the reference is negative and greater than negative
minimum, it is set to the negative minimum. If the minimum is not 0,
hysteresis is applied at 0 to prevent bouncing between positive and negative
minimums. See below.
Speed Reference
Max Spd
2-151
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. This parameter also defines scaling for frequency
reference. This is the frequency that corresponds to 32767 counts when the
frequency reference is provided by a network.
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. It will be updated continually, not only when a start attempt is
made. See also Start Permissives on page 2-153.
Start Permissives
Start Permissives
2-153
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.
Permissive Conditions
1. No faults can be active.
2. No type2 alarms can be active.
3. The TB Enable input (if configured) must be closed.
4. The DC bus precharge logic must indicate it is a start permissive.
5. All Stop inputs must be negated (See special Digital Inputs Stops
Configuration issues below).
6. No configuration changes (parameters being modified) can be
in-progress.
If all permissive conditions are met, a valid start, run or jog command will
start the drive. The status of all inhibit conditions, except for item 6 above,
are reflected in the output parameter Start Inhibits. The configuration
change condition is a transient (short-term) condition and not directly user
controlled. It is therefore not reflected in the Start Inhibits parameter.
Note that the Start Inhibits conditions do not include any of the
functionality imposed by the DPI logic such as owners, masks, local
control, etc.
2-154
Start-Up
Start-Up
Start-Up Routines
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.
S.M.A.R.T. Start
During a Start Up, the majority of applications require changes to only a
few parameters. The LCD HIM on a PowerFlex 70 drive offers S.M.A.R.T.
start, which displays the most commonly changed parameters. With these
parameters, you can set the following functions:
S - Start Mode and Stop Mode
M - Minimum and Maximum Speed
A - Accel Time 1 and Decel Time 1
R - Reference Source
T - Thermal Motor Overload
To run a S.M.A.R.T. start routine:
Step
1. Press ALT and then Esc (S.M.A.R.T).
The S.M.A.R.T. start screen appears.
2. View and change parameter values as
desired. For HIM information, see
Appendix B.
3. Press ALT and then Sel (Exit) to exit
the S.M.A.R.T. start.
Key(s)
Example LCD Displays
ALT
Esc
ALT
Sel
S.M.A.R.T. List
Start Mode
Stop Mode
Minimum Speed
Basic Start Up
The Basic Start Up routine leads the user through the necessary information
in a simple question and answer format. The user can make the choice to
execute or skip any section of the routine. Below is a complete flow chart of
the routine.
Start-Up
2-155
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup
HIM
Basic Start Up (Top Level)
Main Menu:
<Diagnostics>
Parameter
Device Select
Memory Storage
StartUp
Preferences
Esc
0-2
Startup
Drive active?
Abort
Yes
PowerFlex 70
StartUp
.
The drive must
be stopped to
proceed. Press
Esc to cancel.
Any state
'Esc' key
No
Stop
0-3
Startup
previously
aborted?
7. Done
/Exit
Yes
PowerFlex 70
StartUp
.
Make a selection
Abort
<Backup>
Resume
StartUp Menu
Resume
Backup
Go to previous
state
Go to Backup
screen for previous
state
No
0-0
PowerFlex 70
StartUp
.
This routine is
to help setup a
drive for basic
applications.
Parameter access
through other
menus may be
necessary to
setup advanced
features.
Enter
0-1
PowerFlex 70
StartUp
.
Complete these
steps in order:
1. Input Voltage
2. Motr Dat/Ramp
3. Motor Tests
4. Speed Limits
5. Speed Control
6. Strt,Stop,I/O
7. Done / Exit
Go to 1-0
Backup
Startup Menu
Go to 2-0
1. Input
Voltage
2. Motor
Dat/Ramps
Go to 3-0
3. Motor
Tests
Go to 4-0
4. Speed
Limits
5. Speed
Control
Go to 5-0
6. Strt,Stop,
I/O
Go to 6-0
2-156
Start-Up
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (1)
Basic Start Up (Input Voltage)
1-0
StartUp
1. Input Voltage
This step should
be done only
when "alternate
voltage" is
needed (see user
manual). It will
reset all drive
parameters with
specific choice
of Volts and Hz.
Enter
Backup
Backup
Rated Volts
>300?
Yes
Backup
No
1-1
1-2
StartUp
1. Input Voltage
Enter choice for
Input Supply
400V, 50 Hz
<480V, 60 Hz>
StartUp
1. Input Voltage
Enter choice for
Input Supply
208V, 60 Hz
<240V, 60 Hz>
Enter
Enter
1-3
StartUp
1. Input Voltage
Reset all
parameters to
their defaults?
<Yes>
No
No
Yes
1-4
StartUp
1. Input Voltage
Clear fault to
continue.
Fault Clear
Go to 0-1 (2)
Start-Up
2-157
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (2)
2-0
Basic Start Up (Motor Data/Ramp)
StartUp
2. Motr Dat/Ramp
Use motor nameplate data and
required ramp
times for the
following steps.
Enter
2-1
StartUp
2. Motr Dat/Ramp
Enter choice for
Mtr NP Pwr Units
Enter
2-2
2-7
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Power
123.4 kW
xxx.x <> yyy.y
StartUp
2. Motr Dat/Ramp
Enter choice for
Stop Mode A
Backup
Enter
Enter
2-3
2-10
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP FLA
+456.78 Amps
xxx.xx <> yyy.yy
Backup
Stop Mode A
= "DC Brake" or
"Ramp to
Hold"?
No
Enter
2-4
StartUp
2. Motr Dat/Ramp
Enter choice for
DB Resistor Type
None
Internal
External
Yes
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Volts
123.4 Volt
xxx.x <> yyy.y
Enter
2-8
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
DC Brake Level
1.0 Amps
0.0 < 30.0 Amps
Enter
None - Bus Reg Mode A = Adj Freq.
Intenal - Bus Reg Mode A = Both, DB 1st.
External - Bus Reg Mode A = Both, DB 1st.
2-11
StartUp
2. Motr Dat/Ramp
Enter value for
Accel Time 1
6.0 Secs
0.0 < 60.0 secs
No
Enter
2-5
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP Hertz
60.0 Hz
x.x <> y.y
Enter
Backup
Stop Mode A
= "DC
Brake"?
Enter
2-6
StartUp
2. Motr Dat/Ramp
Enter value for
Motor NP RPM
+456 RPM
xxx <> yyy
2-9
2-12
StartUp
2. Motr Dat/Ramp
Enter value for
Decel Time 1
6.0 Secs
0.0 < 60.0 secs
Yes
StartUp
2. Motr Dat/Ramp
Enter value for
DC BrakeTime
1.0 Secs
0.0 < 90.0 Secs
2-13
Enter
StartUp
2. Motr Dat/Ramp
Enter value for
S Curve %
0%
0 < 100 %
Enter
Go to 0-1 (3)
2-158
Start-Up
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (3)
3-0
Basic Start Up (Motor Tests)
Startup
3. Motor Tests
This section
optimizes torque
performance and
tests for proper
direction.
Enter
3-1
Startup
3. Motor Tests
Complete these
steps in order:
<A. Auto Tune>
B. Directn Test
C. Done
Go to 0-1 (4)
Done
Auto Tune
3-2
Startup
A. AutoTune
Rotate Tune only
with no load and
low friction.
Static Tune when
load or friction
are present.
Direction
Test
3-3
Fault Clear
Enter/
Backup
Enter
Startup
A. AutoTune
Make a selectioon
<Rotate Tune>
Static Tune
Static
Tune
3-4
Startup
B. Directn Test
Press Jog or Start
to begin.
Enter/
Backup
3-8
3-9
Startup
A. Auto Tune.
Static Tune will
energize motor
with no shaft
rotation. Press
Start to begin.
Start
Start
Enter/
Backup
3-5
Startup
B. Directn Test
Is direction of
motor forward?
<Yes>
No
Yes
(stops drive)
Rotate
Tune
Startup
A. Auto Tune
Rotate Tune will
energize motor,
then cause shaft
rotation. Press
Start to begin.
Start
3-10
Startup
A. Auto Tune
Executing test.
Please wait....
No
(stops drive)
Rotate/Static
Tune complete
(stops drive)
3-6
3-7
3-11
Startup
B. Directn Test
Test complete.
Startup
B. Directn Test
Press Enter.
Then power down
and swap 2 output
wires to motor.
Startup
A. Auto Tune
Test complete.
3-12
Startup
3. Motor Tests
Test aborted due
to user stop.
Clear fault to
continue.
Stop or Esc
(stops drive)
Fault
3-13
Startup
3. Motor Tests
Test aborted!
Clear the fault.
Check motor data
settings. Verify
load is removed.
Start-Up
2-159
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (4)
4-0
Basic Start Up (Speed Limits)
StartUp
4. Speed Limits
This section
defines min/max
speeds, and
direction method
Enter
4-1
4-2
StartUp
4. Speed Limits
Disable reverse
operation?
Yes
<No>
StartUp
4. Speed Limits
Enter choice for
Direction Method
<Fwd/Rev Command>
+/- Speed Ref
No
Yes
Enter
4-3
Backup
StartUp
4. Speed Limits
Enter value for
Maximum Speed
+60.00 Hz
xxx.xx <> yyy.yy
Backup
4-4
Enter
MaxSpd + OSL
> MaxFreq?
Backup
4-5
No
StartUp
4. Speed Limits
Enter value for
Minimum Speed
+5.78 Hz
xxx.xx <> yyy.yy
Enter
Yes
StartUp
4. Speed Limits
Maximum Freq and
Overspeed Limit
will be changed
to support your
Maximum Speed.
Enter
4-6
StartUp
4. Speed Limits
Rejecting this
change will
prevent starting
Accept
Reject
OS Limit =
MaxFreq - MaxSpd
Reject
MaxFreq = MaxSpd
+ OS Limit
Accept
MaxSpd + OS
Lmt > 400Hz?
No
Yes
MaxFreq = 400Hz
Go to 0-1 (5)
2-160
Start-Up
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (5)
Basic Start Up (Speed Control)
5-0
StartUp
5. Speed Control
This section
defines a source
from which to control
speed.
Adapter
5-2
StartUp
5. Speed Control
Enter choice for
Input Signal
Analog Input 1
Analog Input 2
5-1
StartUp
5. Speed Control
Enter choice for
Speed Control
<Analog Input>
Comm Adapter
Local HIM-Port 1
Remote HIM
Preset Speeds
MOP
StartUp
5. Speed Control
Enter choice for
Comm Adapter
Port 5-internal
Port 2-external
Port 3-external
Enter
5-13
Enter
Analog Input
MOP
Local HIMPort 1
Go to 0-1 (6)
5-18
StartUp
5. Speed Control
Digital Inputs
5 & 6 will be
set to MOP Inc &
MOP Dec.
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
5-15
Preset
Speeds
Enter
5-19
StartUp
5. Speed Control
Save MOP speed
at power down ?
<Yes>
No
Remote
HIM
Go to 0-1 (6)
StartUp
5. Speed Control
Note: Factory default
settings
provide preset
speed operation
from the digital
inputs, unless
you change
their function.
5-3
StartUp
5. Speed Control
Enter choice for
Remote HIM
Port 2 (common)
Port 3
5-16
5-21
Enter
StartUp
5. Speed Control
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
PF70 StartUp
5. Speed Control
Enter value for
MOP Rate
5.0 Hz
xx.x < yy.y
Preset
Speed 1
5-5
StartUp
5. Speed Control
Enter value for
Preset Speed 2
10.0 Hz
xxx.x < yyy.y
Preset
Speed 2
5-6
StartUp
5. Speed Control
Enter value for
Preset Speed 3
15.0 Hz
xxx.x < yyy.y
Enter
5-12
StartUp
5. Speed Control
Make a selection .
<Preset Speed 1>
Preset Speed 2
Preset Speed 3
Preset Speed 4
Preset Speed 5
Preset Speed 6
Preset Speed 7
Done
Preset
Speed 5
Enter
Preset
Speed 6
Go to 0-1 (6)
Preset
Speed 7
5-23
Enter
5-7
5-8
5-9
5-10
StartUp
5. Speed Control
Enter value for
Preset Speed 4
20.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 5
25.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 6
30.0 Hz
xxx.x < yyy.y
StartUp
5. Speed Control
Enter value for
Preset Speed 7
35.0 Hz
xxx.x < yyy.y
Enter
StartUp
5. Speed Control
The next two
parameters link
a low speed
with a low
analog value.
Preset
Speed 3
Preset
Speed 4
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
5-22
Done
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Hi
10.0 V
xxx.x < yyy.y
StartUp
5. Speed Control
Save MOP speed
at stop ?
<Yes>
No
5-17
Enter/
Backup
5-20
Enter
5-4
Enter
StartUp
5. Speed Control
The next two
parameters link
a high speed
with a high
analog value.
5-11
Enter
Analog
Input 1
5-14
Enter
StartUp
5. Speed Control
Enter value for
Analog In 1 Lo
0.0 V
xxx.x < yyy.y
5-24
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
Analog
Input 2
5-24
5-25
StartUp
5. Speed Control
Enter choice for
Signal Type
Voltage
Current
5-26
Enter
StartUp
5. Speed Control
The next two
parameters link
a high speed
with a high
analog value.
5-27
Enter
StartUp
5. Speed Control
Enter value for
Analog In 2 Hi
10.0 V
xxx.x < yyy.y
5-28
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
xxx.x < yyy.y
5-29
Enter
StartUp
5. Speed Control
The next two
parameters link
a low speed
with a low
analog value.
5-30
Enter
StartUp
5. Speed Control
Enter value for
Analog In 2 Lo
0.0 V
xxx.x < yyy.y
5-31
Enter
StartUp
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
xxx.x < yyy.y
Start-Up
2-161
Figure 2.21 PowerFlex 70 & 700 Standard Control Option Startup (6)
6-0
6-1
StartUp
6. Strt,Stop,I/O
This section
defines I/O functions including
start and stop
from digital ins
StartUp
6. Strt,Stop,I/O
Complete these
steps in order:
<A. Dig Inputs>
B. Dig Outputs
C. Anlg Outputs
D. Done
Enter
Basic Start Up (Start,Stop,I/O)
D. Done
Go to 6-24
C. Anlg
Outputs
A. Dig Inputs
6-2
Go to 0-1 (7)
B. Dig
Outputs
6-18
Enter/
Backup
StartUp
A. Dig Inputs
Enter choice for
Digital In1 Sel
Go to 6-1 (B)
Go to 6-29
StartUp
A. Dig Inputs
Make a selection
<Easy Configure>
Custom Configure
Done
Digital In 1
6-19
Digital In 2
StartUp
A. Dig Inputs
Enter choice for
Digital In2 Sel
6-17
Custom Configure
StartUp
A. Dig Inputs
Make a selection
<Digital Input 1>
Digital Input 2
Digital Input 3
Digital Input 4
Digital Input 5
Digital Input 6
Done
Easy Configure
Backup
DigIn 5,6 = MOP
Inc, Dec?
Backup
6-3
Yes
No
StartUp
A. Dig Inputs
Digital Inputs
1-4 will be set
to defaults.
6-4
6-20
StartUp
A. Dig Inputs
Enter choice for
Digital In3 Sel
Digital In 3
Digital In 4
StartUp
A. Dig Inputs
Digital Inputs
1-6 will be set
to defaults.
6-21
StartUp
A. Dig Inputs
Enter choice for
Digital In4 Sel
Digital In 5
6-22
Digital In 6
Backup
Enter
Dir Mode =
Reverse
Disable?
Dir Mode =
Bipolar?
No
Yes
No
StartUp
A. Dig Inputs
Is reverse
required from
digital inputs?
<Yes>
No
Yes
No
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
2-wire
6-7
3-wire
6-12
6-10
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Run/Stop.
6-13
Enter
Enter
Go to 6-1 (B)
6-14
3-wire
StartUp
A. Dig Inputs
Digital Input 3
will be set to Fwd/
Reverse.
Enter
2-wire
6-15
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Stop.
Enter
6-16
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Run Reverse.
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Start.
Enter
6-11
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Run Forward.
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Stop.
Enter
StartUp
A. Dig Inputs
Enter choice for
Digital In6 Sel
StartUp
A. Dig Inputs
Enter choice for
Control Method
<3-wire>
2-wire
6-9
StartUp
A. Dig Inputs
Digital Input 1
will be set to
Not Used.
6-23
Yes
6-6
6-8
StartUp
A. Dig Inputs
Enter choice for
Digital In5 Sel
6-5
Enter
Enter
StartUp
A. Dig Inputs
Digital Input 2
will be set to
Start.
Enter
Enter
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)
Done
StartUp
B . Dig Outputs
Make a selection
<Digital Out 1>
Digital Out 2
Done
Digital
Out 1
6-29
StartUp
C. Anlg Outpts
Enter choice for
Analog Out 1 Sel
Digital
Out 2
Enter
6-25
6-30
6-27
StartUp
B. Dig Outputs
Enter choice for
Digital Out 1 Sel
StartUp
B. Dig Outputs
Enter choice for
Digital Out 2 Sel
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Hi
Enter
No
Enter
Enter
Digital Out 1 Sel
= ENUM choice
that uses
"Level"?
Digital Out 2 Sel
= ENUM choice
that uses
"Level"?
6-26
Enter
Yes
StartUp
B. Dig Outputs
Enter value for
Dig Out 1 Level
Backup
Backup
6-31
No
Enter
Yes
StartUp
B. Dig Outputs
Enter value for
Dig Out 2 Level
StartUp
C. Anlg Outpts
Enter value for
Analog Out 1 Lo
Go to 6-1 (D)
Enter
Start-Up
2-163
Figure 2.22 PowerFlex 700 Vector Control Option Startup
For first time powerup...
HIM
Select:
<English>
Francais
Espanol
Deustch
Italiano
Main Menu:
<Diagnostics>
Parameter
Device Select
Memory Storage
Start-Up
Preferences
Flux Vector Start Up (Top Level)
Start-Up/Continue
(disallow Start/Jog)
Abort
(allow Start/Jog)
Esc
(allow Start/Jog)
Drive
active?
0-0
PowerFlex 700
Start-Up
.
Startup consists
of several steps
to configure a
drive for basic
applications.
0-3
PowerFlex 700
Start-Up
.
Make a selection
Abort
<Backup>
Resume
Start-Up Menu
No
Yes
0-2
Go to AbortResume state
PowerFlex 700
Start-Up
.
The drive must
be stopped to
proceed. Press
ESC to cancel.
Yes
Drive
active?
STOP
(Stops the Drive)
0-4
0-5
No
PowerFlex 700
Start-Up
.
SMART startup
programs 11 key
drive parameters
for fast setup .
Basic startup
programs basic
drive functions
and options. .
Detailed startup
programs motor
data, reference;
ramps; limits; &
analog/digital
I/O.
PowerFlex 700
Start-Up
.
Make a selection
<1.SMART>
2.Basic
3.Detailed
4.More Info
Done/Exit
(allow Start/Jog)
Basic/
Detailed
Backup
SMART
Go to 8-1 (SMART
Start)
First time
into
Startup??
Yes
Startup
Menu
Yes
Drive
active?
Go to 1-1 (Motor
Control)
No
No
Basic
Detailed
0-1
PowerFlex 700
Start-Up
.
Complete these
steps in order:
<1.Motor Control>
2.Motr Data/Ramp
3.Motor Tests
4.Speed Limits
5.Speed/Trq Cntl
6.Start/Stop/I/O
7.Done/Exit
Go to 1-0
0-1
PowerFlex 700
Start-Up
.
Complete these
steps in order:
<1.Motor Control>
2.Motr Data/Ramp
3.Motor Tests
4.Speed Limits
5.Speed/Trq Cntl
6.Start/Stop/I/O
7.Appl Features
8.Done/Exit
Any state
(except 0-2)
'Esc' key
Start-Up/Restart
(disallow Start/Jog)
Motor Control
Go to 2-0
Motor Dat/Ramp
Go to 3-0
Motor Tests
Speed Limits
Speed/Torque Control
Go to 4-0
Go to 5-0
Strt/Stop/ I/O
Appl Features
Done/Exit
Go to 6-0
Go to 7-0
Go to HIM
Main Menu
Resume/Esc
Backup
Go to previous
state
Go to Backup
screen for previous
state
2-164
Start-Up
Figure 2.22 PowerFlex 700 Vector Control Option Startup (1)
Flux Vector Start Up (Motor Control Select)
1-31
1-1 B
1-0
Start-Up
1. Motor Control
This section
selects the type
of Motor Control
the drive will
use.
1-2 B
B = Basic mode
Start-Up
1. Motor Control
Make a selection
<1.SVC>
2.V/Hz
3.Flux Vector
4.More info
SVC- Set
#53= 0
Flux
Vector
Start-Up
SVC
Enter choice of
Speed Units
<Hz>
RPM
Frequency
More
info
1-18
1-17
Start-Up
V/Hz
Select a V/Hz
control option:
<1.V/Hz-Fan/Pump>
2.V/Hz-Cust/Std.
3.More info
Start-Up
1.Motor Control
Use SVC
for applications
requiring speed
regulation.
Use V/Hz control
for Fan/Pump and
other V/Hz
applications.
Use Flux Vector
for applications
requiring Torque
control or tight
speed regulation.
More
info
1-6 B
Start-Up
Flux Vector
NOTE! An Encoder
is required for
the Flux Vector
Control option.
1-19
Start-Up
V/Hz
Enter choice for
Slip Comp
<Enable>
Disable
Start-Up
Flux Vector
Enter value for
Encoder PPR
1024
SVC
Enter choice for
Slip Comp
<Enable>
Disable
1-32
1-23
Start-Up
V/Hz
Define Custom
V/Hz curve?
<Yes>
No
Fan/Pump-Set #53=3
1-7 B
1-3 Start-Up
V/Hz
Custom/Std.
Start-Up
V/Hz
The Fan/Pump
option selects a
predefined V/Hz
curve.
The Custom/Std.
option allows
you to define a
V/Hz curve or
select a default
V/Hz curve.
Yes
Standardset params #54
& 69-72 to
default values
Disable
Set #80=0
Set #80 to
selection made
1-24
1-20
B
Start-Up
V/Hz
Enter choice for
Slip Comp
<Enable>
Disable
Start-Up
V\Hz
Control selected
is Standard V/Hz
Start-Up
V/Hz
Enter value for
Run Boost
10V
xx.x < yy.y
1-8 B
Disable
Enable
Set #80=0 Set #80=1
1-5 B
1-4
Start-Up
SVC
Control selected
is SVC with
no Slip Comp
Start-Up
SVC
Control selected
is SVC with
Slip Comp
Enable
Set #80=1
Start-Up
Flux Vector
Enter choice of
Speed Units
<Hz>
RPM
Speed pathSet #88 to 1
1-10
Start-Up
Flux Vector
Select Torque
Regulate option:
<1.Torque Regul.>
2.Min Torque/Spd
3.Max Torque/Spd
4.Sum Torque/Spd
Min Torque/ 5.Absolute
Speed Set #88 =3
1-11
1-13
Start-Up
V/Hz
Enter value for
Break Voltage
10.0 Hz
x.x < y.y
B
1-27
Start-Up
Flux V ector
Control selected
is FOC Speed
Regulate.
Start-Up
V/Hz
Enter value for
Break Frequency
10.0 Hz
x.xxxx < y.yyyy
1-16
AbsoluteSet #88
=6
1-12
Start-Up
Flux Vector
Control selected
is Torque/FOC
Max Torque/Speed
1-26
Start-Up
V/Hz
Control selected
is Fan/Pump
with Slip Comp
Torque path
Max
Trq/Speed Set #88 = 4
Start-Up
V/Hz
Control selected
is Fan/Pump
no Slip Comp
Trq
Regulate
Set #88
=2
1-25
Start-Up
V/Hz
Enter value for
Start Boost
10.0 V
x.xxxx < y.yyyy
1-21
1-9
Start-Up
Flux Vector
Enter choice of
Regulation
<Speed>
Torque
Start-Up
Flux Vector
Control selected
is Torque/FOC
Min Torque/Speed
1-22
1-28
Start-Up
Flux Vector
Control selected
is Torque/FOC
Absolute
Start-Up
V/Hz
Enter value for
Max Voltage
10.0 V
x.x < y.y
Sum Trq/SpeedSet #88 = 5
1-15
1-14
Start-Up
Flux Vector
Control selected
is Torque/FOC
Torque Regulate
1-30
Start-Up
Flux Vector
Control selected
is Torque/FOC
Sum Torque/Speed
Start-Up
V/Hz
Control selected
is V/Hz/Custom
no Slip Comp.
Go to 0-1
2. Motr Dat/Ramp
1-29
Start-Up
V/Hz
Control selected
is V/Hz/Custom
with Slip Comp.
Start-Up
2-165
Figure 2.22 PowerFlex 700 Vector Control Option Startup (2)
Flux Vector Start Up (Motor Dat/Ramp)
2-0
B
Start-Up
2. Motr Dat/Ramp
Use motor nameplate data and
required ramp
times for the
following steps.
2-1
B
Enter
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Volts
123.4 Volt
xxx.x <> yyy.y
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Hertz
60.0 Hz
x.x <> y.y
2-6
B
Start-Up
2. Motr Dat/Ramp
Enter Stop Mode:
1.Coast
<2.Ramp>
3.Ramp to Hold
4.DC Brake
Enter
2-5
B
2-7
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP FLA
+456.78 Amps
xxx.xx <> yyy.yy
2-4
B
2-14
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor Poles
12
xx <> yy
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP Power
123.4 kW
xxx.x <> yyy.y
2-3
B
Enter
Start-Up
2. Motr Dat/Ramp
Enter choice for
Power Units
<HP>
Killowatt
2-2
B
B = Basic mode
Enter
Use formula:
Poles= 120 * NP Hz
NP RPM
2-10
Stop Mode A =
"DC Brake" or
"Ramp to Hold"?
No
as Motor Poles
parameter value.
Start-Up
2. Motr Dat/Ramp
Enter choice for
DB Resistor type
<None>
Internal
External
Start-Up
2. Motr Dat/Ramp
Enter value for
DC Brake Level
1.0 Amps
0.0 < 30.0 Amps
Enter
2-11
2-9
Yes
Start-Up
2. Motr Dat/Ramp
Enter value for
DC BrakeTime
1.0 Secs
0.0 < 90.0 Secs
Note:
- For V/Hz mode, only states 2-0 thru 2-6 & 2-14 are displayed.
- For V/Hz mode, configure Stop Mode A as Coast to Stop.
- Going from state 2-7 to 2-10 directly sets the DC Brake Level/Time
parameters to their default value.
Note: If Stop Mode A = COAST, then
skip 2-10.
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Accel Time 1
6.0 Secs
0.0 < 60.0 secs
No
Enter
2-12
Stop Mode A =
"DC Brake"?
Note: Depending on selection, set parameter
#161 (Bus Reg Mode A):
None - Bus Reg Mode A = Adj Freq.
Intenal - Bus Reg Mode A = Both, DB 1st.
External - Bus Reg Mode A = Both, DB 1st.
Note: Default should be NONE.
Yes
2-8
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Motor NP RPM
+456 RPM
xxx <> yyy
Backup
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
Decel Time 1
6.0 Secs
0.0 < 60.0 secs
2-13
B
Enter
Start-Up
2. Motr Dat/Ramp
Enter value for
S Curve %
0%
0 < 100 %
Enter
Go to 0-1 (3. Motor
Tests)
Note: If Stop Mode A = COAST, then
skip 2-12. If in Quick/Basic mode, then
exit Motor Data/Ramp.
B
2-166
Start-Up
Figure 2.22 PowerFlex 700 Vector Control Option Startup (3)
3-0
3-22
Start-Up
3. Motor Tests
This section
optimizes motor
performance and
tests for proper
direction.
Flux Vector Start Up (Motor Tests)
Start-Up
3. Motor Tests
Select source of
Start/Stop
<Digital Inputs>
Local HIM-Port1
Remote HIM-Port2
3-21
If Digital Inputs:- Set
#361/2 to START/STOP resp.
If Local HIM:- Set
#361/2 to Not Used &
#90 to 18
3-1
Enter
Start Inhibit
param != 0
Note:
- Fix Jog/Reference to
5 Hz.
- State 3-4 allows
Start/Jog 3-4
Yes
No
Start-Up
A. Directn Test
Press Jog or Start
to begin.
Enter/
Backup
3-18
Start-Up
A. Directn Test
Test complete.
Press <ENTER>
3-2 Start-Up
3-14
B. AutoTune
IMPORTANT!!
Use Rotate Tune
if no load/low
friction/Flux
Vector mode.
Else use Static
Tune. For
special applications, see reference maual.
Start Inhibit
param != 0
Start-Up
3. Motor Tests
Cannot start due
to open Stop
input or other
[Start Inhibits]
Press Enter.
Yes
No
Static
Tune
3-19
Start-Up
C. Inertia Test
Caution:Inertia
Test causes
shaft rotation.
<START> to begin
3-20
Note: States 3-8
& 3-9 allow Start.
If NO..
(stops
drive)
3-8
3-7
3-17
Start-Up
A. Directn Test
Power down and
swap encoder
leads.
Go to State 3-4
No
FOC?
Yes
Start-Up
B. Auto Tune
Caution: Rotate
Tune will cause
shaft rotation.
Press START to
begin.
3-10
3-15
Start (disallow
Start/Jog)
Start-Up
C. Inertia Test
Enter value for
Speed Desired BW
60.0 RPM
xxx.x <> yyy.y
Start-Up
B. Auto Tune
Executing test.
Please wait...
FOC
Mode?
Yes
3-11
Note:
- The Motor Tests are NOT executed while in V/Hz mode.
Fault
(stops drive)
3-23
Stop or ESC
(stops drive)
Start-Up
C. Inertia Test
Test complete.
Press <ENTER>
Stop or Esc
(stops drive)
Fault
(stops drive)
Go to 3-1
3-13
No
Start-Up
B. Auto Tune
Test complete.
Press <ENTER>
3-16
Start-Up
B. Auto Tune
Enter value for
Autotune Torque
6.0 %
xxx.x <> yyy.y
Rotate/Static Tune
complete
(stops drive)
3-24
Start-Up
B. Auto Tune
Rotate Tune
done. Press
ENTER to continue with
Inertia Test.
Rotate Tune
3-9
Start-Up
B. Auto Tune.
Static Tune will
energize motor
with no shaft
rotation. Press
START to begin.
Start-Up
A. Directn Test
Startup will
automatically
reverse the
MotorLeads.
Start-Up
C. Inertia Test
Executing test.
Please wait...
Start-Up
B. AutoTune
Make a selectioon
Static Tune
<Rotate Tune>
Note: Set #61
(Autotune) to '2' or
'1' depending on
selection
Start (disallow
Start/Jog)
Go to State 3-18
Start-Up
C. Inertia Test
Connect load to
motor for
Inertia Test.
B. Auto Tune
Enter
If YES &
negative
encoder
counts..
(stops
drive)
Go to 3-1
C. Inertia Test
A. Directn Test
Motor rotation
correct for
application?
<Yes>
No
3-6
SV
Motor
Cntl
Sel?
3-3
3-5 Start-Up
If YES & positive
encoder counts..
(stops drive)
V/Hz
FOC
Start/Jog
(disallow Start/Jog)
Backup
3-25
Start-Up
C.Inertia Test
Sensrls Vector
does not require
an Inertia Test.
Go to 0-1 (4.Speed
Limits)
D. Done
Start-Up
3. Motor Tests
Complete these
steps in order:
<A. Directn Test>
B. Auto Tune
C. Inertia Test
D. Done
Direction
Test
Start-Up
C.Inertia Test
V/Hz Control
does not require
an Inertia Test.
3-12
Start-Up
3. Motor Tests
Test aborted due
to user stop.
Clear fault to
continue.
Go to 3-1
Start-Up
3. Motor Tests
Test aborted!
Clear the fault.
Check motor data
settings. Verify
load is removed.
Start-Up
2-167
Figure 2.22 PowerFlex 700 Vector Control Option Startup (4)
Flux Vector Start Up (Speed Limits)
4-0
Start-Up
4. Speed Limits
This section
defines min/max
speeds and
direction method
B
4-1
Start-Up
4. Speed Limits
Enter value for
Maximum Speed
+60.00 Hz
xxx.xx <> yyy.yy
B
4-2
Start-Up
4. Speed Limits
Enter value for
Minimum Speed
+5.78 Hz
xxx.xx <> yyy.yy
B
FOC
Mode?
Yes
4-3
No
Go to 0-1 (5.
Speed Control)
Start-Up
4. Speed Limits
Enter value for
Rev Speed Lim
+5.78 Hz
xxx.xx <> yyy.yy
B
2-168
Start-Up
Figure 2.22 PowerFlex 700 Vector Control Option Startup (5)
5-0 Start-Up
Flux
Vector
Mode?
5. Speed Control
This section
selects the
speed/torque
control source.
Note:
- Only Analog and Local HIM
are displayed in 5-1 for Basic
mode.
Comm Adapter write to #90 (Ref A
Sel) selection
5-2
Start-Up
Comm Adapter
Make a selection
<Port 5-internal>
Port 2-common
Port 3-external
Port 4-external
Go to 0-1 (6.Strt/
Stop/I/O)
Yes
No
5-1
Speed
Start-Up
5. Speed Control
Choose source
of Reference:
<1.Analog Input>
2.Preset Speed 1
3.Digital Inputs
4.Comm Adapter
5.Local HIM
6.Remote HIM
7.MOP
Local HIM- Port 1Set param #90
(Ref A Sel) to '18'
5-3
5-11
Start-Up
5. Speed Control
Note: Factory
default settings
provide preset
speed operation
from the digital
inputs.
5. Speed Control
Enter value for
Preset Speed 2
10.0 Hz
xxx.x < yyy.y
5-6 Start-Up
5. Speed Control
Enter value for
Preset Speed 3
15.0 Hz
xxx.x < yyy.y
5-8 Start-Up
5. Speed Control
Enter value for
Preset Speed 5
25.0 Hz
xxx.x < yyy.y
5-9 Start-Up
5-18
5-35
Start-Up
5. Speed Control
Digital Inputs
5 & 6 will be
set to MOP Inc &
MOP Dec.
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
Set params: #90 (Ref A
Sel) to Anlg In 1; #93 (Ref
B Sel) to Preset Spd 1;
#364-66 (Digital In 4-6)
to Speed Sel 1, 2, 3.
Start-Up
5. Speed Control
Save MOP speed
at Stop ?
<Yes>
No
Start-Up
5. Speed Control
Select a Preset
Speed:
<1.Preset Speed 1>
2.Preset Speed 2
3.Preset Speed 3
4.Preset Speed 4
5.Preset Speed 5
6.Preset Speed 6
7.Preset Speed 7
8.Done
Preset
Speed 3
Preset
Speed 4
Upon "Enter", write to
bit '1' of param #194
(Save MOP Ref)
Start-Up
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
x.x < y.y
PF70 Start-Up
5. Speed Control
Enter value for
MOP Rate
5.0 Hz
xx.x < yy.y
Done
Enter
Enter
Enter
Go to 0-1
(6. Strt/Stop/I/O)
Note :
- For V/Hz mode, the MOP option in 5-1 is NOT displayed, screens 5-14
thru 5-17 and 5-18 thru 5-31 are also NOT displayed.
Go to 5-1
5-27
Start-Up
5. Speed Control
Enter value for
Analog In 2 Hi
10.0 V
x.xxxx < y.yyyy
5-28
Yes
Start-Up
5. Speed Control
Enter value for
Speed Ref A Hi
60.0 Hz
x.x < y.y
5-29
Start-Up
5. Speed Control
The next two
steps scale a
low speed with
a low analog
value.
5-24
5-10 Start-Up
Yes
Start-Up
5. Speed Control
The next two
steps scale a
high speed to
a high analog
value.
Start-Up
5. Speed Control
The next two
steps scale a
low speed with
a low analog
value.
Start-Up
5. Speed Control
Enter value for
Analog In 1 Lo
0.0 V
x.xxxx < y.yyyy
Start-Up
5. Speed Control
Configure other
Spd References?
<Yes>
No
No
5-26
5-22
5-23
5-33
5. Speed Control
Enter value for
Preset Speed 7
35.0 Hz
xxx.x < yyy.y
No-If AIn 2 Hi/Lo
value out of range,
set to min of Signal
type selected.
5-21
5-17
Preset
Speed 6
5. Speed Control
Enter value for
Preset Speed 6
30.0 Hz
xxx.x < yyy.y
No-If AIn 1 Hi/Lo
value out of range,
set to min of Signal
type selected
Start-Up
5. Speed Control
Enter value for
Analog In 1 Hi
10.0 V
x.xxxx < y.yyyy
Preset
Speed 5
Preset
Speed 7
V/Hz
Mode?
5-20
5-12
Preset
Speed 2
V/Hz
Mode?
Start-Up
5. Speed Control
The next two
steps scale a
high speed to
a high analog
value.
5-16
Enter/
Backup
Preset
Speed 1
Set bit 1 of #320 to '0'
(for Volts) & '1' (for Amps)
5-19
Upon "Enter", write to
bit '0' of param #194
(Save MOP Ref)
5-25
Start-Up
5. Speed Control
Enter choice for
Signal Type
<Voltage>
Current
Set bit 0 of #320 to '0'
(for Volts) & '1' (for Amps)
Start-Up
5. Speed Control
Save MOP speed
at power down ?
<Yes>
No
5. Speed Control
Set #90 to
Set #90 to
Analog Input 1 Analog Input 2
Start-Up
5. Speed Control
Enter choice for
Signal Type
<Voltage>
Current
5-15
Start-Up
5-7 Start-Up
5. Speed Control
Enter value for
Preset Speed 4
20.0 Hz
xxx.x < yyy.y
MOP - Set
Param #90
(Ref A Sel)
to '9'
Preset
Speed - Set
param #90
(Ref A Sel)
to '11'
5. Speed Control
Enter value for
Preset Speed 1
5.0 Hz
xxx.x < yyy.y
Start-Up
5. Speed Control
Enter choice for
Input Signal
<Analog Input 1>
Analog Input 2
5-14
Digital
Inputs
5-4 Start-Up
5-13
Go to 6-49
Analog Input
Start-Up
Remote HIM
Make a selection
<Port 2 (common)>
Port 3
Port 4
5-5 Start-Up
Torque
Go to 0-1 (6. Strt/
Stop/I/O)
Remote
HIM -write
to #90 (Ref
A Sel)
selection
Flux Vector Start Up (Speed/Torque Control)
5-34
Start-Up
C. Anlg Inputs
Enter choice for
Reference::
<Speed>
Torque
Start-Up
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
x.x < y.y
5-32
Start-Up
5. Speed Control
Verify high/low
speeds with
high/low analog
signals.
5-30
Start-Up
5. Speed Control
Enter value for
Analog In 2 Lo
0.0 V
x.xxxx < y.yyyy
5-31
Start-Up
5. Speed Control
Enter value for
Speed Ref A Lo
0.0 Hz
x.x < y.y
Start-Up
2-169
Figure 2.22 PowerFlex 700 Vector Control Option Startup (6)
Flux Vector Start Up (Strt,Stop,I/O)
B
6-0
Start-Up
6. Strt,Stop,I/O
This section
defines I/O
functions
including Start
and Stop.
B = Basic mode
6-1
Start-Up
6. Strt,Stop,I/O
Complete these
steps in order:
<A.Dig Inputs>
B.Dig Outputs
C.Analog Outputs
D.Done
A. Dig Inputs
6-2
B. Dig
Outputs
Go to 6-27
C.Analog
Output
Go to 6-49
Enter/
Backup
D. Done
6-19
More
info
Start-Up
A. Dig Inputs
Easy Configure
asks questions
before writing
to digital ins.
Custom Configure
allows you to
program each
digital input(s)
6-26
DigIn 5,6 = MOP
Inc, Dec?
No
B
6-4
Start-Up
A. Dig Inputs
Digital Inputs
1-4 will be set
to defaults.
Digital In 4
6-5
Digital In 5
6-8
2-wire
B
Start-Up
A. Dig Inputs
Digital In1 set
to Not Used.
Digital In2 set
to Run/Stop.
B
Start-Up
A. Dig Inputs
Enter choice for
Control Method
<3 wire>
2 wire
More info
3-wire
B 6-11
Start-Up
A. Dig Inputs
Digital In1 set
to Stop.
Digital In2 set
to Start.
B
B 6-12
Start-Up
A. Dig Inputs
Digital Inputs
configured for
3-wire control
no reversing.
Note:
- For V/Hz mode, states 6-3 - 6-5, & 6-11 - 6-16 are not displayed.
6-7
Start-Up
A. Dig Inputs
2 wire control
uses a contact
that acts as
both STOP (Open)
& Run (Closed).
3 wire control
uses 2 contacts;
one for START
& one for STOP.
Yes
6-13
6-14
2-wire
More
Info..
3-wire
B
Start-Up
A. Dig Inputs
Digital In1 set
to Run Forward.
Digital In2 set
to Run Reverse.
6-15
Start-Up
A. Dig Inputs
Digital Inputs
configured for
2-wire control
with reversing.
Go to 6-1 (B. Dig
Outputs)
Start-Up
A. Dig Inputs
Enter choice for
Digital In4 Sel
6-24
Start-Up
A. Dig Inputs
Enter choice for
Digital In6 Sel
B
B
More
Info..
Start-Up
A. Dig Inputs
Enter choice for
Digital In3 Sel
6-25
B 6-6
Start-Up
A. Dig Inputs
2 wire control
uses a contact
that acts as
both STOP (Open)
& Run (Closed).
3 wire control
uses 2 contacts;
one for START
& one for STOP.
Start-Up
A. Dig Inputs
Enter choice for
Control Method
<3 wire>
2 wire
More info
6-22
Start-Up
A. Dig Inputs
Enter choice for
Digital In5 Sel
B
Start-Up
A. Dig Inputs
Is REVERSE
required from
digital inputs?
<Yes>
No
No
Start-Up
A. Dig Inputs
Enter choice for
Digital In2 Sel
6-23
Digital In 6
Backup
Start-Up
A. Dig Inputs
Digital Inputs
configured for
2-wire control
no reversing
Digital In 3
Done
Backup
6-10
Digital In 2
Go to 6-1 (B.Dig
Outputs)
Start-Up
A. Dig Inputs
Digital Inputs
1-6 will be set
to defaults.
6-9
Start-Up
A. Dig Inputs
Select a Digital
Input:
<1.Digital In 1>
2.Digital In 2
3.Digital In 3
4.Digital In 4
5.Digital In 5
6.Digital In 6
7.Done
Custom Configure
Easy Configure
6-3
Digital In 1
6-21
Start-Up
A. Dig Inputs
Digital Input
Config options:
<Easy Configure>
Custom Configure
More info
Yes
Start-Up
A. Dig Inputs
Enter choice for
Digital In1 Sel
Go to 0-1 (7. Application
Features)
B
6-20
B
6-16
Start-Up
A. Dig Inputs
Digital Input 3
will be set to Fwd/
Reverse.
B
6-17
Start-Up
A. Dig Inputs
Digital In1 set
to Stop.
Digital In2 set
to Start.
B
B
Start-Up
A. Dig Inputs
Digital Inputs
configured for
3-wire control
with reversing.
6-18
2-170
Start-Up
Figure 2.22 PowerFlex 700 Vector Control Option Startup (7)
6-27
Digital Out 1
6-28
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 1 Sel
No
Flux Vector Start Up (Start,Stop,I/O [2])
Start-Up
B. Dig Outputs
Make a selection
<Digital Out 1>
Digital Out 2
Digital Out 3
Done
6-30
Go to 6-1 (C.Anlg
Inputs)
Done
6-34
Digital Out 3
6-32
Start-Up
C. Anlg Inputs
Enter choice for
Input Signal
<Analog Input 1>
Analog Input 2
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 3 Sel
Digital Out 2
Start-Up
B. Dig Outputs
Enter choice for
Digital Out 2 Sel
Anlg 1
6-35
Digital Out 1
Sel = ENUM
choice that
uses "Level"?
Start-Up
Digital Out 3
Sel = ENUM
choice that
uses "Level"?
Digital Out 2
Sel = ENUM
choice that
uses "Level"?
6-29 Yes
Start-Up
B. Dig Outputs
Enter value for
Dig Out 1 Level
Yes
6-31
6-33
Start-Up
B. Dig Outputs
Enter value for
Dig Out 3 Level
Yes
Start-Up
B. Dig Outputs
Enter value for
Dig Out 2 Level
No
No
Anlg 2
Enter choice for
Signal type:
<Voltage>
Current
Torque RefAnlg 1
Torque RefAnlg 2
Start-Up
C. Anlg Inputs
The next two
steps scale a
high torque with
a high analog
value.
Start-Up
C. Anlg Inputs
The next two
steps scale a
high torque with
a high analog
value.
6-36
6-37
6-49
Start-Up
C.Analog Outputs
Make a selection
<Anlgl Out 1>
Anlg Out 2
Done
Go to 6-1 (D.
Done)
6-42
Start-Up
C. Anlg Inputs
Enter choice for
Signal type:
<Voltage>
Current
6-44
Start-Up
C. Anlg Inputs
Enter value for
Analog In 1 Hi
10.0 V
x.xxxx < y.yyyy
Start-Up
C. Anlg Inputs
Enter value for
Analog In 2 Hi
10.0 V
x.xxxx < y.yyyy
6-38
6-50
Analog 1
Start-Up
C.Analog Outputs
Enter choice for
Analog Out 1 Sel
Output Freq
6-51
Start-Up
C.Analog Outputs
Enter choice for
Signal Type
<Voltage>
Current
6-52
Analog 2
6-54
Start-Up
C.Analog Outputs
Enter choice for
Analog Out 2 Sel
Output Amps
6-55
Start-Up
C.Analog Outputs
Enter choice for
Signal Type
<Voltage>
Current
6-56
Start-Up
C.Analog Outputs
Enter value for
Start-Up
C.Analog Outputs
Enter value for
Analog Out 1 Hi
10.000 Volt
x.xxxx < y.yyyy
Analog Out 2 Hi
10.000 Volt
x.xxxx < y.yyyy
6-53
6-57
Start-Up
C.Analog Outputs
Enter value for
Start-Up
C.Analog Outputs
Enter value for
Analog Out 1 Lo
0.0 Volt
x.xxxx < y.yyyy
Analog Out 2 Lo
0.0 Volt
x.xxxx < y.yyyy
6-43
6-45
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
6-39
6-46
Start-Up
C. Anlg Inputs
The next two
steps scale a
low torque with
a low analog
value.
Start-Up
C. Anlg Inputs
The next two
steps scale a
low torque with
a low analog
value.
6-47
6-40
Start-Up
C. Anlg Inputs
Enter value for
Analog In 1 Lo
10.0 V
x.xxxx < y.yyyy
Start-Up
C. Anlg Inputs
Enter value for
Analog In 2 Lo
10.0 V
x.xxxx < y.yyyy
6-48
6-41
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Go to 6-1 (D.Anlg
Outputs)
Start-Up
C. Anlg Inputs
Enter value for
Torque Ref A Hi
100.0 %
x.x < y.y
Start-Up
2-171
Figure 2.22 PowerFlex 700 Vector Control Option Startup (8)
7-0 Start-Up
Flux Vector Start Up (Application Functions)
7.Appl. Features
This allows
programming of
additional drive
features.
7-1 Start-Up
7.Appl Features
Make a Selection
<Flying Start>
Auto Restart
Done
7-2
No
Start-Up
7.Appl Features
Enter choice for
PI Reference
1
Analog In 1
7-3 Start-Up
7.Appl Features
Enter choice for
PI Feedback
1
Analog In 1
7-4 Start-Up
7.Appl Features
Enter value for
PI Setpoint
50.0%
xx.x < yy.y
7-5
7-6
Start-Up
7.Appl Features
Enter value for
PI Upper Limit
60.0 Hz
xx.x < yy.y
Start-Up
8.Appl Features
Enter value for
PI Lower Limit
-60.0 Hz
xx.x < yy.y
7-7 Start-Up
8.Appl Features
Enter value for
PI Integral Time
2.0 Secs
x.x < y.y
7-8 Start-Up
8.Appl Features
Select other PI
options in
parameter #124.
Go to 0-1 (8. Done/
Exit)
7-4
Start-Up
7.Appl Features
Enable Flying
Start?
<Yes>
No
Process PI
7-2
Auto
Restart
Flying
Start
7-3
Start-Up
7.Appl Features
Set Auto Restart
Tries to Zero to
disable the
function.
Yes
7-5
Start-Up
7.Appl Features
Enter value for
Flying StartGain
4000
xxx < yyyy
Start-Up
7.Appl Features
Enter value for
Auto Rstrt Tries
0
xxx < yyyy
Go to 7-1 (Auto
Restart)
Auto Restart
tries = 0?
Yes
Go to 7-1 (Done)
7-6
No
Start-Up
7.Appl Features
Enter value for
Auto Rstrt Delay
1.0 Secs
xx.x < yy.y
2-172
Start-Up
Figure 2.22 PowerFlex 700 Vector Control Option Startup (9)
8-0
Start-Up
SMART
Enter choice of
Speed units:
<Hz>
RPM
8-1
Start-Up
SMART
Enter value for
Digital In 2 Sel
5
Start
8-2
Start-Up
2. Motr Dat/Ramp
Enter choice for
Stop Mode A
Coast
<Ramp>
Ramp to Hold
DC Brake
8-3
8-4
8-5
Start-Up
SMART
Enter value for
Minimum Speed
0.0 Hz
Start-Up
SMART
Enter value for
Maximum Speed
60.0 Hz
Start-Up
SMART
Enter value for
Accel Time 1
10.0 Secs
8-6
Start-Up
SMART
Enter value for
Decel Time 1
10.0 Secs
8-7
Start-Up
SMART
Enter value for
Speed Ref A Sel
Analog In 2
8-8
Start-Up
SMART
Enter value for
Motor NP FLA
0.8 Amps
8-9
Start-Up
SMART
Enter value for
Motor OL Hertz
10.0 Hz
8-10
Start-Up
SMART
Enter value for
Motor OL Factor
1.0
8-11
Start-Up
SMART
SMART Startup
is now complete.
Flux Vector Start Up (S.M.A.R.T.)
Start-Up
2-173
Figure 2.22 PowerFlex 700 Vector Control Option Startup (10)
1-0
Flux Vector Start Up (Motor Control Select)
1-1
Start-Up
1. Motor Control
This section
selects the type
of Motor Control
the drive will
use.
Start-Up
1. Motor Control
Enter choice of
Control:
<Speed>
Torque
More info
Torque
Speed
1-11
1-2
Start-Up
Torque
Is an encoder
present?
<Yes>
No
Torque- No
Start-Up
Speed
Is an encoder
present?
<Yes>
No
TorqueYes
1-3
1-12
1-4
Start-Up
Torque-FOC
An Encoder is
required for the
Torque Control
option. Select
another Motor
Control option
or install an
encoder.
1-6
Start-Up
Speed-SVC
Enter value for
Encoder PPR
1024
1-5
Min Torque/
Speed Set #88 to 3
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Min Torque/Speed
YES-Speed pathSet #88 to 1
Start-Up
Speed-SVC
Control selected
is FOC Speed
Regulate.
Start-Up
Torque-FOC
Select Torque
Regulate option:
<Torque Regulate>
Min Torque/Speed
Max Torque/Speed
Sum Torque/Speed
Absolute
1-7
V/Hz
Custom/Multi
Motor - Set
param #53 to '2'
& #80 to '0'
1-15
Start-Up
Frequency-V/Hz
Select V/Hz
Parameters.
<Standard V/Hz>
Custom V/Hz
V/Hz
1-13
Sensorless
Vector - set param #53
to '0' & #80 to '0'
Fan/Pump Set param
#53 to '3' &
#80 to '0'
Start-Up
Frequency-V/Hz
Control selected
is Frequency/SV
no Slip Comp
1-10
Start-Up
Torque-FOC
Sum Trq/SpeedControl selected
Set #88 to 5
is Torque/FOC
Trq
Absolute
Regulate
1-9
Set #88
Start-Up
to 2
Torque-FOC
Control selected
is Torque/FOC
Sum Torque/Speed
1-8
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Torque Regulate
Start-Up
Speed-SVC
Control selected
is Speed/SVC
with Slip Comp
1-21
Standard
Start-Up
Frequency-V/Hz
Control selected
is Freq/Fan/Pump
no Slip Comp
Start-Up
Frequency-V/Hz
Enter value for
Break Voltage
10.0 Hz
x.x < y.y
1-22
Start-Up
Frequency-V/Hz
Enter value for
Break Frequency
10.0 Hz
x.xxxx < y.yyyy
1-18
Start-Up
Frequency-V/Hz
Control selected
is Freq/V/Hz.
Start-Up
Speed-SVC
Enter value for
Max Voltage
10.0 V
x.x < y.y
1-19
Start-Up
Frequency-V/Hz
Enter value for
Run Boost
10V
xx.x < yy.y
1-20
1-17
1-25
Custom
Start-Up
Frequency-V/Hz
Enter value for
Start Boost
10.0 V
x.xxxx < y.yyyy
1-16
AbsoluteSet #88
to 6
Start-Up
Torque-FOC
Control selected
is Torque/FOC
Max Torque/Speed
NO
Start-Up
Frequency-V/Hz
Select Motor
Control Mode
<SVC-common>
V/Hz
More info
Torque path
Max
Trq/Speed Set #88 to 4
1-14
Start-Up
Frequency-V/Hz
Select Motor
Control Mode
<V/Hz-Fan/Pump>
V/Hz-Custom
V/Hz-Multi Motor
SV-No regulation
1-23
Start-Up
Frequency-V/Hz
Enter value for
Max Voltage
10.0 V
x.x < y.y
1-24
Go to 1-1
Start-Up
Speed-SVC
Use Speed-SVC
for applications
requiring speed
regulation.
Start-Up
Frequency-V/Hz
Control selected
is Freq/Custom.
Start-Up
Speed-SVC
Enter choice of
Speed Units
<V/Hz>
RPM
Go to 0-1
2. Motr Dat/Ramp
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. The load/motor will coast or free spin until the mechanical
energy is dissipated.
Output Voltage
Output Current
Motor Speed
Time
Stop
Command
Coast Time is load dependent
2. Dynamic Braking is explained in detail in the PowerFlex Dynamic
Braking Selection Guide, presented in Appendix A.
3. DC Brake is selected by setting [Stop Mode A] to a value of “3.” The
user can also select the amount of time the braking will be applied and
the magnitude of the current used for braking with [DC Brake Time] and
[DC Brake Level]. This mode of braking will generate up to 40% of
rated motor torque for braking and is typically used for low inertia loads.
When in Brake to Stop, the drive acknowledges the Stop command by
immediately stopping the output and then applying a programmable DC
voltage [DC Brake Level] to 1 phase of the motor.
The voltage is applied for the time programmed in [DC Brake Time].
After this time has expired, all output ceases. If the load is not stopped, it
will continue to coast until all energy is depleted (A on the diagram
below). If the time programmed exceeds the needed time to stop, the
drive will continue to apply the DC hold voltage to the non-rotating
motor (B on the diagram below). Excess motor current could cause
motor damage. The user is also cautioned that motor voltage can exist
long after the Stop command is issued. The right combination of Brake
Level and Brake Time must be determined to provide the safest, most
efficient stop (C on the diagram below).
Output Voltage
Output Current
Motor Speed
DC
Hold Level
Time
Stop
Command
(B)
DC Hold Time
(C)
(A)
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]. If the “Machine Stop” mode requires a faster
deceleration than desired for normal mode, the “Machine Stop” can
activate [Decel Time 2] with a faster rate selected. When in Ramp to
Stop, the drive acknowledges the Stop command by decreasing or
“ramping” the output voltage and frequency to zero in a programmed
period (Decel Time), maintaining control of the motor until the drive
output reaches zero. The output transistors are then shut off.
The load/motor should follow the decel ramp. Other factors such as bus
regulation and current limit can alter the decel time and modify the ramp
function.
Ramp mode can also include a “timed” hold brake. Once the drive has
reached zero output hertz on a Ramp-to-Stop and both parameters [DC
Hold Time] and [DC Hold Level] are not zero, the drive applies DC to
the motor producing current at the DC Hold Level for the DC Hold
Time.
Output Voltage
Output Current
Motor Speed
Output Current
Output Voltage
DC
Hold
Level
Time
Stop
Command
Zero
Command
Speed
DC Hold Time
Motor speed during and after the application of DC depends upon the
combination of the these two parameter settings, and the mechanical
system. The drive output voltage will be zero when the hold time is
finished.
The level and uniformity of the DC braking offered at zero speed may
not be suitably smooth for many applications. If this is an application
requirement, a vector control drive, motion control drive or mechanical
brake should be used.
The drive output voltage will be zero when the hold time is finished
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. The level of current is set in [DC
Brake Level].
In this mode, the braking is applied Continuously. [DC Hold Time] has
no effect in this mode. Braking will continue until one of the following
events occur:
– The Enable Input is opened, or . . .
– A Start command is re-issued.
Again, caution must be exercised to not overheat the motor by applying
excess voltage and/or for excess time, particularly if the motor is not
rotating.
Output Voltage
Output Voltage
Output Current
Output Current
Motor Speed
Motor Speed
Output Current
Output Voltage
DC
Hold Level
Time
Stop
Command
Zero
Command
Speed
Re-issuing a
Start Command
Test Points
Test Points
Selects the function whose value is
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.
Diagnostics
UTILITY (File E)
234 [Testpoint 1 Sel]
236 [Testpoint 2 Sel]
235 [Testpoint 1 Data]
237 [Testpoint 2 Data]
32
The present value of the function
selected in [Testpoint x Sel].
Table 2.W Testpoint Codes and Functions
Code Selected in
[Testpoint x Sel]
0
1
2
3
4
5
6
7
8-99
Thermal Regulator
Function Whose Value is
Displayed in [Testpoint x Data]
DPI Error Status
Heatsink Temperature
Active Current Limit
Active PWM Frequency
Lifetime MegaWatt Hours
Lifetime Run Time
Lifetime Powered Up Time
Lifetime Power Cycles
Reserved for Factory Use
See Drive Overload on page 2-76.
Default:
499
Min/Max: 0/999
Display: 1
Default:
Read Only
Min/Max: 0/65535
Display: 1
2-177
2-178
Torque Performance Modes
Torque Performance
Modes
[Torque Perf Mode] selects the output mode of 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.
• Sensorless Vector
Used for most general constant torque applications. Provides excellent
starting, acceleration and running torque.
• Sensorless Vector w/Economizer
Used in constant torque applications that have significant “idle” time
(time spent at greatly reduced load) to offer additional energy
conservation.
The following table shows the performance differences between V/Hz and
Sensorless Vector.
Torque Mode
Speed Regulation/accuracy (w/
slip compensation)
Operating Speed Range (w/slip
compensation)
Dynamic Speed Accuracy
(speed response to a 95% step
load change)
Velocity Bandwidth (w/slip
compensation and no encoder)
Minimum setting of velocity
bandwidth/slip compensation
Fan/Pump and
Custom V/Hz SVC
0.5%
0.5%
40:1
80:1
0.5% base
speed
0.5% base
speed
10 rad/s
20 rad/s (50
rad/s desired)
0.1 rad/s
0.1 rad/s
Volts/Hertz
Volts/Hertz operation creates a fixed relationship between output voltage
and output frequency. The relationship can be defined in two ways.
1. Fan/Pump
When this option is chosen, the relationship is 1/X2. Therefore;
for full frequency, full voltage is supplied and for 1/2 rated frequency,
1/4 voltage is applied, etc. This pattern closely matches the torque
requirement of a variable torque load (centrifugal fan or pump – load
increases as speed increases) and offers the best energy savings for these
applications.
Maximum Voltage
Base Voltage
(Nameplate)
Run Boost
Base Frequency
(Nameplate)
Maximum
Frequency
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. 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:
– Start Boost - Used to create additional torque for breakaway from
zero speed and acceleration of heavy loads at lower speeds
– Run Boost - Used to create additional running torque at low speeds.
The value is typically less than the required acceleration torque. The
drive will lower the boost voltage to this level when running at low
speeds (not accelerating). This reduces excess motor heating that
could be caused if the higher start / accel boost level were used.
– Break Voltage/Frequency - Used to increase the slope of the lower
portion of the Volts / hertz curve, providing additional torque.
– Motor Nameplate Voltage/Frequency - sets the upper portion of the
curve to match the motor design. Marks the beginning of the constant
horsepower region
– Maximum Voltage/Frequency - Slopes that portion of the curve
used above base speed.
Maximum Voltage
Base Voltage
(Nameplate) Voltage
Break Voltage
Start/Accel Boost
Run Boost
Break
Frequency
Base Frequency
(Nameplate)
Maximum
Frequency
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
Resolver
TORQUE I EST.
CURRENT FEEDBACK
V/Hz Control
SPEED REF.
+
FREQUENCY REF.
+
Current
Limit
ELEC. FREQ.
V/Hz
Flux
Vector
Control
Voltage
Control
GATE
SIGNALS
Inverter
Motor
TORQUE I EST.
TORQUE I EST.
V REF.
V VECTOR
Slip
Estimator
SLIP FREQUENCY
The algorithms operate on the knowledge that motor current is the vector
sum of the torque and flux producing components. Values can be entered to
identify the motor values or an autotune routine can be run to interrogate
and identify the motor values (see Autotune on page 2-181). Early versions
required feedback, but today, performance is sensorless. It offers high
breakaway torque, exceptional running torque, a wider speed range than V/
Hz, higher dynamic response and a fast accel “feed forward” selectable for
low inertia loads (adaptive current limit).
Sensorless vector is not a torque regulating technology. It does NOT
independently control the flux and torque producing currents. Therefore, it
cannot be used to regulate torque (torque follower).
In sensorless vector control, the drive maintains a constant flux current up to
base speed, allowing the balance of the drive available current to develop
maximum motor torque. By manipulating output voltage as a function of
load, excellent motor torque can be generated.
Maximum Voltage
Base Voltage
(Nameplate)
Ir Voltage
urve
ad C
ll Lo
u
F
te
ima
urve
prox
ad C
o
App
L
o
te N
ima
prox
p
p
A
Base Frequency
(Nameplate)
Maximum
Frequency
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]. The product of [Flux Current] and the result of the stator
resistance test procedure will be stored in the parameter [IR Voltage Drop].
There are two options for autotuning:
• Static - the motor shaft will not rotate during this test.
• Dynamic - the motor shaft will rotate during this test.
The static test determines only stator resistance, while the dynamic
Autotune procedure determines both the stator resistance and motor flux
current.
[IR Voltage Drop] is used by the IR Compensation procedure to provide
additional voltage at all frequencies to offset the voltage drop developed
across the stator resistance. An accurate calculation of the [IR Voltage
Drop] will ensure higher starting torque and better performance at low
speed operation.
If it is not possible or desirable to run the Autotune tests, there are two other
methods for the drive to determine the [IR Voltage Drop] and [Flux Current]
parameters. One method retrieves the default parameters stored in the power
EEprom, and the other method calculates them from the user-entered motor
nameplate data parameters.
If the stator resistance and flux current of the motor are known, the user can
calculate the voltage drop across the stator resistance and directly enter
these values into the [Flux Current] and [IR Voltage Drop] parameters.
The user must enter motor nameplate data into the following parameters for
the Autotune procedure to obtain accurate results:
[Motor NP Volts]
[Motor NP Hertz]
[Motor NP Power]
In addition to the motor nameplate parameters, the user must also enter a
value in the [Autotune] parameter to determine which Autotune tests to
perform.
The following options for the [Autotune] parameter are as follows:
0 = Ready
1 = Static Tune
2 = Rotate Tune
3 = Calculate
The procedure to identify the motor flux current, stator resistance, and IR
voltage drop is started with the [Autotune] parameter. The tests are initiated
after a value is entered (1 for static or 2 for dynamic) into this parameter and
the start button is pressed. When the tests are finished, the [Autotune]
parameter is set to 0 (ready), the drive is stopped, and the Autotune
procedure is complete.
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.
The following conditions will generate a fault during an Autotune
procedure:
•
•
•
•
Incorrect stator resistance measurement
Incorrect motor flux current measurement
Load too large
Autotune aborted by user
When the drive is initially powered up, the [Autotune] parameter is
defaulted to a value of 3(calculate). With this setting, any changes made by
the user to motor nameplate HP, Voltage, Frequency, or Power activates a
new calculation, which will update the [IR Voltage Drop] and [Flux
Current] parameters. This calculation is based on a typical motor with those
nameplate values. The Autotune parameter will not be reset to zero after
this calculation is performed; calculations will continue to be performed
every time motor nameplate values are changed.
Flux Current
[Flux Current Ref]
The test to identify the motor flux current requires the load to be uncoupled
from the motor to find an accurate value. If this is not possible and the no
load current is know then the value can be entered into the flux current
parameter and this step in the drive commissioning can be skipped. If it is
not possible to uncouple the load and the no load current is not known, then
a value of zero is entered into flux and this step in the drive commissioning
can be skipped.
This parameter displays only the flux producing component of output
current. It displays the amount of current that is out of phase with the output
voltage. This current is reactive current and is used to produce flux in the
motor.
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.
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. In the
motor, the acceleration profile may not follow the commanded acceleration
profile due to the lack of developed torque.
Figure 2.23 Accel Profile during Normal Start - No Flux Up
Frequency
Frequency
Reference
Rated Flux
Stator
Rotor
Oscillation due
to flux being
established
0
Time
The second method is Flux Up Mode. In this mode, DC current is applied to
the motor at a level equal to the lesser of the current limit setting, drive rated
current, and drive DC current rating. The flux up time period is based on the
level of flux up current and the rotor time constant of the motor.
The flux up current is not user adjustable.
Figure 2.24 Flux Up Current versus Flux Up Time
Flux Up Current
Flux Up Current = Maximum DC Current
Rated Flux
Current
Rated Motor Flux
Motor Flux
T1
T2
T3
T4
Flux Up Time
[Flux Up Time]
Once rated flux is reached in the motor, normal operation begins and the
desired acceleration profile is achieved.
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
Rotor Speed
Motor Flux
Stator Freq
Flux Up
Voltage
Motor Flux
Flux Up
Normal
Operation
Time
Torque Current
This parameter displays only the torque producing component of output
current. It displays the amount of current that is in phase with the output
voltage. This current is real current and is used to produce torque in the
motor.
IR Drop Volts
[IR Voltage Drop]
The test to identify the IR drop of the drive and motor does not require the
load to be uncoupled from the motor and should be run even if the flux
current identification procedure is skipped.
Troubleshooting
Troubleshooting
2-185
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.
This value will rollover to 0 after the drive has been powered on for more
than the hours shown in the Range field (approximately 47.667 years).
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
operation, suitable isolation is required for the drive. Where this potential
exists, an isolation transformer is strongly recommended.
Ungrounded Distribution Systems
All drives are equipped with an MOV (Metal Oxide Varistor) that provides
voltage surge protection and phase-to-phase plus phase-to-ground
protection which is designed to meet IEEE 587. The MOV circuit is
designed for surge suppression only (transient line protection), not
continuous operation.
With ungrounded distribution systems, the phase-to-ground MOV
connection could become a continuous current path to ground. Energy
ratings are listed below. Exceeding the published phase-to-phase or
phase-to-ground energy ratings may cause physical damage to the MOV.
Three-Phase
AC Input
Ground
R
S
T
Joules (J)
Phase-to-Phase MOV Rating
Includes 2 Phase-Phase MOVs
Joules (J)
Joules (J)
Phase-to-Ground MOV Rating
Includes Phase-Phase & Phase-Ground MOVs
Joules (J)
1
2
3
4
Device Rating (V AC)
240
Phase-Phase Total
Phase-Ground Total
160J 320J
220J 380J
480/600
240/480 600
240/480 600
280J
360J
280J
360J
320J
410J
300J
370J
PowerFlex drives contain protective MOVs and common mode capacitors
that are referenced to ground. To guard against drive damage, these devices
should be disconnected if the drive is installed on an ungrounded
distribution system where the line-to-ground voltages on any phase could
exceed 125% of the nominal line-to-line voltage. Refer to your PowerFlex
User Manual for details.
Also refer to “Wiring and Grounding Guidelines for PWM AC Drives,”
publication DRIVES-IN001A-EN-P.
User Sets
User Sets
2-187
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” or other needs. All parameter information is
stored. The user can then recall this data to the active drive operating
memory as needed. Each User Set can also be identified with a
programmable name, selected by the user for clarity.
Two operations are available to manage User Sets, “Save To User Set” and
“Restore From User Set.” The user selects 1, 2, or 3 as the area in which to
store data. After data is successfully transferred, “Save User Set” returns to
a value of 0. To copy a given area back into the active EEprom memory, the
user selects Set 1, 2, or 3 for “Restore User Set.” After data is successfully
transferred, “Restore User Set” returns to a value of 0. When shipped from
the factory all user sets have the same factory default values. Reset Defaults
does not effect the contents of User Sets.
Important: User Sets can only be transferred via the HIM. No provisions
exist for control via digital I/O or communications module.
Figure 2.26 User Sets
PowerBoard
EEprom
Factory
Default Data
Reset Defaults
Drive Rating & Motor
Parameters
1
Reset
Active EE
Non Drive Rating & Motor
Parameters
Flash Memory
SaveUserSet
400V
Default Data
480V
Default Data
2
1
User Set 1
2
User Set 2
3
User Set 3
Save
User set
3
Active EE
Restore
User set
RestoreUserSet
Load
Application
Set
Application Set
Flash Memory
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. While the hardware remains
the same for each class, other variables, such as factory defaults, catalog
number and power unit ratings will change. In most cases, all drives within
a voltage class can be reprogrammed to another drive in the class by
resetting the defaults to something other than “factory” settings. The
[Voltage Class] parameter can be used to reset a drive to a different setup
within the voltage class.
As an example, consider a 480 volt drive. This drive comes with factory
default values for 480V, 60 Hz with motor data defaulted for U.S. motors
(HP rated, 1750 RPM, etc.) By setting the [Voltage Class] parameter to
“low Voltage” (this represents 400V in this case) the defaults are changed to
400V, 50 Hz settings with motor data for European motors (kW rated, 1500
RPM, etc.). Refer to Figure 2.26.
Watts Loss
Watts Loss
2-189
The following table lists watts loss data for PowerFlex drives running at full
load, full speed and a factory default 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.
Table 2.X PowerFlex 70 Watts Loss at Full Load/Speed, 4kHz (1)
Voltage
480
240V
Normal Duty HP
0.5
1
2
3
5
7.5
10
15
20
0.5
1
2
3
5
7.5
10
Internal
17.9
19.5
21.6
24.0
28.2
27.8
32.0
34.2
42.9
19.2
20.5
22.6
25.4
33.2
34.2
48.1
External
11.5
27.8
43.6
64.6
99.5
140.0
193.3
305.4
432.9
12.2
30.7
44.6
67.3
141.3
205.7
270.4
Total
29.4
47.3
65.2
88.6
127.7
167.8
225.3
339.6
475.8
31.4
51.2
67.2
92.7
174.5
239.9
318.5
PowerFlex 700
PowerFlex 700 drives are offered in panel mount versions only. At this time,
no method exists for venting outside of a secondary enclosure. This requires
enclosure sizing for total watts. see Table 2.Y.
(1) Includes HIM.
2-190
Watts Loss
Table 2.Y PowerFlex 700 Watts Loss at Full Load/Speed, 4kHz (1)
Voltage
480V
ND HP
0.5
1
2
3
5
7.5
10
15
20
25
30
40
50
60
75
100
Internal
42
44
45
46
87
79
84
99
91
102
103
117
148
210
241
332
(1) Includes HIM and Standard I/O Board.
External
11
19
31
46
78
115
134
226
303
339
357
492
568
764
906
1143
Total
53
63
76
93
164
194
218
326
394
441
459
610
717
974
1146
1475
Appendix
A
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
A-2
Dynamic Brake Selection Guide
Dynamic Braking
Resistor Calculator
www.abpowerflex.com
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls” (Publication SGI-1.1 available from
your local Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi)
describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also
because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each intended
application of this equipment is acceptable.
In no event will the Allen-Bradley Company be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, the Allen-Bradley Company cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
!
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss.
Attentions help you:
•
•
•
identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
Shock Hazard labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the drive to alert
people that surfaces may be at dangerous temperatures.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
Table of Contents
Section 1
Understanding How Dynamic Braking Works
This section provides an overview of the components required to
do Dynamic Braking and their functionality.
How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dynamic Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2
Determining Dynamic Brake Requirements
This section steps you through the calculations necessary to
determine the amount of Dynamic Braking required for your
application.
How to Determine Dynamic Brake Requirements . . . . . . . . . . . 2-1
Determine Values of Equation Variables . . . . . . . . . . . . . . . . . . 2-4
Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Section 3
Evaluating the Internal Resistor
This section steps you through the process to determine whether
or not the available PowerFlex internal resistors are adequate for
your application.
Evaluating the Capability of the
Internal Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PowerFlex 70 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
PowerFlex 700 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Section 4
Selecting An External Resistor
This section steps you through the process of selecting an
external resistor when the internal resistors prove to be
insufficient for your application.
How to Select an External Dynamic Brake Resistor . . . . . . . . . 4-1
Appendix A
ii
Table of Contents
Section 1
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. This process is referred to as
motoring. When the rotor is turning faster than the synchronous speed
set by the drive’s output power, the motor is transforming mechanical
energy available at the drive shaft of the motor into electrical energy that
can be transferred back to the drive. This process is referred to as
regeneration.
Most AC PWM drives convert AC power from the fixed frequency utility
grid into DC power by means of a diode rectifier bridge or controlled
SCR bridge before it is inverted into variable frequency AC power.
Diode and SCR bridges are cost effective, but can only handle power in
the motoring direction. Therefore, if the motor is regenerating, the
bridge cannot conduct the necessary negative DC current, the DC bus
voltage will increase and cause an overvoltage fault at the drive. More
complex bridge configurations use SCRs or transistors that can
transform DC regenerative electrical power into fixed frequency utility
electrical energy. This process is known as line regeneration.
A more cost effective solution can be provided by allowing the drive to
feed the regenerated electrical power to a resistor which transforms it
into thermal energy. This process is referred to as dynamic braking.
1-2
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
FWD
Dynamic
Brake
Resistor
Voltage
Divider
To
Voltage
Control
Signal
Common
To
Voltage Dividers
Chopper Transistor
Voltage Control
Chopper
Transistor
FWD
To
Voltage
Control
Voltage
Divider
– DC Bus
Chopper
The Chopper is the Dynamic Braking circuitry that senses rising DC bus
voltage and shunts the excess energy to the Dynamic Brake Resistor. A
Chopper contains three significant power components:
The Chopper Transistor is an Isolated Gate Bipolar Transistor (IGBT).
The Chopper Transistor is either ON or OFF, connecting the Dynamic
Brake Resistor to the DC bus and dissipating power, or isolating the
resistor from the DC bus. The most important rating is the collector
current rating of the Chopper Transistor that helps to determine the
minimum resistance value used for the Dynamic Brake Resistor.
Understanding How Dynamic Braking Works
1-3
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)
790V DC (for 480V AC input)
987V DC (for 600V AC input)
Voltage dividers reduce the DC bus voltage to a value that is usable in
signal circuit isolation and control. The DC bus feedback voltage from
the voltage dividers is compared to a reference voltage to actuate the
Chopper Transistor.
The Freewheel Diode (FWD), in parallel with the Dynamic Brake
Resistor, allows any magnetic energy stored in the parasitic inductance
of that circuit to be safely dissipated during turn off of the Chopper
Transistor.
Resistor
The Resistor dissipates the regenerated energy in the form of heat. The
PowerFlex Family of Drives can use either the internal dynamic brake
resistor option or an externally mounted dynamic brake resistor wired to
the drive.
1-4
Notes:
Understanding How Dynamic Braking Works
Section 2
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. In
general, the motor power rating, speed, torque, and details regarding the
regenerative mode of operation will be needed in order to estimate what
Dynamic Brake Resistor value is needed.
The Peak Regenerative Power and Average Regenerative Power
required for the application must be calculated in order to determine the
resistor needed for the application. Once these values are determined, the
resistors can be chosen. If an internal resistor is chosen, the resistor must
be capable of handling the regenerated power or the drive will trip. If an
external resistor is chosen, in addition to the power capabilities, the
resistance must also be less than the application maximum and greater
than the drive minimum or the drive will trip.
The power rating of the Dynamic Brake Resistor is estimated by
applying what is known about the drive’s motoring and regenerating
modes of operation. The Average Power Dissipation must be estimated
and the power rating of the Dynamic Brake Resistor chosen to be greater
than that average. If the Dynamic Brake Resistor has a large
thermodynamic heat capacity, then the resistor element will be able to
absorb a large amount of energy without the temperature of the resistor
element exceeding the operational temperature rating. Thermal time
constants in the order of 50 seconds and higher satisfy the criteria of
large heat capacities for these applications. If a resistor has a small heat
capacity (defined as thermal time constants less than 5 seconds) the
temperature of the resistor element could exceed its maximum.
Peak Regenerative Power can be calculated as:
•
Horsepower (English units)
•
Watts (The International System of Units, SI)
•
Per Unit System (pu) which is relative to a value
The final number must be in watts of power to estimate the resistance
value of the Dynamic Brake Resistor. The following calculations are
demonstrated in SI units.
2-2
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, t3 – t2). This time is a process
requirement and must be within the capabilities of the drive
programming.
•
Motor inertia and load inertia in kg-m2 or lb.-ft.2
•
Gear ratio (GR) if a gear is present between the motor and load
•
Motor shaft speed, torque, and power profile of the drive application
Figure 2.1 shows typical application profiles for speed, torque and
power. The examples are for cyclical application that is periodic over t4
seconds. The following variables are defined for Figure 2.1:
ω(t)
N
2πN
= Motor shaft speed in radians per second (rps) ω = ---------60
= Motor shaft speed in Revolutions Per Minute (RPM)
T(t)
= Motor shaft torque in Newton-meters
1.0 lb.-ft. = 1.355818 N-m
P(t)
= Motor shaft power in watts
1.0 HP = 746 watts
ωb
Rad
= Rated angular rotational speed --------s
Rad
= Angular rotational speed less than ωb (can equal 0) --------s
= Motor shaft peak regenerative power in watts
ωo
-Pb
Determining Dynamic Brake Requirements
2-3
Figure 2.1 Application Speed, Torque and Power Profiles
Speed
ω(t)
ωb
ωo
0
t1
t2
t3
t4
t1 + t4
t
t1
t2
t3
t4
t1 + t4
t
t1
t2
t3
t4
t1 + t4
t
t1
t2
t3
t4
t1 + t4
t
Torque
T(t)
0
Power
P(t)
0
-Pb
Drive Rated
Regen Power
Prg
0
2-4
Determining Dynamic Brake Requirements
Determine Values of Equation Variables
Step 2
Total Inertia
2
J T = J m + ( GR × J L )
JT
= Total inertia reflected to the motor shaft (kg-m2 or lb.-ft.2)
Jm
= Motor inertia (kg-m2 or lb.-ft.2)
GR
= Gear ratio for any gear between motor and load
(dimensionless)
JL
= Load inertia (kg-m2 or lb.-ft.2)
1.0 lb.-ft.2 = 0.04214011 kg-m2
Calculate Total Inertia:
J T = [ oooooooooo ] + ( oooooooooo × oooooooooo )
Record Total Inertia:
JT
=
Determining Dynamic Brake Requirements
Step 3
2-5
Peak Braking Power
JT [ ωb ( ωb – ωo ) ]
P b = ---------------------------------------( t3 – t2 )
Pb
= Peak braking power (watts)
1.0 HP = 746 watts
JT
= Total inertia reflected to the motor shaft (kg-m2)
2πN
Rad
= Rated angular rotational speed --------- = -----------bs
60
ωb
ωo
= Angular rotational speed,
Rad
less than rated speed down to zero --------s
Nb
= Rated motor speed (RPM)
t3 – t2 = Deceleration time from ωb to ωo (seconds)
Calculate Peak Braking Power:
[ ooooooooo ] × [ ooooooooo ] × ( ooooooooo – ooooooooo )
P b = ----------------------------------------------------------------------------------------------------------------------------------------------( ooooooooo – ooooooooo )
Record Peak Braking Power:
Pb
=
Compare the peak braking power (Pb) to the drive rated regenerative
power (Prg). If the peak braking power is greater than the drive rated
regenerative power, the decel time will have to be increased so that the
drive does not enter current limit. Drive rated regenerative power (Prg) is
determined by:
2
V
P rg = ----R
Prg
= Drive rated regenerative power
V
= DC bus regulation voltage from Table A.A
R
= Minimum brake resistance from Table A.A
2
[ ooooooooo ]
P rg = ---------------------------------( ooooooooo )
Record Rated Regenerative Power:
Prg
=
2-6
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. If (t3 – t2) equals the time in seconds
necessary for deceleration from rated speed to ωo speed, and t4 is the
time in seconds before the process repeats itself, then the average duty
cycle is (t3 – t2)/t4. The power as a function of time is a linearly
decreasing function from a value equal to the peak regenerative power to
some lesser value after (t3 – t2) seconds have elapsed. The average power
regenerated over the interval of (t3 – t2) seconds is: P b ( ω b + ω o )
----- × -----------------------ωb
2
Pav
= Average dynamic brake resister dissipation (watts)
t3 – t2 = Deceleration time from ωb to ωo (seconds)
t4
= Total cycle time or period of process (seconds)
Pb
= Peak braking power (watts)
ωb
Rad
= Rated angular rotational speed --------s
ωo
= Angular rotational speed,
Rad
less than rated speed down to zero --------s
The Average Power in watts regenerated over the period t4 is:
( t3 – t2 ) Pb ( ωb + ωo )
P av = ------------------ ----- -----------------------t4
ωb
2
Calculate Average Power in watts regenerated over the period t4:
( oooooo + oooooo )
( oooooo – oooooo )
[ oooooo ]
P av = ----------------------------------------------- × ----------------------- × ----------------------------------------------[ oooooo ]
[ oooooo ]
2
Record Average Power in watts regenerated over the period t4:
Pav
=
Determining Dynamic Brake Requirements
Step 5
2-7
Percent Average Load of the Internal Dynamic Brake
Resistor
Skip this calculation if an external dynamic brake resistor will be used.
P av
AL = -------- × 100
P db
AL
= Average load in percent of dynamic brake resistor
Pav
= Average dynamic brake resistor dissipation calculated in
Step 4 (watts)
Pdb
= Steady state power dissipation capacity of dynamic brake
resistors obtained from Table A.A (watts)
Calculate Percent Average Load of the dynamic brake resistor:
[ oooooooooo ]
AL = ----------------------------------- × 100
[ oooooooooo ]
Record Percent Average Load of the dynamic brake resistor:
AL
=
The calculation of AL is the Dynamic Brake Resistor load expressed as a
percent. Pdb is the sum of the Dynamic Brake dissipation capacity and is
obtained from Table A.A. This will give a data point for a line to be
drawn on one the curves provided in Section 3.
2-8
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.
Pb
PL = -------- × 100
P db
PL
= Peak load in percent of dynamic brake resistor
Pav
= Peak braking power calculated in Step 2 (watts)
Pdb
= Steady state power dissipation capacity of dynamic brake
resistors obtained from Table A.A (watts)
Calculate Percent Peak Load of the dynamic brake resistor:
[ oooooooooo ]
PL = ----------------------------------- × 100
[ oooooooooo ]
Record Percent Average Load of the dynamic brake resistor:
PL
=
The calculation of PL in percent gives the percentage of the
instantaneous power dissipated by the Dynamic Brake Resistors relative
to the steady state power dissipation capacity of the resistors. This will
give a data point to be drawn on one of the curves provided in Section 3.
Determining Dynamic Brake Requirements
2-9
Example Calculation
A 10 HP, 4 Pole, 480 Volt motor and drive is accelerating and
decelerating as depicted in Figure 2.1.
•
Cycle period t4 is 40 seconds
•
Rated speed is 1785 RPM and is to be decelerated to 0 speed in 15.0
seconds
•
Motor load can be considered purely as inertia, and all power
expended or absorbed by the motor is absorbed by the motor and
load inertia
•
Load inertia is 4.0 lb.-ft.2 and is directly coupled to the motor
•
Motor rotor inertia is 2.2 lb.-ft.2
•
A PowerFlex 70, 10 HP 480V Normal Duty rating is chosen.
Calculate the necessary values to choose an acceptable Dynamic Brake.
Rated Power = 10 HP × 746 watts = 7.46 kW
This information was given and must be known before the calculation
process begins. This can be given in HP, but must be converted to watts
before it can be used in the equations.
1785
186.98 Rad
Rated Speed = ω b = 1785 RPM = 2π × ---------- = ------------------------60
s
0
0 Rad
Lower Speed = ω o = 0 RPM = 2π × ----- = ------------60
s
This information was given and must be known before the calculation
process begins. This can be given in RPM, but must be converted to
radians per second before it can be used in the equations.
Total Inertia = J T = 6.2 lb.-ft. 2 = 0.261 kg-m 2
This value can be in lb.-ft.2 or Wk2, but must be converted into kg-m2
before it can be used in the equations.
Deceleration Time = ( t 3 – t 2 ) = 15 seconds
Period of Cycle = t 4 = 40 seconds
2-10
Determining Dynamic Brake Requirements
V d = 750 Volts
This was known because the drive is rated at 480 Volts rms. If the drive
were rated 230 Volts rms, then Vd = 395 Volts.
All of the preceding data and calculations were made from knowledge of
the application under consideration. The total inertia was given and did
not need further calculations as outlined in Step 2.
JT [ ωb ( ωb – ωo ) ]
Peak Braking Power = P b = ---------------------------------------( t3 – t2 )
0.261 [ 186.92 ( 186.92 – 0 ) ]
P b = ------------------------------------------------------------- = 608.6 watts
15
Note that this is 8.1% of rated power and is less than the maximum drive
limit of 150% current limit. This calculation is the result of Step 3 and
determines the peak power that must be dissipated by the Dynamic
Brake Resistor.
( t3 – t2 ) Pb ( ωb + ωo )
Average Braking Power = P av = ------------------ ----- -----------------------t4
ωb
2
15 608.6 186.92 + 0
P av =  -----  ------------  ------------------------ = 114.1 watts
 40  2   186.92 
This is the result of calculating the average power dissipation as outlined
in Step 5. Verify that the sum of the power ratings of the Dynamic Brake
Resistors chosen in Step 4 is greater than the value calculated in Step 5.
Refer to Table A.A to determine the continuous power rating of the
resistor in the given drive you are using. You will need this number to
determine the Percent Average Load and the Percent Peak Load.
P av
Percent Average Load = AL = 100 × -------P db
114.1
AL = 100 × ------------ = 285%
40
This is the result of the calculation outlined in Step 6. Record this value
on page 3-1.
Determining Dynamic Brake Requirements
2-11
Pb
Percent Peak Load = PL = 100 × -------P db
608.6
PL = 100 × ------------ = 1521%
40
This is the result of the calculation outlined in Step 6. Record this value
on 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. Since
the internal resistor package offers significant cost and space advantages,
it will be evaluated first.
2-12
Notes:
Determining Dynamic Brake Requirements
Section 3
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. If any portion of this line
lies to the right of the constant temperature power curve, the resistor
element temperature will exceed the operating temperature limit.
Important: The drive will protect the resistor and shut down the
Chopper transistor. The drive will then likely trip on an
overvoltage fault.
1. Record the values calculated in Section 2.
AL
=
PL
=
t3 – t2 =
3-2
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
240
240
240
400/480
400/480
400/480
Drive Frame(s)
A and B
C
D
A and B
C
D
Figure Number
3.1
3.3
3.4
3.5
3.6
3.7
OR
Power Curves for PowerFlex 700 Internal DB Resistors
Drive Voltage
400/480
400/480
400/480
400/480
Drive Frame
0
1
2
3
Figure Number
3.8
3.9
3.10
Uses external DB resistors
only. Refer to Section 4
3. Plot the point where the value of AL, calculated in Step 5 of
Section 2, and the desired deceleration time (t3 – t2) intersect.
4. Plot the value of PL, calculated in Step 6 of Section 2, on the vertical
axis (0 seconds).
5. Connect AL at (t3 – t2) and PL at 0 seconds with a straight line. This
line is the power curve described by the motor as it decelerates to
minimum speed.
Evaluating the Internal Resistor
3-3
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
2600
2400
2200
% Peak Power
2000
1800
PL (Peak Percent Load) = 1521%
1600
1400
1200
1000
800
600
AL (Average Percent Load) = 285%
400
Decel Time = 15.0 Seconds
200
0
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)
If any portion of the line connecting AL and PL lies to the right of the
Power Curve, then the capability of the internal resistor is insufficient
for the proposed application.
•
Increase deceleration time (t3 – t2) until the line connecting AL and PL
lies entirely to the left of the Power Curve
or
•
Go to Section 4 and select an external resistor from the tables
3-4
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
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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 – 240 Volt, Frame C
3000
240V Frame C
2800
2600
2400
2200
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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)
Evaluating the Internal Resistor
3-5
Figure 3.4 PowerFlex 70 – 240 Volt, Frame D
3000
240V Frame D
2800
2600
2400
2200
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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 & B
2800
2600
2400
2200
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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)
3-6
Evaluating the Internal Resistor
Figure 3.6 PowerFlex 70 – 480 Volt, Frame C
3000
480V Frame C
2800
2600
2400
2200
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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 – 480 Volt, Frame D
3000
480V Frame D
2800
2600
2400
2200
% Peak Power
2000
1800
1600
1400
1200
1000
800
600
400
200
0
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)
Evaluating the Internal Resistor
3-7
PowerFlex 700 Power Curves
Figure 3.8 PowerFlex 700 – 480 Volt, Frame 0
10000
480V Frame 0
9000
8000
% Peak Power
7000
6000
5000
4000
3000
2000
1000
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Decel Time (Seconds)
Figure 3.9 PowerFlex 700 – 480 Volt, Frame 1
10000
480V Frame 1
9000
8000
% Peak Power
7000
6000
5000
4000
3000
2000
1000
0
0
1
2
3
4
5
6
7
8
9
10
11
12
Decel Time (Seconds)
13
14
15
16
17
18
19
20
3-8
Evaluating the Internal Resistor
Figure 3.10 PowerFlex 700 – 480 Volt, Frame 2
10000
480V Frame 2
9000
8000
% Peak Power
7000
6000
5000
4000
3000
2000
1000
0
0
1
2
3
4
5
6
7
8
9
10
11
12
Decel Time (Seconds)
13
14
15
16
17
18
19
20
Section 4
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. If this value is greater than the maximum
imposed by the peak regenerative power of the drive, the drive can trip
off due to transient DC bus overvoltage problems.
Power Rating of the Dynamic Brake Resistor
The average power dissipation of the regenerative mode must be
estimat4ed and the power rating of the Dynamic Brake Resistor chosen
to be greater than the average regenerative power dissipation of the
drive.
4-2
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.
Figure 4.1 External Brake Resistor Circuitry
Three-Phase
AC Input
(Input Contactor) M
R (L1)
S (L2)
T (L3)
Power Off
Power On
M
M
Power Source
DB Resistor Thermostat
Selecting An External Resistor
4-3
Record the Values Calculated in Section 2
Pb
=
Pav
=
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 (Rdb1) must be calculated.
( Vd )2
R db1 = -----------Pb
Rdb1 = Maximum allowable value for the dynamic brake resistor
(ohms)
Vd
= DC bus voltage the chopper module regulates to
(395V DC, 790V DC, or 987V DC)
Pb
= Peak breaking power calculated in Section 2: Step 3
(watts)
Calculate Maximum Dynamic Brake Resistance:
( ooooooooo ) 2
R db1 = ---------------------------------[ ooooooooo ]
Record Maximum Dynamic Brake Resistance:
Rdb1 =
The choice of the Dynamic Brake resistance value should be less than
the value calculated in this step. If the value is greater, the drive can trip
on DC bus overvoltage. Do not reduce Pb by any ratio because of
estimated losses in the motor and inverter. This has been accounted for
by an offsetting increase in the manufacturing tolerance of the resistance
value and the increase in resistance value due to the temperature
coefficient of resistor element.
4-4
Selecting An External Resistor
Select Resistor
Select a resistor bank from Table 4.A or 4.B or your resistor supplier that
has all of the following:
!
•
a resistance value that is less than the value calculated (Rdb1 in ohms)
•
a resistance value that is greater than the minimum resistance listed
in Table A.A
•
a power value that is greater than the value calculated in Step 4
(Pav in watts)
ATTENTION: The internal dynamic brake IGBT will be damaged if
the resistance value of the resistor bank is less than the minimum
resistance value of the drive. Use Table A.A to verify that the resistance
value of the selected resistor bank is greater than the minimum
resistance of the drive.
If no resistor appears in the following tables that is greater than the
minimum allowable resistance and is less than the calculated maximum
resistance:
•
Adjust the deceleration time of the application to fit an available
resistor package.
or
•
Use the calculated data to purchase resistors locally.
or
•
Consult the factory for other possible resistor packages.
Selecting An External Resistor
Table 4.A Resistor Selection for 240V AC Drives
Ohms
154
154
154
154
154
154
110
110
110
110
110
110
85
85
85
85
85
85
59
59
59
59
59
59
Watts
182
242
408
604
610
913
255
338
570
845
850
1278
326
438
730
1089
1094
1954
473
631
1056
1576
1577
2384
Catalog
Number
222-1A
222-1
225-1A
225-1
220-1A
220-1
222-2A
222-2
225-2A
225-2
220-2A
220-2
222-3A
222-3
225-3A
220-3A
225-3
220-3
222-4A
222-4
225-4A
225-4
220-4A
220-4
Ohms
45
45
45
45
45
45
32
32
32
32
32
32
20
20
20
20
20
20
Watts
617
827
1378
2056
2066
3125
875
1162
1955
2906
2918
4395
1372
1860
3063
4572
4650
7031
Catalog
Number
222-5A
222-5
225-5A
220-5A
225-5
220-5
222-6A
222-6
225-6A
225-6
220-6A
220-6
222-7A
222-7
225-7A
220-7A
225-7
220-7
4-5
4-6
Selecting An External Resistor
Table 4.B Resistor Selection for 480V AC Drives
Ohms
615
615
615
615
615
615
439
439
439
439
439
439
342
342
342
342
342
342
237
237
237
237
237
237
181
181
181
181
181
181
Watts
180
242
404
602
605
915
254
339
568
847
848
1281
329
435
734
1088
1096
1645
473
628
1057
1570
1577
2373
620
822
1385
2055
2068
3108
Catalog
Number
442-1A
442-1
445-1A
440-1A
445-1
440-1
442-2A
442-2
445-2A
445-2
440-2A
440-2
442-3A
442-3
445-3A
445-3
440-3A
440-3
442-4A
442-4
445-4A
445-4
440-4A
440-4
442-5A
442-5
445-5A
445-5
440-5A
440-5
Ohms
128
128
128
128
128
128
81
81
81
81
81
81
56
56
56
56
56
56
44
44
44
44
44
44
29
29
29
29
29
29
Watts
874
1162
1951
2906
2912
4395
1389
1837
3102
4592
4629
6944
2010
2657
4490
6642
6702
10045
2561
3381
5720
8454
8537
12784
3800
5130
8487
12667
12826
19396
Catalog
Number
442-6A
442-6
445-6A
445-6
440-6A
440-6
442-7A
442-7
445-7A
445-7
440-7A
440-7
442-8A
442-8
445-8A
445-8
440-8A
440-8
442-9A
442-9
445-9A
445-9
440-9A
440-9
442-10A
442-10
445-10A
440-10A
445-10
440-10
Selecting An External Resistor
4-7
Table 4.C Resistor Selection for 600V AC Drives
Ohms
956
956
956
956
956
956
695
695
695
695
695
695
546
546
546
546
546
546
364
364
364
364
364
364
283
283
283
283
283
283
Watts
175
242
400
597
605
915
248
333
553
825
832
1258
316
424
707
1055
1059
1601
477
635
1065
1588
1590
2402
614
817
1372
2043
2048
3089
Catalog
Number
552-1A
552-1
555-1A
550-1A
555-1
550-1
552-2A
552-2
555-2A
550-2A
555-2
550-2
552-3A
552-3
555-3A
550-3A
555-3
550-3
552-4A
552-4
555-4A
555-4
550-4A
550-4
552-5A
552-5
555-5A
555-5
550-5A
550-5
Ohms
196
196
196
196
196
196
125
125
125
125
125
125
85
85
85
85
85
85
70
70
70
70
70
70
45
45
45
45
45
45
Watts
890
1180
1987
2950
2965
4460
1386
1850
3095
4620
4625
6994
2056
2720
4592
6801
6854
10285
2527
3303
5643
8258
8424
12489
3883
5138
8672
12846
12943
19427
Catalog
Number
552-6A
552-6
555-6A
555-6
550-6A
550-6
552-7A
552-7
555-7A
550-7A
555-7
550-7
552-8A
552-8
555-8A
555-8
550-8A
550-8
552-9A
552-9
555-9A
555-9
550-9A
550-9
552-10A
552-10
555-10A
555-10
550-10A
550-10
4-8
Notes:
Selecting An External Resistor
Appendix A
Table A.A Minimum Dynamic Brake Resistance
Minimum Ohms ( 10%),
External Resistors
Rated Continuous Power,
Internal Resistors (Pdb)
Drive Normal
Duty Rating
240V, 0.5 HP
240V, 1 HP
240V, 2 HP
240V, 3 HP
240V, 5 HP
240V, 7.5 HP
PowerFlex 70
Regen DC Bus
Voltage (Vd ) Frame Watts
395
240V, 10 HP
240V, 15 HP
240V, 20 HP
400V, 0.37 kW
480V, 0.5 HP
400V, 0.75 kW
480V, 1 HP
400V, 1.5 kW
480V, 2 HP
400V, 2.2 kW
480V, 3 HP
400V, 4 kW
480V, 5 HP
400V, 5.5 kW
480V, 7.5 HP
400V, 7.5 kW 658 for 400V
480V, 10 HP
Drive
400V, 11 kW 790 for 480V
Drive
480V, 15 HP
400V, 15 kW
480V, 20 HP
400V, 18.5 kW
480V, 25 HP
400V, 22 kW
480V, 30 HP
400V, 30 kW
480V, 40 HP
400V, 37 kW
480V, 50 HP
400V, 45 kW
480V, 60 HP
(1)
Frame Watts
4
70
700
48
48
28
28
40
36
(2)
(2)
(3)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
60
60
48
32
(2)
(2)
(3)
D
36
(2)
(2)
(3)
(3)
(3)
(2)
(2)
(3)
(3)
(3)
(3)
(2)
(2)
(3)
(3)
A
48
0
50
(3)
A
48
0
50
A
48
0
B
28
B
A
A
B
B
C
D
Nearest (1)
Standard
Resistor
33
33
33
33
30
40
40
39
39
32
117
60
60
48
32
23
23
25
23
15
14
25
23
15
14
68
69
117
121
68
71
117
50
121
68
69
117
0
50
97
68
69
117
28
0
50
97
68
69
97
C
40
0
50
(3)
74
70
77
C
40
1
50
(3)
74
72
77
D
36
1
50
(3)
44
45
45
D
36
2
50
(3)
31
44
45
–
(2)
2
50
(3)
(3)
31
32
–
(2)
3
NA
(3)
(3)
31
32
–
(2)
3
NA
(3)
(3)
26
27
–
(2)
3
NA
(3)
(3)
27
27
–
(2)
4
NA
(3)
(3)
20
20
Chosen from Table 4.A, 4.B, or 4.C.
Not available at time of printing.
(3) Rating not available.
(2)
PowerFlex 700 PowerFlex Product
A-2
Minimum Ohms ( 10%),
External Resistors
Rated Continuous Power,
Internal Resistors (Pdb)
Drive Normal
Duty Rating
PowerFlex 70
Regen DC Bus
Voltage (Vd ) Frame Watts
PowerFlex 700 PowerFlex Product
Frame Watts
4
70
700
Nearest (1)
Standard
Resistor
400V, 55 kW
480V, 75 HP
400V, 75 kW 658 for 400V
480V, 100 HP
Drive
400V, 90 kW 790 for 480V
Drive
480V, 125 HP
400V, 110 kW
480V, 150 HP
–
(2)
5
NA
(3)
(3)
10.4
10.4
–
(2)
5
NA
(3)
(3)
10.1
10.4
–
(2)
6
NA
(3)
(3)
5.4
5.4
–
(2)
6
NA
(3)
(3)
4.8
4.8
600V, 0.5 HP
A
(2)
(2)
(2)
(3)
A
A
B
B
C
C
D
D
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
(2)
(2)
(2)
(3)
117
117
117
117
80
80
80
48
48
(2)
600V, 1 HP
600V, 2 HP
600V, 3 HP
600V, 5 HP
600V, 7.5 HP
600V, 10 HP
600V, 15 HP
600V, 20 HP
117
117
117
117
80
80
80
48
48
(1)
987
Chosen from Table 4.A, 4.B, or 4.C.
Not available at time of printing.
(3) Rating not available.
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
www.rockwellautomation.com
Corporate Headquarters
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U.S. Allen-Bradley Drives Technical Support
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Publication PFLEX-AT001C-EN-P – September 2002
Supersedes June 2002
Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in USA.
Index
A
AC Supply Source Considerations, 2-2
Accel Mask, 2-97
Accel Owner, 2-109
Accel Time, 2-1
Accel Time 1/2, 2-1
Agency Certification, 1-1
Alarm Queue, 2-6
Alarm x Code, 2-6
Alarms, 2-2
Altitude Derates, 1-4
Ambient Temperature Derates, 1-4
Analog I/O, 2-6
Analog I/O Cable Selection, 2-15
Analog In Lo, 2-9
Analog In1 Value, 2-15
Analog In2 Value, 2-15
Analog Input Scaling, 2-9
Analog Inputs, 2-6
Analog Out1 Sel, 2-19
Analog Out2 Sel, 2-19
Analog Outputs, 2-19
Anlg In 1, 2 Loss, 2-13
Anlg In Config, 2-3, 2-6
Anlg In Loss, 2-4
Anlg In Sqr Root, 2-13
Auto / Manual, 2-23, 2-148
Auto Restart, 2-25
Auto Rstrt Delay, 2-25
Auto Rstrt Tries, 2-25
Auto-Economizer, 2-80
Autotune, 2-181
B
Bipolar Inputs, 2-15
Bottom View Dimensions, 1-17
Bus Memory, 2-47
Bus Reg Gain, 2-27
Bus Reg Mode A, B, 2-27
Bus Regulation, 2-27
C
Cable
I/O, Analog, 2-15
I/O, Digital, 2-51
Motor, Length, 2-32
Power, 2-35
Cable Termination, 2-106
Cable Trays, 2-38
Carrier (PWM) Frequency, 2-39
CE
Conformity, 2-40
Requirements, 2-40
Circuit Breakers, 2-87
Clear Fault Owner, 2-109
Coast, 2-174
Common Mode Interference, 2-15
Compensation, 2-132
Conduit, 2-38
Contactor, Output, 2-106
Contactors
Input, 2-105
Output, 2-105
Control Wire, 2-51
Copy Cat, 2-42
Current Limit, 2-43
Current Lmt Gain, 2-43
Current Lmt Sel, 2-6, 2-43, 2-138
Current Lmt Val, 2-43
D
Datalinks, 2-45
DC Brake Level, 2-174
DC Brake Lvl Sel, 2-174
DC Brake Time, 2-174
DC Braking, 2-174
DC Bus Voltage, 2-47
Decel Mask, 2-97
Decel Owner, 2-109
Decel Time, 2-47
Decel Time 1/2, 2-47
Derating Guidelines, 1-4
Diagnostic Parameters, 2-48
Dig Outx Level, 2-70
Dig Outx OffTime, 2-71
Dig Outx OnTime, 2-71
Digital Input Conflicts, 2-65
Digital Inputs, 2-51
Digital Inputs Group, 2-52, 2-53
Digital Inx Sel, 2-52, 2-53
Digital Output Timers, 2-71
Digital Outputs, 2-68
Index-2
Digital Outputs Group, 2-52, 2-69
Digital Outx Sel, 2-5, 2-68, 2-69
Dimensions
Bottom View, 1-17
Mounting
PowerFlex 700, 1-13, 1-15
PowerFlex 70
Bottom View, 1-8
Mounting, 1-7
Direction Control, 2-72
Direction Mask, 2-97
Direction Owner, 2-109
Distribution Systems
Unbalanced, 2-186
Ungrounded, 2-186
DPI, 2-73
Drive Output Contactor, 2-106
Drive Overload, 2-76
Drive Ratings, 2-80
Drive Thermal Manager Protection, 2-78
Dynamic Braking, 2-174, A-1
E
Economizer, 2-80
Efficiency Derates, 1-4, 2-81
EMC
Directive, 2-40
EMC Instructions, 2-40
Exclusive Ownership, 2-109
F
Fan Curve, 2-81
Fault Clr Mask, 2-97
Fault Configuration, 2-84, 2-138
Fault Queue, 2-82
Faults, 2-82
Feedback Select, 2-144
Flux Current, 2-182
Flux Current Ref, 2-182
Flux Up, 2-182
Flux Up Mode, 2-182
Flying Start En, 2-85
Flying Start Gain, 2-85
Flying StartGain, 2-85
Fuses, 2-87
G
Group
Digital Inputs, 2-52, 2-53
Digital Outputs, 2-52, 2-69
Power Loss, 2-114
Speed References, 2-4
H
HIM Memory, 2-92
HIM Operations, 2-92
Human Interface Module
Language, 2-92
Password, 2-92
User Display, 2-92
I
I/O Wiring
Analog, 2-15
Digital, 2-51
Input Contactor
Start/Stop, 2-105
Input Devices, 2-93
Input Modes, 2-94
Input Power Conditioning, 2-95
Input/Output Ratings, 1-3
IR Drop Volts, 2-184
IR Voltage Drop, 2-184
J
Jog, 2-95
Jog Mask, 2-97
Jog Owner, 2-109
L
Language, 2-96
Language Parameter, 2-96
Language Select, HIM, 2-92
Local Mask, 2-97
Local Owner, 2-109
Logic Mask, 2-97
Low Voltage Directive, 2-40
M
Manual Preload, 2-23
Masks, 2-97
Max Speed, 2-150
Maximum frequency, 2-151
MOP Mask, 2-97
MOP Owner, 2-109
Motor Cable Lengths, 2-32
Index-3
Motor Nameplate, 2-101
Motor NP FLA, 2-101
Motor NP Hz, 2-101
Motor NP Power, 2-101
Motor NP Pwr Units, 2-101
Motor NP RPM, 2-101
Motor NP Volts, 2-101
Motor Overload, 2-102
Motor Start/Stop, 2-105
Mounting, 2-105
Mounting Dimensions, 1-7
O
Output Contactor
Start/Stop, 2-105
Output Current, 2-106
Output Devices
Contactors, 2-105, 2-106
Output Reactor, 2-106
Output Frequency, 2-107
Output Power, 2-107
Output Reactor, 2-106
Output Voltage, 2-107
Overspeed, 2-108
Owners, 2-109
P
Parameter access level, 2-111
Parameters
Accel Mask, 2-97
Accel Owner, 2-109
Alarm x Code, 2-6
Analog In Hi, 2-9
Analog In Lo, 2-9
Analog In1 Value, 2-15
Analog In2 Value, 2-15
Analog Out1 Sel, 2-19
Analog Out2 Sel, 2-19
Anlg In Config, 2-3, 2-6
Anlg In Loss, 2-4
Anlg In Sqr Root, 2-13
Auto Rstrt Delay, 2-25
Auto Rstrt Tries, 2-25
Bus Reg Gain, 2-27
Bus Reg Mode A, B, 2-27
Clear Fault Owner, 2-109
Compensation, 2-132
Current Lmt Sel, 2-6, 2-138
Decel Mask, 2-97
Decel Owner, 2-109
Dig Outx Level, 2-70
Dig Outx OffTime, 2-71
Dig Outx OnTime, 2-71
Digital Inx Sel, 2-52, 2-53
Digital Outx Sel, 2-5, 2-68, 2-69
Direction Mask, 2-97
Direction Owner, 2-109
Fault Clr Mask, 2-97
Fault Config x, 2-138
Feedback Select, 2-144
Flying Start En, 2-85
Flying Start Gain, 2-85
Flying StartGain, 2-85
Jog Mask, 2-97
Jog Owner, 2-109
Language, 2-96
Local Mask, 2-97
Local Owner, 2-109
Logic Mask, 2-97
MOP Mask, 2-97
MOP Owner, 2-109
Power Loss Mode, 2-114
Reference Mask, 2-97
Reference Owner, 2-109
Reset Meters, 2-134
Speed Mode, 2-144
Speed Ref A Sel, 2-4
Start Mask, 2-97
Start Owner, 2-109
Stop Owner, 2-109
Testpoint 1 Sel, 2-177
Testpoint x Data, 2-177
Torque Perf Mode, 2-178
Password, HIM, 2-92
PET Ref Wave, 2-111
PI Config, 2-121
PI Control, 2-121
PI Error Meter, 2-121
PI Feedback Meter, 2-121
PI Feedback Sel, 2-121
PI Integral Time, 2-121
PI Output Meter, 2-121
PI Preload, 2-121
PI Prop Gain, 2-121
PI Ref Meter, 2-121
PI Reference Sel, 2-121
PI Setpoint, 2-121
PI Status, 2-121
Index-4
PI Upper/Lower Limit, 2-121
Power Loss, 2-112
Power Loss Group, 2-114
Power Loss Mode, 2-114
Power Up Marker, 2-185
Power Wire, 2-35
Preset Frequency, 2-120
Process PI Loop, 2-121
PWM Frequency, 2-39, 2-79
Speed Regulation, 2-144
Start Inhibits, 2-152
Start Mask, 2-97
Start Owner, 2-109
Start Permissives, 2-153
Start/Stop, Repeated, 2-105
Start-Up, 2-154
Stop Mode A, B, 2-174
Stop Modes, 2-174
Stop Owner, 2-109
R
Reference Mask, 2-97
Reference Owner, 2-109
Reference, Speed, 2-54, 2-58, 2-148
Reflected Wave, 2-132
Repeated Start/Stop, 2-105
Reset Meters, 2-134
Reset Run, 2-134
RFI Filter, 2-134
S
S Curve, 2-135
Scaling Blocks, 2-9, 2-137
Sensorless Vector, 2-180
Shear Pin, 2-138
Shielded Cable, 2-35
Signal Loss, 2-13
Signal Wire, 2-16
Skip Frequency, 2-139
Sleep Mode, 2-141
Slip Compensation, 2-144
Specifications
Agency Certification, 1-1
Control, 1-2
Derating Guidelines, 1-4
Electrical, 1-2
Encoder, 1-3
Environment, 1-2
Heat Dissipation, 1-3
Input/Output Ratings, 1-3
Protection, 1-1, 1-2
Speed Control, 2-144
Speed Mode, 2-144
Speed Ref A Sel, 2-4
Speed Reference, 2-54, 2-58, 2-148
Speed Reference Trim, 2-15, 2-150
Speed References Group, 2-4
T
Terminal Designations, 2-16
Test Points, 2-177
Testpoint 1 Sel, 2-177
Testpoint x Data, 2-177
Thermal Manager Protection, 2-78
Thermal Regulator, 2-177
THHN wire, 2-35
Torque Current, 2-184
Torque Performance Modes, 2-178
Trim, 2-15
Troubleshooting, 2-185
Diagnostic Parameters, 2-48
U
Unbalanced Distribution Systems, 2-186
Ungrounded Distribution Systems, 2-186
User Display, HIM, 2-92
User Sets, 2-187
V
Voltage class, 2-188
Volts/Hertz, 2-178
W
Watts Loss, 2-189
Wire
Control, 2-51
Power, 2-35
Signal, 2-16
Wiring Examples, 2-16
www, 1-1
www.rockwellautomation.com
Corporate Headquarters
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
Europe/Middle East/Africa: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
Europe/Middle East/Africa: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 17741
Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 6356-9077, Fax: (65) 6356-9011
U.S. Allen-Bradley Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
Publication PFLEX-RM001E-EN-E – February, 2003
Supersedes PFLEX-RM001D-EN-E dated October, 2002
Copyright © 2003 Rockwell Automation, Inc. All rights reserved. Printed in USA.
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