Rockwell Automation PowerFlex 700L Frame 1X AC Drive Installation Instructions
Below you will find brief information for AC Drive PowerFlex 700L Frame 1X. This document provides a detailed guide for installing and performing a basic start-up of your PowerFlex 700L Frame 1X drive. It includes information on mounting, wiring, cooling loop connections, and start-up procedures. You'll also find helpful troubleshooting tips and specifications.
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Installation Instructions
PowerFlex
®
700L Frame 1X
Liquid-Cooled Adjustable
Frequency AC Drive
Introduction
When reading this document, look for this symbol “
Step x
” to guide you through the 6 BASIC STEPS needed to install and perform a Basic Start-Up of the PowerFlex 700L Frame 1X drive. A Human Interface Module (HIM) is required to perform the Basic Start-Up routine covered in this document.
The information provided is intended for qualified drive service personnel only.
Reference Materials
For detailed PowerFlex 700 information including advanced start-up routines, programming, application considerations and related precautions, refer to the following publications online at www.rockwellautomation.com/ literature :
Title
PowerFlex 700 Series B User Manual
PowerFlex Network Communications Adapter User Manuals
PowerFlex 70 Enhanced Control and
PowerFlex 700 Vector Control Reference Manual
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives
Publication
20B-UM002
20COMM-UM
PFLEX-RM004
DRIVES-IN001
To order paper copies of technical documentation, contact your local
Rockwell Automation distributor or sales representative.
To find your local Rockwell Automation distributor, visit www.rockwellautomation.com/locations
Allen-Bradley Drives Technical
Support
Documentation in Other
Languages
Use the contacts below for PowerFlex 700 technical support including spare parts information.
Online at…
www.ab.com/support/abdrives
By Email at…
By Telephone at…
262-512-8176
User Manuals are available in multiple languages at: www.rockwellautomation.com/literature
Select publication language and, for example, type “20B-UM002” in the search field.
2
Table of Contents
Read the Precautions and General Information. . . . . . . . . . . . . . . . . . . . . . . .
General Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive, Fuse, and Circuit Breaker Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting MOVs and Common Mode Capacitors . . . . . . . . . . . . . . . . . . . .
Hardware Enable Circuitry (Vector Control Only) . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Interface Option (Vector Control Only) . . . . . . . . . . . . . . . . . . . . . . . . .
Resistance Temperature Detector (RTD) Board . . . . . . . . . . . . . . . . . . . . . . . . .
Information About Start-Up Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Human Interface Module (HIM) Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Status Indicators and DPI Port Locations . . . . . . . . . . . . . . . . . . . . . . . . .
Common I/O Programming Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting – Abbreviated Fault & Alarm Listing . . . . . . . . . . . . . . . . . . . . .
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parameter List – Vector Control Option (v6.xxx). . . . . . . . . . . . . . . . . . . . . . . . .
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Step 1
Catalog Number Explanation
Each PowerFlex 700L Frame 1X drive can be identified by its catalog number, which is CNMD180W0ENNNC1. The catalog number is on the shipping label and drive data nameplate. The catalog number includes the drive and any factory-installed options.
Read the Precautions and General Information
Qualified Personnel
!
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.
!
!
!
!
Personal Safety
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the DC+ and
DC– Test Pt. sockets on the drive (see item 9 in
for location). The voltage must be zero.
ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products must not be directly connected together via 1202 cables. Unpredictable behavior can result if two or more devices are connected in this manner.
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.
ATTENTION: Loss of control in suspended load applications can cause personal injury and/or equipment damage. Loads must always be controlled by the drive or a mechanical brake. Parameters
600…611 are designed for lifting/torque proving applications. It is the responsibility of the engineer and/or end user to configure drive parameters, test any lifting functionality and meet safety requirements in accordance with all applicable codes and standards.
!
!
Product Safety
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies.
Static control precautions are required when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Guarding Against Electrostatic Damage, publication
8000-4.5.2 or any other applicable ESD protection handbook.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
3
4
!
!
!
!
ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are:
•
Wiring AC line to drive output or control terminals.
•
Improper bypass or output circuits not approved by Allen-Bradley.
•
Output circuits which do not connect directly to the motor.
Contact Allen-Bradley for assistance with application or wiring.
ATTENTION: 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 “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 (F25) will occur if the speed reaches [Maximum Speed] + [Overspeed Limit], (Parameters 82 and 83). 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 (F24) is generated if the drive stops decelerating altogether. If this condition is unacceptable, the “adjust freq” portion of the bus regulator must be disabled (see Parameters 161 and 162). In addition, installing a properly-sized dynamic brake resistor will provide equal or better performance in most cases.
Important: These faults are not instantaneous. Test results have shown that they can take between 2…12 seconds to occur.
ATTENTION: 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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
CE Conformity
Compliance with the Low Voltage Directive and Electromagnetic
Compatibility Directive has been demonstrated using harmonized European
Norm (EN) standards published in the Official Journal of the European
Communities. PowerFlex 700L drives, including Frame 1X, comply with the EN standards listed below when installed according to this PowerFlex
700L Frame 1X Liquid-Cooled Adjustable Frequency AC Drive Installation
Instructions.
CE Declarations of Conformity are available online at: www.rockwellautomation.com/products/certification/
Low Voltage Directive (2006/95/EC)
•
EN 50178 Electronic equipment for use in power installations
EMC Directive (2004/108/EC)
•
EN 61800-3 Adjustable speed elecrical power drive systems – Part 3:
EMC product standard including specific test methods
General Considerations
•
For CE compliance, drives must satisfy installation requirements related to both EN 50178 and EN 61800-3 provided in this document.
•
PowerFlex 700L AC Drives comply with the EMC requirements of EN
61800-3 when installed according to good EMC practices and the instructions provided in this document. However, many factors can influence the EMC compliance of an entire machine or installation, and compliance of the drive itself does not ensure compliance of all applications.
•
PowerFlex 700L drives are not intended to be used on public low-voltage networks which supply domestic premises. Without additional mitigation, radio frequency interference is expected if used on such a network. The installer is responsible to take measures such as supplementary line filters and enclosures to prevent interference, in addition to the installation requirements of this document.
•
Requirements for supplementary mitigation related to specific high frequency emission limits are provided in Table 1 .
Table 1 PowerFlex 700L Frame 1X RF Emission Compliance and Installation
Requirements
Standard / Limits
EN 61800-3 Cat. C1
EN 61000-6-3
CISPR11 Group 1 Class B
EN 61800-3 Cat. C2
EN 61000-6-4
CISPR11 Group 1 Class A
EN 61800-3 Cat. C3
I
≤
100 A Limits
Compliance possible with supplementary mitigation
(Consult factory)
More Stringent Limits
Compliance possible with supplementary mitigation
(Consult factory)
Compliant without supplementary EMC line filter for motor cable
≤
5 m (16.4 ft)
Less Stringent Limits
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
5
6
•
The PowerFlex 700L Frame 1X drive generates harmonic current emissions on the AC supply system. When operated on a public network it is the responsibility of the installer or user to ensure that applicable requirements of the distribution network operator have been met.
Consultation with the network operator and Rockwell Automation may be necessary.
!
ATTENTION: PowerFlex 700L Frame 1X drives produce DC current in the protective earthing conductor which may reduce the ability of RCDs (residual current-operated protective devices) or
RCMs (residual current-operated monitoring devices) of type A or AC to provide protection for other equipment in the installation.
Installation Requirements Related to EN 50178 and the Low Voltage Directive
•
The insulation system of the 480V PowerFlex 700L Frame 1X drive is designed to be CE compliant when connected to either “center-earthed” supply systems or “corner-earthed” supply systems for altitudes up to and including 2000 m (6525 ft).
•
When used at altitudes above 2000 m (6525 ft) up to a maximum of
5000 m (16,404 ft), PowerFlex 700L Frame 1X drives may not be powered from a “corner-earthed” supply system in order to maintain compliance with the CE LV Directive.
•
The PowerFlex 700L Frame 1X drive must be installed in a pollution degree 1 or 2 environment to be compliant with the CE LV Directive.
Characteristics of the different pollution degree ratings are provided in
Table 2 .
Table 2 Pollution Degree Ratings According to EN 61800-5-1
Pollution
Degree Description
1 No pollution or only dry, non-conductive pollution occurs. The pollution has no influence.
2 Normally, only non-conductive pollution occurs. Occasionally, however, a temporary conductivity caused by condensation is to be expected, when the drive is out of operation.
3
4
Conductive pollution or dry non-conductive pollution occurs, which becomes conductive due to condensation, which is to be expected.
The pollution generates persistent conductivity caused, for example by conductive dust or rain or snow.
•
The PowerFlex 700L Frame 1X drive must be installed in a supplementary enclosure to be CE compliant with respect to protection against electrical shock.
•
The PowerFlex 700L Frame 1X drive produces touch current in the protective earthing conductor which exceeds 3.5 mA AC and/or 10 mA
DC. The minimum size of the protective earthing (grounding) conductor used in the application must comply with local safety regulations for high protective earthing conductor current equipment.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
7
Installation Requirements Related to EN 61800-3 and the EMC Directive
•
The drive must be earthed (grounded) as described in these instructions
(see General Grounding Requirements on page 18
).
•
Output power wiring to the motor must employ cable with a braided shield providing 75% or greater coverage, or the cables must be housed in metal conduit, or equivalent shielding must be provided. Continuous shielding must be provided from the drive enclosure to the motor enclosure. Both ends of the motor cable shield (or conduit) must terminate with a low-impedance connection to earth. At the drive end of the motor cable, the cable shield must be connected to the motor PE terminal on the drive.
•
At the motor end of the motor cable, the cable shield or conduit must terminate in a shielded connector which must be properly installed in an earthed motor wiring box attached to the motor. The motor wiring box cover must be installed and earthed.
•
All control (I/O) and signal wiring to the drive must use cable with a braided shield providing 75% or greater coverage, or the cables must be house in metal conduit, or equivalent shielding must be provided. When shielded cable is used, only the drive end of the cable shield should be terminated with a low-impedance connection to earth.
•
Motor cabling must be separated from control and signal wiring wherever possible.
•
Motor cable length must not exceed 5 m (16.4 ft) for compliance with radio frequency emission limits for compliance with the C3 limits of
EN 61800-3 for I
≤
100 A. Longer motor cables may be used if compliance with the C3 limits for I
>
100 A is acceptable in the application. Longer motor cables may also be used if a supplementary
EMC line filter is wired between the drive and the power supply.
•
The drive must be powered from an earthed supply system such as a TN or TT system and the DC Bus Common Mode Caps (PE-B) and Input
Filter Caps (PE-C) jumpers must be installed as described in Table 7 on page 22 .
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
8
Component Locations
Figure 1 Frame 1X Drive Component Locations
➎
➍
➓
➌
➍
➒
R
S
T
➊
➑
Back
➋
➍
LEFT SIDE VIEW
➒
➐
FRONT
➏
Item Component
➊
Input Power Terminal Connections
➋
Output Power Terminal Connections
➌
Brake Resistor Connections
➍
PE Grounds
Item Component
➏
Main Control Board
➐
RTD PC Board
➑
Cooling Loop Connections
➒
DC+ and DC- Test Pt. Sockets
➎
Access Point for Common Mode
Capacitor and MOV Connections
➓
Drive Data Nameplate
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Step 2 Mount the Drive
Lifting
!
ATTENTION: To guard against possible personal injury and/or equipment damage...
• Do Not allow any part of the drive or lifting mechanism to make contact with electrically charged conductors or components.
• At no time should a person or their limbs be directly underneath the items being lifted.
• Do not subject the load to high rates of acceleration or deceleration.
• Inspect all lifting hardware for proper attachment before lifting drive unit.
for lifting information.
Figure 2 Drive Weight and Lifting Orientation
Angle must be less than 45°
Loop strap over handle crossmember and under handle as shown. Typical 4 places.
9
Drive Weight:
44.5 kg (98 lbs.)
STRAP DETAIL
U
T1
V
T2
OUT
PUT
W
T3
NOTE: Sling capacity is typically derated to 70% with a 45° angle.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
10
Figure 3 Lifting Details
Use handles to lift unit.
Do not lift unit by holes in coldplate.
Do not use holes in coldplate for lifting.
T3
W
T2
V
OUTPUT
T1
U
Do not lift unit by holes in coolant port.
Use unit cutouts for lifting.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Mounting Considerations
This drive is intended to be installed in an enclosure by sliding it in on the white Teflon
®
sliders. These sliders should slide into rails inside the enclosure so that the drive cannot move from side to side.
Operating Temperatures
PowerFlex 700L Frame 1X drives are designed to operate at -10…60 °C
(14…140 °F) ambient.
Minimum Mounting Clearances and Heat Dissipation
There is no minimum mounting clearance required for the drive to dissipate heat. However, ensure that there is sufficient space in the front for routing cables and in the rear for connecting the coolant lines. Multiple drives can be mounted in an enclosure with no minimum side-to-side clearance between the drives and the enclosure walls.
Dimensions
Figure 4
Frame 1X Drive Dimensions
Dimensions are in millimeters and (inches).
for weight.
25.0
(1.0)
278.4
(10.96)
190.0
(7.5)
25.0
(1.0)
40.2
(1.6)
11
BR1
288.1
(11.34)
250.8
(9.87)
275.3
(10.83)
47.5
(1.87)
150.0
(5.9)
349.2
(13.75)
18.4
(0.73)
25.0
(1.0)
190.0
(7.5)
25.0
(1.0)
297.3
(11.7)
FRONT VIEW
40.2
(1.6)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
12
Step 3 Connect the Cooling Loop
Drive Coolant Requirements
Recommended Coolants
Table 3 lists approved sources and recommended coolants with appropriate corrosion inhibitors for the drive loop:
Table 3 Recommended Drive Loop Coolants
(1)
(2)
Source
Interstate Chemical http://www.interstatechemical.com/contact.htm
Koolant Koolers/Dimplex Thermal Solutions http://www.koolantkoolers.com/index.php/nic=contact
Dow Chemical http://www.dow.com
Coolant Description
• NFP-50
(1)
, a 50/50 premix of propylene glycol and distilled water
• NFE-50
(1)
, a 50/50 premix of ethylene glycol and distilled water
• K-Kool-E
(1)
, ethylene glycol (available premixed with distilled water)
• Propylene glycol
(1)
also available
• Dowtherm
®
SR-1
(2)
, ethylene glycol
• Dowfrost
® (2)
, propylene glycol
Dowtherm and Dowfrost are registered trademarks of the
Dow Chemical Company
Not premixed with distilled water, and may not be available in 5 gallon quantities.
Available in 5 gallon containers.
Non-premixed coolants require a coolant-to-water mix ratio of 50% by volume.
The estimated amount of coolant needed for Allen-Bradley 20L-LL*
Liquid-to-Liquid Heat Exchangers is 15.1 liters (4 gal). This coolant estimate is based on the heat exchanger using 1.2 m (4 ft) hoses. Longer hoses require more coolant. The maximum hose length of 9.1 m (30 ft) would require up to an additional 2.8 liters (0.74 gal).
Important: Since coolant performance slowly degrades over time, the drive loop coolant should be replaced every two years and/or whenever the loop is drained for servicing.
Corrosion Inhibitor
If an approved coolant is not used, the drive coolant must consist of clean water with a corrosion inhibitor. An approved corrosion inhibitor is
Chemtool, Inc. (www.chemtool.com) part number Watertool 4435-C. The recommended concentration of the inhibitor is 8-10% by volume. Deionized water is prohibited. Use distilled water or water with less than 50 ppm concentrations of:
•
Sulfate and chloride
•
Hard water ions such as Mg++ and Ca++
ATTENTION: Ethylene and propylene glycols must be inhibited and silicate free. Use of common silicate-containing,
!
automotive-type ethylene glycol solutions is prohibited as they may damage the heat exchanger and/or drive and cooling module equipment.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
The drive coolant must be compatible with the following materials:
•
Copper
•
Brass
•
Aluminum
•
Arimid fiber gasket with nitrile binder (Garlock, Inc. Blue-Gard 3000
®
)
Blue-Gard 3000 is a registered trademark of Garlock, Inc.
•
Synthetic rubber hose (Parker Hannifan Corp 801 General Purpose Hose)
•
Viton seal (Complete Drive only)
Biocide
A biocide may be needed to control biological growth. Use of a biocide is permitted. For specific recommendations, consult a reputable water treatment company.
Drive Cooling Loop Specifications
Table 4 Coolant Requirements for One Frame 1X Drive
(3)
(2)
(1)
Coolant
Temp. Range
0…60 °C
(32…140 °F)
Coolant Flow Rate
Minimum Nominal
7.57 LPM
(2 GPM)
9.46 LPM
(2.5 GPM)
Max. Particle
Size in Coolant
5 microns
Pressure Drop
(1)
From Drive Inlet to Drive
Outlet at Minimum Coolant Flow Rate
Less than 0.34 bar at 9.46 LPM, 20 °C
(Less than 5 psi at 2.5 GPM, 68 °F)
Coolant Type
WEG50
WPG50
(2)
(3)
or
Pressure drop does not include any system connections such as hoses or piping. Cooling systems must be sized to provide minimum flow considering entire system pressure drop.
WEG50 equals good quality or distilled water with approved inhibited* ethylene glycol, 50% glycol by volume.
WPG50 equals good quality or distilled water with approved inhibited* propylene glycol, 50% glycol by volume.
* Inhibited ethylene glycol or propylene glycol must contain a corrosion inhibitor. See Corrosion Inhibitor on page 12 for an approved source.
13
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
14
Cooling Loop Application Guidelines
!
ATTENTION: Risk of equipment damage exists. Do not use ferrous and plated-ferrous materials for pipe-treated water to the power modules and drive. Use of ferrous materials will degrade the performance of the power module chillplate.
The following section is intended to provide guidelines for applying cooling loops other than those recommended.
1. The allowable drive coolant temperature range is 0…60 °C
(32…140 °F).
When using coolant at a temperature below the dew point of the surrounding air, condensation could accumulate on the drive heatsink and/or circuit boards and damage the drive. In this situation, install a coolant flow regulating device and tube/hose insulation. A flow regulating device modulates the coolant flow rate to a level that permits the drive heatsink temperature to rise above the dew point. Insulation for customer side tube or hose may be closed-cell foam insulation with minimum 12.7 mm (0.50 in.) wall thickness.
2. The cooling loop should include a flow switch on the connection to the drive inlet to turn off the drive if coolant flow drops below the minimum flow required by the drive (see Table 4 on page 13 ).
3. Circulate coolant through the drive only when the drive is also powered.
Failure to do this may result in condensation accumulating on the drive heatsink and/or circuit boards, which could damage the drive.
4. For applications requiring a closed loop coolant system, ensure the system is vented to remove air that would otherwise degrade the performance of the drive heatsink.
5. Install a flow measuring device at the inlet or outlet of each drive. The coolant flow rate (LPM or GPM) must meet the requirements in Table 4 on page 13 .
6. The following types of pipe are recommended for cooling loop connections:
•
Copper tubing, type L
•
Brass pipe
•
Stainless steel, 300 series
Important: Do not use galvanized pipe.
7. The cooling loop should have a method for draining and replacing the coolant.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Step 4
Drive Coolant Connections
For locations of the coolant inlet and outlet connections on PowerFlex 700L
Liquid-Cooled Frame 1X drives, refer to item 8 in
The rated working pressure of the Frame 1X drive is 6.89 bar (100 psi).
Coolant supply and return lines should be sized for 76 LPM (20 GPM) /
6.89 bar (100 psi) service with a maximum operating temperature of 60 °C
(140 °F). The required operating flow rate and pressure drop is specified in
Table 4 on page 13 .
Coolant inlet and outlet connections are 1/4-inch NPT female. Apply Teflon thread sealing tape or pipe thread sealant to the threads of the coolant pipe that is being connected to the drive. Tighten to prevent leaks, but do not overtighten.
Wire the Drive
!
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.
Special Considerations
The PowerFlex 700L Frame 1X drive is suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes, 480 volts with recommended fuses/circuit breakers.
!
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
If a Residual Current Detector (RCD) is used as a system ground fault monitor, only Type B (adjustable) devices should be used to avoid nuisance tripping.
Unbalanced, Ungrounded, Impedance or Phase-Grounded Distribution
Systems
If phase-to-ground voltage will exceed 125% of normal line-to-line voltage or the supply system is ungrounded, refer to Wiring and Grounding
Guidelines for PWM AC Drives (publication DRIVES-IN001).
In addition, on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage, an isolation transformer should be installed. See Wiring and
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
15
16
Grounding Guidelines for PWM AC Drives (publication DRIVES-IN001) for more information on impedance grounded and ungrounded systems.
!
ATTENTION: The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on an ungrounded, impedance or phase-grounded distribution system.
See Table 7 on page 22 for recommended jumper configurations.
AC Line Reactor
There is no DC link reactor or AC input reactor built into the drive.
Therefore, a 3% three-phase line reactor must be installed at the AC input terminals of the drive.
Recommended Reactors
Enclosure Type
IP00 (Open Type)
Catalog Number
1321-3R200-B
IP11 (NEMA/UL Type 1) 1321-3RA200-B
Input Power Conditioning
Certain events on the power system supplying a drive can cause component damage or shortened product life. These conditions include:
• The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company.
• The power source has intermittent voltage spikes in excess of 6000 volts.
These spikes could be caused by other equipment on the line or by events such as lightning strikes.
• The power source has frequent interruptions.
Cable Trays and Conduit
If cable trays or large conduits are to be used, refer to the guidelines presented in the Wiring and Grounding Guidelines for PWM AC Drives
(publication DRIVES-IN001).
!
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.
Motor Cable Lengths
Typically, motor lead lengths less than 91 meters (300 feet) are acceptable.
However, if your application requires longer lengths, refer to the Wiring and
Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Wire Recommendations
Type
Power
(1)(2)
Standard
Min. Insulation
Rating Wire Type(s)
600V, 90 °C (194 °F) XHHW2/RHW-2
Anixter B209500-B209507, Belden
29501-29507, or equivalent
Description
• Four tinned copper conductors with XLPE insulation.
• Copper braid/aluminum foil combination shield and tinned copper drain wire.
(8)
(7)
Signal
(3) (4)
Standard Analog I/O 300V,
75…90 °C
(167…194 °F)
(6)
Encoder/Pulse I/O:
<30 m (100 ft.)
(5)
(4)
Encoder/Pulse I/O:
30…152 m (100…500 ft.)
Signal: Belden 9730/9728
Power: Belden 8790
(6)
Combined: Belden 9892
(7)
0.196 mm
2
(24 AWG)
0.750 mm
2
(18 AWG)
0.330 mm
2
(18 AWG), power is 0.500 mm
2
(20 AWG)
0.196 mm
2
(24 AWG) Encoder/Pulse I/O:
(1)
(2)
(3)
Digital I/O
152…259 m (500…850 ft.)
Shielded
Power: Belden 8790
Combined: Belden 9773/9774 as Belden 8770 (or equivalent)
(8)
Multi-conductor shielded cable such
0.750 mm
2
0.750 mm
2
0.750 mm
2
(18 AWG)
(18 AWG)
(18 AWG),
3 conductor, shielded.
Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).
The use of shielded wire for AC input power may not be necessary but is always recommended.
300V,
60 °C (140 °F)
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.
Signal: Belden 9730/9728
I/O terminals labeled “(–)” or “Common” are not referenced to earth ground and are designed to greatly reduce common mode interference.
Grounding these terminals can cause signal noise.
Belden 9730 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use Belden 9728.
Belden 8790 is 1 shielded pair.
• PVC jacket.
Belden 8760/9460 (or equivalent) 0.750 mm
2
(18 AWG), twisted pair,
100% shield with drain.
Belden 8770 (or equivalent) 0.750 mm
2
(18 AWG), 3 conductor, shielded for remote pot only.
Combined: Belden 9730
(5)
0.196 mm
2
(24 AWG)
Belden 9892 is 3 individually shielded pairs (3 channel) + 1 shielded pair for power.
Belden 9773 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use Belden 9774.
17
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
18
General Grounding Requirements
The drive Safety Ground - PE must be connected to system ground.
Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.
Figure 5 Typical Grounding
R (L1)
S (L2)
T (L3)
Drive
U (T1)
V (T2)
W (T3)
PE
SHLD
Safety Ground - PE
This is the safety ground for the drive that is required by code. This point must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see above). Grounding points must comply with national and local industrial safety regulations and/or electrical codes.
Shield Termination
The Shield terminal (PE) provides a grounding point for the motor cable shield. The motor cable shield should be connected to this terminal on the drive (drive end) and the motor frame (motor end). A shield terminating cable gland may also be used.
When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.
RFI Filter Grounding
Using an RFI filter (user supplied) may result in relatively high ground leakage currents. Therefore, any filter must only be used in installations
with grounded AC supply systems and be permanently installed and
solidly grounded (bonded) to the building power distribution ground.
Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. Refer to the instructions supplied with the filter.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Power Wiring
Figure 6 Power Terminal Locations
➍
➍
➋
R
S
T
➍
Table 5 Power Terminal Specifications
Item Name Description
➊
Input
Power
R (L1), S (L2), and T (L3) connections
Wire Size Range
(1)
Maximum Minimum
70 mm
2
50 mm
2
(2/0 AWG) (1 AWG)
➋
Output
Power
➌
Brake
Resistor
U (T1), V (T2), and W (T3) connections
70 mm
2
(2/0 AWG)
BR1 (DC Brake +) and BR2
(DC Brake -) connections
35 mm
2
(2 AWG)
50 mm
2
(1 AWG)
25 mm
2
(4 AWG)
Recommended Terminal
Torque (±10%)
Bolt Size
7.9 N•m
(70 lb•in)
M6
3.95 N•m
(35 lb•in)
3.95 N•m
(35 lb•in)
➍
Ground PE and motor ground connections
(1)
70 mm
2
(2/0 AWG)
50 mm
2
(1 AWG)
7.9 N•m
(70 lb•in)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
M5
M5
M6
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
➊
➌
19
20
Drive, Fuse, and Circuit Breaker Ratings
The PowerFlex 700L Frame 1X drive includes input fuses. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. Refer to
for recommended fuses/circuit breakers.
!
ATTENTION: The PowerFlex 700L Frame 1X drive does not provide branch short circuit protection. Specifications for the recommended fuse or circuit breaker to provide protection
against short circuits are provided in Table 6 .
provides 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 °C and the U.S. NEC. 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.
Table 6 480 Volt AC Input Protection Devices
Drive
Catalog Number
480 Volt AC Input
HP Rating
ND HD
PWM
Freq. Temp.
kHz
CNMD180W0ENNNC1 150 —
— 125
4
4
°C
50
50
Input
Ratings Output Amps
Amps
169
147
Cont. 1 Min. 3 Sec. Min.
180
156
198
234
270
312
Dual Element
Time Delay Fuse
225
200
(1)
Max.
400
350
(2)
Non-Time
Delay Fuse
Min.
Max.
225
200
600
600
Circuit
Breaker
(3)
Motor Circuit
Protector
(4)
Maximum Maximum
500
450
250
250
(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.
(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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Using Input/Output Contactors
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
!
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.
Bypass Contactor Precaution
!
ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are:
•
Wiring AC line to drive output or control terminals.
•
Improper bypass or output circuits not approved by
Allen-Bradley.
•
Output circuits which do not connect directly to the motor.
Contact Allen-Bradley for assistance with application or wiring.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
21
22
Disconnecting MOVs and Common Mode Capacitors
The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage and/or operation problems, these devices must be properly configured according to Table 7 .
Figure 7 MOV and AC EMI Capacitor Phase to Ground
R/L1
S/L2
T/L3
2 3 4
2 3 4
1
1
PE–A PE–C
Figure 8 Common Mode Capacitors to Ground
DC+
DC–
PE–B
!
!
ATTENTION: The PowerFlex 700L Frame 1X drive contains protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on an ungrounded, impedance or phase-grounded distribution system.
See Table 7 for recommended jumper configurations.
ATTENTION: PE-A, PE-B, and PE-C jumpers must be configured according to the recommendations in Table 7 . The
PE-D and PE-E power jumpers must always remain connected.
Table 7 Recommended Power Jumper Configurations
Power Source Type
(1)
Unknown
• AC fed Solidly Grounded
• DC fed from passive rectifier which has a Solidly Grounded
AC source
MOV
(PE-A)
(2)
Connected
(3)
DC Bus
Common Mode
Caps (PE-B)
Disconnected
(3)
Connected Connected
Input Filter
Caps (PE-C)
Connected
(3)
Connected
Bridge
Circuit Bd
Gnd (PE-D)
Connected
(3)
RTD Circuit
Bd Ground
(PE-E)
Connected
(3)
Benefits Of Correct
Configuration on Power
Source Type
See below.
UL compliance,
Reduced electrical noise,
Most stable operation,
EMC compliance,
Reduced voltage stress on components and motor bearings
• AC fed Ungrounded Disconnected Disconnected Disconnected Helps avoid severe equipment damage when ground fault
• Impedance Grounded occurs
• DC fed from an active converter
(1)
(2)
(3)
It is highly recommended to accurately determine the power source type and then configure appropriately.
When MOVs are disconnected, the power system must have its own transient protection to insure known and controlled voltages.
This is the factory default configuration. NOTE: The PE-D and PE-E power jumpers must be connected regardless of the power source type.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
23
!
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before connecting/ disconnecting the MOV, EMI Snubber Board, and common mode capacitor wires. Measure the DC bus voltage at the DC+ and
The power jumpers PE-A, PE-C, PE-D, and PE-E are factory connected to ground using one of the two screws shown in Figure 9 . Jumpers PE-D and
PE-E must remain connected.
To connect or disconnect the drive’s protective MOVs and common mode capacitors, refer to Table 7 and Figure 9 . Then:
1. Remove the appropriate screw(s) from the drive flange that connect the wire(s).
2. Cut the lugs off the ground wire(s) to be disconnected. Apply wire nuts to the end(s) of the disconnected wires.
3. Tie wrap the disconnected ground wires to keep them away from any electrical connections.
4. Gather together the wire lugs of the remaining ground wires to be connected. Using the screw(s), fasten the ground wires to the drive flange. Torque to 3.2 N
• m (28 lb
• in).
5. Tuck the wires back into the drive flange.
Figure 9 Protective Circuit Connections for Grounded Drive Distribution Systems
Labeled ground wires PE-A, PE-B,
PE-C, PE-D, and
PE-E
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
24
Step 5 I/O Wiring
Important points to remember about I/O wiring:
• Use Copper wire only. Wire gauge requirements and recommendations are based on 75 °C (167 °F). Do not reduce wire gauge when using higher temperature 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 earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.
!
!
ATTENTION: Configuring an analog input for 0…20 mA 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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
25
I/O Terminals
Figure 10 shows the drive Main Control Board and its terminal block locations. The Main Control Board includes the drive control firmware, I/O terminal block, and optional encoder board.
Figure 10 Drive Main Control Board and I/O Control Terminal Blocks
Pin 1
Pin 1
BR1
Main Control Board
Terminal Details
➊ ➋
Table 8 I/O Terminal Block Specifications
No. Name
➋
Encoder (optional)
Terminal Block
Description
➊
I/O Terminal Block Signal and control connections
Encoder power and signal connections
Wire Size Range
(1)
Torque
Maximum Minimum Maximum Recommended
2.1 mm
2
0.30 mm
2
0.6 N•m 0.6 N•m
(14 AWG)
0.75 mm
2
(18 AWG)
(22 AWG)
0.196 mm
(24 AWG)
2
(5.2 lb•in)
0.6 N•m
(5.2 lb•in)
(5.2 lb•in)
0.6 N•m
(5.2 lb•in)
(1)
Maximum/minimum that the terminal block will accept - these are not recommendations.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
26
Table 9 Vector Control Option I/O Terminal Designations
1
16
32
No. Signal
1 Analog In 1 (–)
2 Analog In 1 (+)
3 Analog In 2 (–)
4 Analog In 2 (+)
(1)
(1)
(1)
(1)
5 Pot Common
6 Analog Out 1 (–)
7 Analog Out 1 (+)
8 Analog Out 2 (–)
9 Analog Out 2 (+)
10 HW PTC Input 1
Factory
Default
(2)
—
(2)
Description
Isolated
(3)
, bipolar, differential,
±
10V/
0…20 mA, 11 bit and sign. For 0-20 mA, a jumper must be installed at terminals 17 and 18 (or 19 and 20). 88k ohm input impedance when configured for volt and
95.3 ohm for current
Related
Parameters
320… 327
For (+) and (–) 10V pot references
Single-ended bipolar (current output is not bipolar),
±
10V/0…20 mA, 11 bit and sign,
Voltage mode - limit current to 5 mA.
Current mode - max. load is 400 ohms.
340…347
11 Digital Out 1 – N.C.
(4)
12 Digital Out 1 Common
13 Digital Out 1 – N.O.
(4)
14 Digital Out 2 – N.C.
(4)
15 Digital Out 2/3 Com.
16 Digital Out 3 – N.O.
(4)
17 Current In Jumper
(1)
–
18
Analog In 1
19 Current In Jumper
(1)
–
20
Analog In 2
21 –10VDC Pot Ref.
22 +10VDC Pot Ref.
23 HW PTC Input 2
24 +24VDC
(5)
25 Digital In Common
26 24V Common
(5)
27 Digital In 1
(6)
28 Digital In 2
(6)
29 Digital In 3
(6)
30 Digital In 4
(6)
31 Digital In 5
(6)
32 Digital In 6/Hardware
Enable
(6)
, see
—
Fault
NOT Fault
NOT Run
Run
1.8k ohm PTC, Internal 3.32k ohm pull-up resistor
238, 259
Max. Resistive Load:
240V AC/30V DC – 1200VA, 150 W
Max. Current: 5 A, Min. Load: 10 mA
Max. Inductive Load:
240V AC/30V DC – 840VA, 105 W
Max. Current: 3.5 A, Min. Load: 10 mA
Placing a jumper across terminals 17 and
18 (or 19 and 20) will configure that analog input for current.
380…391
320…327
—
—
—
—
Speed Sel 1
Speed Sel 2
Speed Sel 3
2k ohm minimum load
See above
Drive-supplied logic input power
(5)
—
— Common for internal power supply
Stop - CF 115V AC, 50/60 Hz - Opto isolated
Start
Low State: less than 30V AC
Auto/Man.
High State: greater than 100V AC, 5.7 mA
361…366
24V DC - Opto isolated
Low State: less than 5V DC
High State: greater than 20V DC, 10 mA
DC Digital Input Impedance: 21k ohm
(1)
(2)
(3)
(4)
(5)
(6)
Important: 0…20 mA operation requires a jumper at terminals 17 and 18 (or 19 and 20). Drive damage may occur if jumper is not installed.
These inputs/outputs are dependant on a number of parameters (see “Related Parameters”).
Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input provides high common mode immunity.
Contacts in unpowered state. Any relay programmed as Fault or Alarm will energize (pick up) when power is applied to drive and deenergize (drop out) when a fault or alarm exists. Relays selected for other functions will energize only when that condition exists and will deenergize when condition is removed.
150 mA maximum load designed to power digital inputs only. Not present on 115V versions.
A 10k ohm, 2 watt burden resistor must be installed on each digital input when using a triac type device. The resistor is installed between each digital input and neutral/common.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
I/O Wiring Examples
Input/Output
Potentiometer Unipolar
Speed Reference
(1)
10k Ohm Pot. Recommended
(2k Ohm Minimum)
Connection Example
3
4
5
Required Parameter Changes
• Adjust Scaling:
Parameters 91/92 and 325/326
• View Results: Parameter 002
22
Analog Input Bipolar
Speed Reference
±
10V Input
Analog Voltage Input
Unipolar Speed Reference
0…10V Input
Common
+
3
4
• Set Direction Mode:
Parameter 190 = “1” (Bipolar)
• Adjust Scaling:
Parameters 91/92 and 325/326
• View Results: Parameter 002
• Configure Input with Parameter 320
• Adjust Scaling:
Parameters 91/92 and 325/326
• View results: Parameter 002
Common
+
3
4
Analog Current Input
Unipolar Speed Reference
Vector
0…20 mA Input
Analog Current Input
Unipolar Speed Reference
Standard
4…20 mA Input
Common
+
3
4
19
20
19
20
Common
+
• Configure Input for Current:
Parameter 320 and add jumper at appropriate terminals
• Adjust Scaling:
Parameters 91/92 and 325/326
• View results: Parameter 002
• Configure Input for Current:
Parameter 320, bit 1 = “Current”
• Adjust Scaling:
Parameters 91/92 and 325/326
• View Results: Parameter 002
Ferrite
Bead
1
2
Analog Input, PTC
Vector
PTC OT set > 5V
PTC OT cleared < 4V
PTC Short < 0.2V
1.8k
PTC
5
22
• Set Fault Config 1:
Parameter 238, bit 7 = “Enabled”
• Set Alarm Config 1:
Parameter 259, bit 11 = “Enabled”
• View Status Drive Alarm 1:
Parameter 211, bit 11 = “True”
3.32k
Ohm
HW PTC Input
(2)
PTC OT set > 5V
PTC OT cleared < 4V
PTC Short < 0.2V
2-Wire Control
Non-Reversing
(3)
24V DC internal supply
1.8k
PTC
Ferrite
Bead
24
25
26
28
Stop-Run
23
2-Wire Control
External supply (I/O Board dependent)
10
Neutral/
Common
25
27
28
Run Fwd.
115V/
+24V
• Set Fault Config 1:
Parameter 238, bit 13 = “Enabled”
• Set Alarm Config 1:
Parameter 259, bit 18 = “Enabled”
• View Status: Drive Alarm 1:
Parameter 211, bit 18 = “True”
• Disable Digital Input #1:
Parameter 361 = “0” (Not Used)
• Set Digital Input #2:
Parameter 362 = “7” (Run)
• Set Direction Mode:
Parameter 190 = “0” (Unipolar)
• Set Digital Input #1:
Parameter 361 = “8” (Run Forward)
• Set Digital Input #2:
Parameter 362 = “9” (Run Reverse)
Run Rev.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
27
28
Input/Output
3-Wire Control
Internal supply
3-Wire Control
External supply (I/O Board dependent). Requires 3-wire functions only ([Digital In1
Sel]). Using 2-wire selections will cause a type 2 alarm.
Digital Input
PLC Output Card (Board dependent). Resistors are recommended to dissipate leakage current.
Connection Example
24
25
26
27
28
Stop
25
27
28
Neutral/
Common
Start
115V/
+24V
25
Stop
27
28
Required Parameter Changes
• No changes required if parameters are at factory default settings
• No changes required if parameters are at factory default settings
Start
Neutral/
Common
10k Ohm, 2 Watt
Control from
Prog. Controller
• No changes required if parameters are at factory default settings
Digital Output
Relays shown in powered state with drive faulted. See
.
Vector Control:
2 relays at terminal 14…16
Power Source or
11
12
13
14
15
16
Fault
NOT Fault
Vector Control:
• Select Source to Activate:
Parameters 380/384/388
NOT Run
Run
Standard Control:
• Select Source to Activate:
Parameters 380/384
Standard Control:
1 relay at terminals 14…16
Enable Input
32
Vector Control
• Configure with Parameter 366.
For dedicated hardware Enable:
Remove Jumper J10 (see page 30
)
Standard Control:
• Configure with Parameter 366
(1)
(2)
(3)
Refer to the Attention statements on
page 24 for important bipolar wiring information.
A PTC (Positive Temperature Coefficient) device (motor thermistor), embedded in the motor windings, can be monitored by the drive for motor thermal protection.
Important: Programming inputs for 2 wire control (Run) deactivates all HIM Start buttons unless Parameter 192
[Save HIM Ref], bit 1 (Manual Mode) = “1.” This will allow the HIM to control Start and Jog.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Hardware Enable Circuitry (Vector Control Only)
By default, the user can program a digital input as an Enable input. The status of this input is interpreted by drive software. If the application requires the drive to be disabled without software interpretation, a
“dedicated” hardware enable configuration can be used. This is done by removing a jumper and wiring the enable input to “Digital In 6.”
1. Remove the drive Main Control Board (see Figure 11 ).
Figure 11 Main Control Board Removal
Flathead Screw
M4 x 10 mm Long
2X
1.9 N
• m (17 lb
• in)
29
Flathead Screw
M4 x 10 mm Long
4X
1.9 N
• m (17 lb
• in)
U
T1
V
T2
OUTPUT
W
T3
V
U
W
T
S
R
Flathead Screw
M4 x 10 mm Long
1X
1.9 N
• m (17 lb
• in)
Flathead Screw
M4 x 12 mm Long
2X (apply Loctite to threads)
1.9 N
• m (17 lb
• in)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
30
2. Locate and remove Jumper J10 on the Main Control Board (see
).
3. Re-install the Main Control Board into the drive.
4. Wire Enable to “Digital In 6” (see page 26
).
5. Verify that [Digital In6 Sel], Parameter 366 is set to “1” (Enable).
Figure 12 Hardware Enable Jumper Location
Main Control
Board Assembly
Optional
Encoder Board
Jumper J10 on
Main Control Board
=
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
31
Encoder Interface Option (Vector Control Only)
Table 10 Encoder Terminal Designations
See “Detail” in
Figure 10
8
1
3
2
1
6
5
No.
Description
8 +12V
(1)
DC Power
7 +12V
4
Encoder Z (NOT)
Encoder Z
Encoder B (NOT)
Encoder B
Encoder A (NOT)
Encoder A
Internal power source 250 mA.
Pulse, marker or registration input.
Quadrature B input.
(2)
Single channel or quadrature A input.
(1)
(2)
Jumper selectable +5/12V is available on 20B-ENC-1 Encoder Boards.
Z channel can be used as a pulse input while A and B are used for encoder.
Table 11 Encoder Specifications
Type:
Supply:
Quadrature:
Duty Cycle:
Incremental, dual channel
12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter,
250 kHz maximum.
90°
, ±
27° at 25 °C.
50%, +10%
Requirements: Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 8…15V DC output (3.5…6V DC when jumpers are in 5V position), 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. With the jumpers in the 5V position, the encoder will accept a 5V DC square-wave with a minimum high state voltage of 3.1V DC. In either jumper position, the maximum low state voltage is 0.4V DC.
Figure 13 Encoder Board Jumper Settings
+12V
+5V
J3
Output
Configuration
+12V
+5V
J3
Output
Configuration
+12V
+5V
J2
Input
Configuration
5/12V
(20B-ENC-1, Series B)
5/12V
(20B-ENC-2)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
32
Figure 14 Sample Encoder Wiring
I/O
Encoder Power – Internal Drive Power
Internal (drive) 12V DC, 250 mA
(1)
Encoder Signal – Single-Ended, Dual Channel
(2)
3
2
1
5
4
8
7
6
5
4
3
2
1
8
7
6
Connection Example
+12V DC
(250 mA)
Common to SHLD
(1) to Power Supply
Common
Z NOT to SHLD
(1)
Z
B NOT
B
A NOT
A
Encoder Power – External Power Source
External
Power
Supply to SHLD
(1)
Encoder Signal – Differential, Dual Channel
8
7
6
5
4
3
2
1
(1)
(2)
SHLD connection is on the drive chassis (item 4 in Figure 6 on page 19 )
Example applies to 20B-ENC-1 only.
to SHLD
(1)
Z NOT
Z
B NOT
B
A NOT
A
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
33
Resistance Temperature Detector (RTD) Board
Up to eight RTD or NTC (negative temperature coefficient) temperature sensors are supported by the RTD board in the PowerFlex 700L Frame 1X drive. The number of I/O connections required from an upper level controller to use the RTD board can be managed by selecting one of several configuration options.
Figure 15 RTD Board Location
Pin 1 Pin 6 Pin 1 Pin 12
RTD PC Board (Assembled In Enclosure)
U V W
Connections
Figure 16 RTD Board Connections
24 13
12
J2 - RTD Inputs
1
Gain
Mode
Time
1 2 3 1 2 3
12
S1 S2
6
J3 - I/O
1
7
J2
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
34
Table 12 J2 RTD Board I/O Function Settings
8
9
10
11
12
6
7
4
5
2
3
J2 Position
1
I/O Function
+24V COM
LOUT1 COM
LOUT2 COM
LOUT3 COM
LIN COM
AOUT COM
+24VDC
LOUT1 NO
LOUT2 NO
LOUT3 NO
LIN
AOUT
Important: A motor temperature sensor (RTD, NTC or thermocouple) should be considered equivalent to a motor thermostat and wired with the same considerations. Motor thermostat contacts are generally not isolated from the drive/controller digital inputs. Therefore, the sensor inputs will not be isolated on the
RTD board.
Hardware
The hardware consists of a single PC board with two wired connectors, one for temperature sensors and the second for power and I/O signals.
RTD/NTC Sourcing
A 2-wire RTD or NTC temperature sensor may be used. A chassis connection is available for each sensor for use with shielded cable. Each channel requires up to three connections.
Multiplexer and Amplifier
An analog multiplexer sequentially connects the temperature sensors one at a time to the analog output. The active sensor channel is indicated by a 3-bit output (A0…A2). When using an RTD or NTC, a simple voltage divider is formed and the device is probed differentially.
The sensor voltages are amplified using a high-quality, rail-to-rail instrumentation amplifier with gain adjustment. To accommodate a variety of sensors and temperature ranges, an amplifier boosts the analog sensor voltage in order to increase the temperature resolution. Discrete gains of x10 through x80 are selectable through DIP switch settings. A 4th order low pass filter rejects normal-mode noise at the analog input with a cutoff frequency of approximately 16 Hz.
To determine the proper gain setting:
1. Determine R
MAX
, the maximum resistance of the sensor over the temperature range to be measured.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
2. Determine the maximum voltage across R
MAX using the following equation:
V
MAX
= 1.00V x R
MAX
/ (R
MAX
+ 998)
3. Select the largest gain that results in V
MAX
* Gain (x10, x20, or x40), being less than 10 volts.
Example:
Using a 100 Ohm Pt RTD (a = 0.00385) to measure temperatures from
0…200 °C, the maximum resistance occurs at 200 °C and is approximately
177 Ohm. The maximum voltage across the sensor is 151 mV. If the x40 gain is used, the output voltage at 200 °C is 6.04 Volts.
Figure 17 Scaled Analog Output for RTD Board
A0
A1
A2
Analog Multiplexer
Channel
Address
4th Order Low Pass Filter
FC = 16 Hz
NTC/RTD
Sourcing
SA (1 of 8)
SB (1 of 8)
DA
DB
MAX4194
Instrumentation Amp
Rail-to-Rail
Gain Adjustable
5V
S1
50K
12V x10
100K
11.1K
F
F
100K 100K
100K 100K
F
Gain Adjust
DIP Switch Settings, S1
(overall gain) up down x10 x20
LMC6484
Quad Op Amp
Railt-to-Rail
MAX4194
Rg x30
Gain = 1 + 50K/Rg x40 x50 x60 x70 x80
F
12V
0.01
F
10
10
Analog Out
0-10V
Digital I/O
The digital outputs are isolated with solid state relays. The outputs are internally short circuit protected. The digital input is optically isolated.
Microcontroller Software
A microcontroller monitors three DIP switches to determine the operational mode of the RTD board. A single “Mode” switch determines whether the board uses an internal timebase or the digital input as a clock to step through the eight analog input channels. When using the internal timebase, the other two DIP switches select one of four clock periods.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
35
36
When the “Mode” switch is up (open) the board uses the digital input as an enable/reset. When the board’s digital input is inactive (open or ground), the analog output is held at the first channel. When the digital input is active
(24V), the microcontroller sequentially cycles through the eight temperature sensor channels. Each channel is available at the analog output for the selected period of time. After the eighth channel is completed, the cycle begins again with the first channel. Deactivating the digital input will asynchronously reset the sequence back to the first channel. The “Time” jumpers/DIP switches select one of four time periods between temperature sensor channels.
Table 13 Microcontroller Settings
Time Period
1 second
10 seconds
30 seconds
60 seconds
S2-2
Down
Up
Down
Up
S2-3
Down
Down
Up
Up
When the “Mode” switch (S2-1) is down (closed), the board uses the digital input as an external clock to sequentially cycle through the eight temperature sensor channels. The analog output channel advances with both the rising and falling edges of the digital input. In both modes, the active channel is output as a 3-bit binary address on the RTD board’s digital outputs. An inactive output (open) indicates a “0.” When using the digital input as an external clock, it may be necessary to monitor the address lines in order to maintain synchronization with the controller. When using the internal clock mode, the digital outputs may be ignored to reduce the required number of I/O. In either mode, the board’s digital input is debounced with a period of 50 milliseconds.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Step 6 Start-Up Check List
• This check list supports the Basic Start-Up menu option. See
for information on other start-up routines.
• A Human Interface Module (HIM) is required to run the Basic Start-Up routine.
• The Basic Start-Up routine may modify parameter values for Analog and
Digital I/O. Refer to
Common I/O Programming Changes on page 45
.
!
ATTENTION: Power must be applied to the drive to perform the following start-up procedure. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning.
Prepare For Drive Start-Up
❏ 1. Confirm that all inputs are connected to the correct terminals and are secure.
❏ 2. Verify that AC line power at the disconnect device is within the rated value of the drive.
❏ 3. Verify that control power voltage is correct.
❏ 4. The remainder of this procedure requires that a Human Interface Module
(HIM) be installed. Connect a HIM to Drive Peripheral Interface (DPI)
Port 2 (item 4 in
Figure 19 on page 44 ). If an operator interface is not
available, remote devices should be used to start up the drive.
Important: When power is first applied, the HIM may require approximately 5 seconds until commands are recognized
(including the Stop key). An explanation of the LED indicators can be found on
.
❏ 5. Apply AC power and control voltages to the drive.
If any of the six digital inputs are configured to “Stop – CF”
(CF = Clear Fault) or “Enable,” verify that signals are present or reconfigure [Digital Inx Sel], Parameters 361…366. If an I/O option is not installed (that is, no I/O terminal block), verify that [Digital Inx Sel] is not configured to “Stop – CF” or “Enable.” If this is not done, the drive will not start. Refer to
Troubleshooting – Abbreviated Fault & Alarm
Listing on page 46 for a list of potential digital input conflicts.
If the STS LED is not flashing green at this point, refer to Drive Status
Indicators and DPI Port Locations on page 44
.
❏ 6. When prompted, select a display language. The PowerFlex 700 Start-Up
Screen will then display.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
37
38
❏ 7. Press the Enter key to display the Start-Up Menu.
❏ 8. Use the Arrow keys to highlight “2. Basic”.
❏ 9. Press the Enter key. Follow the menu using the Enter key which will step you through the Start-Up routine.
The Basic Start-Up routine asks simple questions and prompts you to
input required information. See also Common I/O Programming
Information About Start-Up Motor Tests
Control schemes vary based on which Start/Jog Source is selected in Step 3
(Motor Tests) of the HIM Basic Start-Up procedure described in Assisted
Start Up on
. The following table lists the Start/Jog Source for each selection:
Start/Jog Source
Digital Inputs
Local Human Interface
Module (HIM) – Port 1
Remote HIM
Control Source Description
Digital In 1 = Stop; Digital In 2 = Start; Digital In 3 = Jog
Human Interface Module (HIM) connected to DPI Port 1 controls Stop/
Start/Jog
Digital In 1…6 are temporarily disabled during motor tests.
Human Interface Module (HIM) connected to DPI Port 2 controls Stop/
Start/Jog
Digital In 1…6 are temporarily disabled during motor tests.
During motor tests and tuning procedures, the drive may modify certain parameter values for proper Start Up operation. These values are then reset to their original values when Start Up is complete. The affected parameters are 053, 080, 276, 278, and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure, these parameters may not reset to their original value. If this situation occurs, reset the drive to factory defaults (see
Restoring Factory Defaults on page 45
) and repeat the Start Up procedure.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
First Powerup Menu Structure
English?
Français?
Español?
Italiano?
Deutsch?
Português?
Nederlands?
Not Selected
Main Menu:
Diagnostics
Parameter
Device Select
Memory Storage
Start-Up
Preferences
PowerFlex 700
Start-Up
Startup consists of several steps to configure a drive for basic applications.
PowerFlex 700
Start-Up
Make a selection:
1. SMART
2. Basic
3. Detailed
4. More info
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
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
39
40
Human Interface Module (HIM) Overview
LCD Display Elements
Display
F-> Power Loss Auto
0.0
Hz
Main Menu:
Diagnostics
Parameter
Device Select
Description
Direction
⎥
Drive Status
⎥
Alarm
⎥
Auto/Man
⎥
Information
Commanded or Output Frequency
Programming / Monitoring / Troubleshooting
Human Interface Module (HIM) Key Functions
Key
Esc
Sel
Description
Exit a menu, cancel a change to a parameter value, or acknowledge a fault/alarm.
Select a digit, select a bit, or enter edit mode in a parameter screen.
Scroll through options, increase a value, or toggle a bit.
ALT
Jog
Scroll through options, decrease a value, or toggle a bit.
Enter a menu, enter edit mode in a parameter screen, or save a change to a parameter value.
Access the function associated with a programming or numeric key. See
for details.
Start the drive.
Stop the drive or clear a fault.
S.M.A.R.T.
Esc
View
Sel
Lang Auto / Man Remove
Alt
7
4
1
.
Exp
2
0
8
5
9
6
3
+/-
Param #
Jog
Jog the drive.
Human Interface Module (HIM)
Change direction. These keys are active only when the HIM is granted Manual Control, or
Parameter 090 [Speed Ref A Sel] or 093 [Speed Ref B Sel] is set to
Increase speed.
option “19” (DPI Port 2) for a HIM connected by cable for handheld or
Decrease speed.
remote installation.
Human Interface Module (HIM) Main Menu
Main Menu Screen
F-> Power Loss Auto
0.0
Hz
Main Menu:
Diagnostics
Parameter
Device Select
Menu Selections
Main Menu:
Diagnostics
Parameter
Device Select
Memory Storage
Start-Up
Preferences
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
ALT Functions
To use an ALT function, start at the Main Menu and press the ALT key, release it, then press the programming key associated with one of the following functions:
ALT Key…then Function Function Description
Esc
S.M.A.R.T.
Displays the S.M.A.R.T. screen. This function allows the drive parameter values to be quickly programed by directly accessing the most frequently used drive functions. Refer to
for more information.
Log In/Out Log in to change parameter settings.
Log out to protect parameter settings.
Change a password.
View
Device
Allows the selection of how parameters will be viewed or detailed information about a parameter or component.
Select a connected adapter for editing.
ALT
Sel
Sel
Lang
Auto/Man Switches between Auto and Manual Modes. If the Human Interface
Module (HIM) requests Manual Mode, the Speed Reference source is transferred to the Human Interface Module (HIM).
Remove
Displays the language selection screen. The LCD Human Interface
Module (HIM) on an architecture class drive allows you to change the display language any time.
Allows Human Interface Module (HIM) removal without causing a fault if the Human Interface Module (HIM) is not the last controlling device and does not have Manual control of the drive.
Param # Allows entry of a parameter number for viewing/editing.
+/–
Start-Up Routines
The PowerFlex 700 start up routines allow the user to commission the drive more quickly and accurately. If you have an LCD HIM, two methods are provided.
•
S.M.A.R.T. Start
This routine is accessible by using the “ALT” function key on the LCD
HIM. This keystroke brings up a list of parameters needed to program the eight most commonly adjusted drive functions. These include Start,
Stop, Minimum Speed, Maximum Speed, Acceleration Time,
Deceleration Time, Reference source (speed command) and Electronic
Overload setting for the motor. No knowledge of parameter organization or access is required. S.M.A.R.T. Start can commission the drive in just a
few minutes. See Running S.M.A.R.T. Start on page 43
for details.
•
Assisted Start Up
Three levels of Assisted Start Up (Basic, Detailed and Application) assist the user in commissioning the drive by asking simple Yes/No or “Enter
Data” questions. The user is guided through the Start Up to reduce the amount of time necessary to get the drive “up and running.” The following are included in startup:
– Input Voltage Ratings
– Motor Data
– Motor Tests & Auto-tuning
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
41
42
– Speed/Torque Control & Direction Limits
– Speed Reference
– Start & Stop Modes
– Ramp Setup
– Digital and Analog I/O
– Application Set-up (TorqProve, Oil Well Pumps, Positioning/Speed
Profiling)
See
Running an Assisted Start Up on page 43 for details.
Important Information
Power must be applied to the drive when viewing or changing parameters.
Previous programming may affect the drive status and operation when power is applied. If the I/O Cassette has been changed, a Reset Defaults operation must be performed.
Torque Proving applications can use the Assisted Start Up to tune the motor.
However, it is recommended that the motor be disconnected from the hoist/ crane equipment during the routine. If this is not possible, refer to the
TorqProve Manual Start Up procedure in the PowerFlex 700 Series B User
Manual (publication 20B-UM002).
Figure 18 Start Up Menu
Start-Up
Start Over
Continue
Intro
Selection:
1. SMART
2. Basic
3. Detailed
4. Application
Basic
Detailed
Done /
Exit
Motor Control
Select
Motor Data &
Ramp Times
Motor
Tests
(1)
Speed
Limits
Speed/Torque
Control
Start/Stop/
I/O
Application
Configures
Motor Control
Method
Enter Motor NP
Data, Stop Mode,
Accel/Decel
Ramp Times
Optimize Torque and
Verify Direction
Set Min/Max
Speed and
Direction Control
Configure
Source, Value and Scale for
Speed References
Configure
Control Method
(2 Wire/3 Wire),
I/O, Digital I/O
& Analog Outputs
Configure for a
Specific Application such as; Auto Restart,
Flying Start, etc.
Done /
Exit
Selection:
1. Torq Prove
2. Pos/Spd Profile
3. Oil Well Pumps
Motor Control
Select
Configures
Motor Control
Method
Pos/Spd Profile
Motor Data &
Ramp Times
Motor
Tests
Enter Motor NP
Data, Stop Mode,
Accel/Decel
Ramp Times
Optimize Torque and
Verify Direction
Pos/Spd
Profile
Speed
Limits
Torque Proving
Set Min/Max
Speed and
Direction Control
Speed/Torque
Control
Configure
Source, Value and Scale for
Speed References
Torque
Proving
Done /
Exit
Done /
Exit
Well Pump
Type
Motor Data &
Ramp Times
Pump
Data
Start/Stop/
I/O
Motor
Tests
Speed/Torque
Control
Torque
Alarm
Process
Display
Enter Pump
Data
Enter Motor NP
Data, Stop Mode,
Accel/Decel
Configure
Control Method
(2 Wire/3 Wire),
Optimize Torque and
Verify Direction
Configure
Source, Value and Scale for
Ramp Times I/O, Digital I/O Speed References
& Analog Outputs
(1)
During Motor Tests and tuning procedures, the drive may modify certain parameter values for proper Start Up operation. These values are then reset to their original values when
Start Up is complete. The affected Parameters are 053, 080, 276, 278, and 361…366. If power is removed from the drive during the tests without aborting the auto-tune procedure,
these parameters may not be reset to their original value. If this situation occurs, reset the drive to factory defaults and repeat the Start Up procedure.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Done /
Exit
Running S.M.A.R.T. Start
During a Start Up, the majority of applications require changes to only a few parameters. The LCD HIM used with the 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 Key(s) Example LCD Displays
ALT Esc
F-> Stopped
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 more HIM information, see
Appendix B in the PowerFlex 700 Series
Esc
3. Press Esc to exit the S.M.A.R.T. start.
Running an Assisted Start Up
B User Manual (publication 20B-UM002).
Important: This start-up routine requires an LCD HIM.
0.0
Hz
SMART List:
Auto
The Assisted start-up routine prompts you to input required information.
Access Assisted Start Up by selecting “Start Up” from the Main Menu.
To perform an Assisted Start-Up
Step
1. In the Main Menu, press the Up Arrow or
Down Arrow to scroll to “Start Up”.
Key(s)
2. Press Enter.
Example LCD Displays
F-> Stopped
0.0
Hz
Main Menu:
Memory Storage
Start Up
Preferences
Auto
Important: Done/Exit must be selected upon completion of the Start Up routine in order for any Start Up/Autotune data to be saved.
43
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
44
Drive Status Indicators and DPI Port Locations
Figure 19 Drive Status Indicators and DPI Port Locations
➍
BR1
➎
Optional
1203-S03
Splitter
Cable
(located behind cross brace)
➊
➋
(located behind cross brace)
No. Name
➊
PWR
(Power)
➋
STS
(Status)
Color State
Green Steady
Green Flashing
Steady
Yellow Flashing,
Drive Stopped
Flashing,
Drive Running
Red
Steady,
Drive Running
Flashing
Steady
➌
PORT Optional
MOD
Communication Adapter
NET A
(refer to User Manual)
NET B
No. Connector
➍
DPI Port 2
➎
➏
DPI Port 3 or 2
DPI Port 5
Description
Illuminates when power is applied to the drive.
Drive ready, but not running and no faults are present.
Drive running, no faults are present.
A start inhibit condition exists, the drive cannot be started. Check Parameter 214 [Start Inhibits].
An intermittent type 1 alarm condition is occurring.
Check Parameter 211 [Drive Alarm 1].
A continuous type 1 alarm condition exists.
Check Parameter 211 [Drive Alarm 1].
Fault has occurred. Check [Fault x Code] or Fault Queue.
A non-resettable fault has occurred.
Status of DPI port internal communications (if present).
Status of communications module (when installed).
Status of network (if connected).
Status of secondary network (if connected).
Description
Cable connection for handheld and remote options.
1203-S03 splitter cable (purchased separately) connected to DPI Port 2 provides additional port.
Cable connection for optional communications adapter.
➏
➌
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Common I/O Programming Changes
Your application needs may require changing parameters from their factory default settings.
Speed Reference A
Change Speed Reference A from Analog In 2 to Analog In 1 to connect an external potentiometer.
1. Set Parameter 090 [Speed Ref A Sel] to option “1” (Analog In 1).
This sets the speed reference input to I/O terminals 14 and 15 for voltage and I/O terminals 16 and 17 for current.
2. Set Parameter 096 [TB Man Ref Sel] to option “9” (MOP Level).
This eliminates a potential Conflict alarm condition. Analog In 2 is not a valid Speed Reference source if selected for any of the following:
•
Parameter 117 [Trim In Select]
•
Parameter 126 [PI Reference Sel]
•
Parameter 128 [PI Feedback Sel]
•
Parameter 147 [Current Lmt Sel]
3. Set Parameter 091 [Speed Ref A Hi] to the upper value of the desired speed reference range in Hz.
4. Set Parameter 092 [Speed Ref A Lo] to the lower value of the desired speed reference range in Hz.
Control Scheme
Change from 3 Wire Start/Stop to 2 Wire Run/Not Run at Digital In 1 and
Digital In 2.
Important: This will disable the Start button on the HIM.
1. Set Parameter 361 [Digital In1 Sel] to option “7” (Run) or “9” (Run
Reverse).
2. Set Parameter 362 [Digital In2 Sel] to another option such as “8” (Run
Forward) or “10” (Jog1).
See I/O Wiring Examples on page 27
.
Restoring Factory Defaults
From the Human Interface Module (HIM) Main Menu select: Memory
Storage / Reset To Defaults
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
45
46
Troubleshooting – Abbreviated Fault & Alarm Listing
For a complete listing of Faults and Alarms, refer to the PowerFlex 700
Series B User Manual (publication 20B-UM002).
Fault
Auxiliary Input 2
Decel Inhibit 24
Description
➀
Auxiliary input interlock is open.
➂
The drive is not following a commanded deceleration because it is attempting to limit bus voltage.
Action
Check remote wiring.
1. Verify input voltage is within drive specified limits.
2. Verify system ground impedance follows proper grounding techniques.
3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration
for further info.
FluxAmpsRef
Range
HW
OverCurrent
OverSpeed
Limit
SW
OverCurrent
78
12
IR Volts Range 77
Motor Overload 7
OverVoltage
25
5
36
➀
The value for flux amps determined by the Autotune procedure exceeds the programmed [Motor NP FLA],
Parameter 042.
The drive output current has exceeded the hardware current limit.
“Calculate” is the autotune default and the value determined by the autotune procedure for IR Drop Volts is not in the range of acceptable values.
➀
➂
Internal electronic overload trip.
Enable/Disable with Parameter 238
[Fault Config 1].
➀
Functions such as Slip
Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in Parameter 083
[Overspeed Limit].
➀
DC bus voltage exceeded maximum value.
4. Disable with Parameter 238.
1. Reprogram Parameter 042
[Motor NP FLA] with the correct motor nameplate value.
2. Repeat Autotune.
Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current.
Re-enter motor nameplate data.
An excessive motor load exists.
Reduce load so drive output current does not exceed the current set by
Parameter 042 [Motor NP FLA].
Remove excessive load or overhauling conditions or increase
Parameter 083 [Overspeed Limit].
➀
Drive output current has exceeded the 1ms current rating. This rating is greater than the 3 second current rating and less than the hardware overcurrent fault level. It is typically
200…250% of the drive continuous rating.
Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option.
Check for excess load, improper DC boost setting. DC brake volts set too high.
(1)
See the User Manual for a description of fault types.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Alarm
Dig In
ConflictA
Dig In
ConflictB
17
Description
➁
Digital input functions are in conflict. Combinations marked with a “ ” will cause an alarm.
Acc2/Dec2
Accel 2
Decel 2
Jog 1/2
Jog Fwd
Jog Rev
Fwd/Rev
Acc2/Dec2 Accel 2 Decel 2 Jog 1/2 Jog Fwd Jog Rev Fwd/Rev
18
➁
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.
Start
Stop-CF
Run
Run Fwd
Run Rev
Jog 1/2
Jog Fwd
Jog Rev
Fwd/Rev
Start Stop-CF Run Run Fwd Run Rev Jog 1/2 Jog Fwd Jog Rev Fwd/Rev
Dig In
ConflictC
19
➁
More than one physical input has been configured to the same input function.
Multiple configurations are not allowed for the following input functions:
TB Man Ref
Cflct
30
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
Acc2 / Dec2
Accel 2
Decel 2
➁
Occurs when:
• “Auto/Manual” is selected (default) for Parameter 363 [Digital In3 Sel]
and
• Parameter 096 [TB Man Ref Sel] has been reprogrammed.
No other use for the selected analog input may be programmed.
Example: If Parameter 096 [TB Man Ref Sel] is reprogrammed to “2” (Analog
In 2), all of the factory default uses for Analog In 2 must be reprogrammed
(such as Parameters 90, 117, 128 and 179). Refer to the Auto/Manual
Examples section of the PowerFlex 700 Series B User Manual.
To correct:
• Verify/reprogram the parameters that reference an analog input
or
• Reprogram Parameter 363 [Digital In3 Sel] to another function or “0” (Not
Used).
(1)
See the PowerFlex 700 Series B User Manual for a description of alarm types.
47
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
48
Common Symptoms and Corrective Actions
Drive does not Start from Start or Run Inputs wired to the terminal block.
Cause(s)
Drive is Faulted
Indication
Flashing red status light
Corrective Action
Clear fault.
• Press Stop
• Cycle power
• Set [Fault Clear] to 1
• “Clear Faults” on the HIM
Diagnostic menu.
Wire inputs correctly and/or install jumper.
Incorrect input wiring. Refer to the wiring examples starting on
• 2 wire control requires Run, Run
Forward, Run Reverse or Jog input.
None
• 3 wire control requires Start and
Stop inputs.
• Jumper from terminal 25 to 26 is required.
Incorrect digital input programming.
None
• Mutually exclusive choices have been made (that is, Jog and Jog
Forward).
• 2 wire and 3 wire programming may be conflicting.
• Exclusive functions (that is, direction control) may have multiple inputs configured.
• Stop is factory default and is not wired.
Flashing yellow status light and “DigIn
CflctB” indication on
LCD HIM. Parameter
210 [Drive Status 2] shows type 2 alarm(s).
Program [Digital Inx Sel] Parameters
361…366 for correct inputs.
Start or Run programming may be missing.
Program [Digital Inx Sel] Parameters
361…366 to resolve conflicts.
Remove multiple selections for the same function.
Install stop button to apply a signal at stop terminal.
Drive does not Start from Human Interface Module (HIM).
Cause(s)
Drive is programmed for 2 wire control.
HIM Start button is disabled for 2 wire control unless Parameter 192 [Save
HIM Ref], bit 1 = “1.”
Indication
None
Corrective Action
If 2 wire control is required, no action needed.
If 3 wire control is required, program
[Digital Inx Sel] Parameters 361…366 for correct inputs.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
49
Drive does not respond to changes in speed command.
Cause(s)
No value is coming from the source of the command.
Indication
LCD HIM Status Line indicates “At Speed” and output is 0 Hz.
Corrective Action
1. If the source is an analog input, check wiring and use a meter to check for presence of signal.
Incorrect reference source has been programmed.
Incorrect Reference source is being selected via remote device or digital inputs.
None
None
2. Check Parameter 002
[Commanded Speed] for correct source.
3. Check Parameter 213 [Speed Ref
Source] for the source of the speed reference.
4. Reprogram Parameter 090
[Speed Ref A Sel] for correct source.
5. Check Parameter 209 [Drive
Status 1], bits 12 and 13 for unexpected source selections.
6. Check Parameter 216 [Dig In
Status] to see if inputs are selecting an alternate source.
7. Reprogram digital input
Parameters 361…366 to correct
“Speed Sel x” option.
Motor and/or drive will not accelerate to commanded speed.
Cause(s)
Acceleration time is excessive.
Indication
None
Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.
None
Corrective Action
Reprogram Parameter 140/141 [Accel
Time x].
Check Parameter 210 [Drive Status 2] bit 10 to see if the drive is in Current
Limit.
Speed command source or value is not as expected.
None
Programming is preventing the drive output from exceeding limiting values.
None
Remove excess load or reprogram
Parameter 140/141 [Accel Time x].
Check for the proper Speed
Command using Steps 1 through 7 above.
Check Parameters 082 [Maximum
Speed] and 055 [Maximum Freq] to assure that speed is not limited by programming.
Motor operation is unstable.
Cause(s)
Motor data was incorrectly entered or
Autotune was not performed.
Indication
None
Corrective Action
1. Correctly enter motor nameplate data.
2. Perform “Static” or “Rotate”
Autotune procedure.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
50
Drive will not reverse motor direction.
Cause(s)
Digital input is not selected for reversing control.
Indication
None
Digital input is incorrectly wired.
Direction mode parameter is incorrectly programmed.
None
None
Motor wiring is improperly phased for reverse.
A bipolar analog speed command input is incorrectly wired or signal is absent.
None
None
Corrective Action
Check Parameters 361…366 [Digital
Inx Sel]. Choose correct input and program for reversing mode.
Check input wiring.
Reprogram Parameter 190 [Direction
Mode] for analog “Bipolar” or digital
“Unipolar” control.
Switch two motor leads.
1. Use meter to check that an analog input voltage is present.
2. Check wiring.
Positive voltage commands forward direction. Negative voltage commands reverse direction.
Stopping the drive results in a Decel Inhibit fault.
Cause(s) Indication
The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage. Excess bus voltage is normally due to excessive
Decel Inhibit fault screen.
regenerated energy or unstable AC line input voltages.
LCD Status Line indicates “Faulted”.
Internal timer has halted drive operation.
Corrective Action
1. See Attention statements on
2. Reprogram Parameters 161/162
[Bus Reg Mode x] to eliminate any
“Adjust Freq” selection.
3. Disable bus regulation
(Parameters 161 and 162) and add a dynamic brake.
4. Correct AC input line instability or add an isolation transformer.
5. Reset drive.
Manually Clearing Faults
Step
1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the Human Interface Module (HIM).
Key(s)
Esc
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
3. After corrective action has been taken, clear the fault by one of these methods:
• Press Stop
• Cycle drive power
• Set Parameter 240 [Fault Clear] to “1” (Clear Faults).
• “Clear Faults” on the Human Interface Module (HIM) Diagnostic menu.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
51
27
28
29
40
24
25
26
41
42
43
21
22
23
16
17
18
8
9
10
5
6
7
11
12
13
14
3
4
Number
1
2
64
66
67
61
62
63
69
70
71
53
54
55
48
49
50
44
45
46
47
56
57
58
59
Parameter List – Vector Control Option (v6.xxx)
Parameter Name
Output Freq
Commanded Freq
Output Current
Torque Current
Flux Current
Output Voltage
Output Power
Output Powr Fctr
Elapsed MWh
Elapsed Run Time
MOP Reference
DC Bus Voltage
DC Bus Memory
Elapsed kWh
Analog In1 Value
Analog In2 Value
PTC HW Value
Group
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Metering
Number
72
79
80
81
82
83
84…86
87
88
90, 93
91, 94
92, 95
96
97
98
Parameter Name
Break Frequency*
Speed Units
Feedback Select
Minimum Speed
Maximum Speed
Overspeed Limit
Skip Frequency 1-3*
Skip Freq Band*
Speed/Torque Mod**
Speed Ref X Sel
Speed Ref X Hi
Speed Ref X Lo
TB Man Ref Sel
TB Man Ref Hi
TB Man Ref Lo
Group
Volts per Hertz
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Spd Mode & Limits
Speed Reference
Speed Reference
Speed Reference
Speed Reference
Speed Reference
Speed Reference
Spd Fdbk No Filt
Ramped Speed
Speed Reference
Commanded Torque** Metering
Speed Feedback
Rated kW
Rated Volts
Rated Amps
Control SW Ver
Motor Type
Motor NP Volts
Motor NP FLA
Motor NP Hertz
Motor NP RPM
Motor NP Power
Metering
Metering
Metering
Metering
Drive Data
Drive Data
Drive Data
Drive Data
Motor Data
Motor Data
Motor Data
Motor Data
Motor Data
Motor Data
118
119
120
121
122
123
124
125
126
127
128
99
100
101…107
108
116
117
Pulse Input Ref
Jog Speed 1
Preset Speed 1-7
Jog Speed 2
Trim % Setpoint
Trim In Select
Trim Out Select
Trim Hi
Trim Lo
Slip RPM @ FLA
Slip Comp Gain*
Slip RPM Meter
PI Configuration
PI Control
PI Reference Sel
PI Setpoint
PI Feedback Sel
Speed Reference
Discrete Speeds
Discrete Speeds
Discrete Speeds
Speed Trim
Speed Trim
Speed Trim
Speed Trim
Speed Trim
Slip Comp
Slip Comp
Slip Comp
Process PI
Process PI
Process PI
Process PI
Process PI
Mtr NP Pwr Units
Motor OL Hertz
Motor Data
Motor Data
129
130
131
PI Integral Time
PI Prop Gain
PI Lower Limit
Process PI
Process PI
Process PI
Motor OL Factor
Motor Poles
Motor OL Mode
6.x
Motor Data
Motor Data
Motor Data
132
133
134
PI Upper Limit
PI Preload
PI Status
Process PI
Process PI
Process PI
Motor Cntl Sel
Maximum Voltage
Maximum Freq
Torq Attributes
Torq Attributes
Torq Attributes
135
136
PI Ref Meter
PI Fdback Meter
Process PI
Process PI
Compensation
Flux Up Mode
Torq Attributes
Torq Attributes
137
138
PI Error Meter
PI Output Meter
Process PI
Process PI
Flux Up Time
SV Boost Filter
Torq Attributes
Torq Attributes
139
140, 141
PI BW Filter
Accel Time X
Process PI
Ramp Rates
Autotune
IR Voltage Drop
Flux Current Ref
Torq Attributes
Torq Attributes
Torq Attributes
142, 143
145
146
Decel Time X
DB While Stopped
S Curve %
Ramp Rates
Stop/Brake Modes
Ramp Rates
Ixo Voltage Drop
Autotune Torque**
Torq Attributes
Torq Attributes
147
148
Current Lmt Sel
Current Lmt Val
Load Limits
Load Limits
Inertia Autotune**
Start/Acc Boost
Run Boost*
Break Voltage*
Torq Attributes
Volts per Hertz
Volts per Hertz
Volts per Hertz
149
150
151
152
Current Lmt Gain
Drive OL Mode
PWM Frequency
Droop RPM @ FLA
Load Limits
Load Limits
Load Limits
Load Limits
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
52
195
196
197
198
199
200
201
188
189
190
192
193
194
178
179
180
181
182
183
170
174
175
177
184
185
186
187
202
203
204
205
206
209, 210
211, 212
213
214
163
164
165
166
167
168
169
Number
153
154
155, 156
157
158
159
160
161, 162
Parameter Name
Regen Power Limit**
Current Rate Limit**
Stop Mode X
DC Brk Lvl Sel
DC Brake Level
DC Brake Time
Bus Reg Ki*
Bus Reg Mode X
DB Resistor Type
Bus Reg Kp*
Bus Reg Kd*
Flux Braking
Powerup Delay
Start At PowerUp
Flying Start En
Flying StartGain
Auto Rstrt Tries
Auto Rstrt Delay
Gnd Warn Level
Sleep-Wake Mode
Sleep-Wake Ref
Wake Level
Wake Time
Sleep Level
Sleep Time
Power Loss Mode
Power Loss Time
Power Loss Level
Load Loss Level
Load Loss Time
Shear Pin Time
Direction Mode
Save HIM Ref
Man Ref Preload
Save MOP Ref
MOP Rate
Param Access Lvl
Reset To Defalts
Load Frm Usr Set
Save To User Set
Reset Meters
Language
Voltage Class
Drive Checksum
Dyn UserSet Cnfg
Dyn UserSet Sel
Dyn UserSet Actv
Drive Status X
Drive Alarm X
Speed Ref Source
Start Inhibits
Restart Modes
Restart Modes
Restart Modes
Power Loss
Restart Modes
Restart Modes
Restart Modes
Restart Modes
Restart Modes
Restart Modes
Power Loss
Power Loss
Power Loss
Power Loss
Power Loss
Power Loss
Direction Config
HIM Ref Config
HIM Ref Config
MOP Config
MOP Config
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Drive Memory
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Group
Load Limits
Load Limits
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Stop/Brake Modes
Restart Modes
Restart Modes
Restart Modes
281
282
283
284
277
278
279
280
Start Mask
Jog Mask
Direction Mask
Reference Mask
Accel Mask
Decel Mask
Fault Clr Mask
MOP Mask
215
216
217
218
Last Stop Source
Dig In Status
Dig Out Status
Drive Temp
Diagnostics
Diagnostics
Diagnostics
Diagnostics
285
288
289
290
Local Mask
Stop Owner
Start Owner
Jog Owner
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Parameter Name
Drive OL Count
Motor OL Count
Mtr OL Trip Time
Drive Status 3
6.x
Status 3 @ Fault
6.x
Fault Speed
Fault Amps
Fault Bus Volts
Status X @ Fault
Alarm X @ Fault
Testpoint X Sel
Testpoint X Data
Fault Config 1
Fault Clear
Fault Clear Mode
Power Up Marker
Fault 1 Code
Fault 1 Time
Fault 2 Code
Fault 2 Time
Fault 3 Code
Fault 3 Time
Fault 4 Code
Fault 4 Time
Fault 5 Code
Fault 5 Time
Fault 6 Code
Fault 6 Time
Fault 7 Code
Fault 7 Time
Fault 8 Code
Fault 8 Time
Alarm Config 1
Alarm Clear
Alarm X Code
DPI Baud Rate
Drive Logic Rslt
Drive Ref Rslt
Drive Ramp Rslt
DPI Port Sel
DPI Port Value
Logic Mask
270
271
272
273
274
275
276
256
257
258
259
261
262…269
246
247
248
249
250
251
242
243
244
245
252
253
254
255
Number
219
220
221
222
223
224
225
226
227, 228
229, 230
234, 236
235, 237
238
240
241
Group
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Diagnostics
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Faults
Alarms
Alarms
Alarms
Comm Control
Comm Control
Comm Control
Comm Control
Comm Control
Comm Control
Masks & Owners
Security
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
435
436
437
438
440
441
428, 432
429, 433
430
434
383, 387, 391
392
393
394
411
412
413
414
415
416
419
420
421
422
423
427, 431
323, 326
324, 327
340
341
342, 345
343, 346
344, 347
354, 355
361…366
377, 378
379
380, 384, 388
381, 385, 389
382, 386, 390
Number
291
292
293
294
295
296
297
298
299
300…307
308
310…317
320
321
322, 325
Parameter Name
Direction Owner
Reference Owner
Accel Owner
Decel Owner
Fault Clr Owner
MOP Owner
Local Owner
DPI Ref Select
DPI Fdbk Select
Data In XX
HighRes Ref
6.x
Analog OutX Sel
Analog OutX Hi
Analog OutX Lo
Anlg OutX Scale
Digital InX Sel
Anlg OutX Setpt
Dig Out Setpt
Digital OutX Sel
Group
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Masks & Owners
Comm Control
Number
445
446
447
448
449
450
451
454
Parameter Name
Ki Speed Loop**
Kp Speed Loop**
Kf Speed Loop**
Spd Err Filt BW
6.x
Speed Desired BW**
Total Inertia**
Speed Loop Meter**
Rev Speed Limit**
Group
Speed Regulator
Speed Regulator
Speed Regulator
Speed Regulator
Speed Regulator
Speed Regulator
Speed Regulator
Speed Regulator
Data Out XX
Anlg In Config
Anlg In Sqr Root
Analog In X Hi
Analog In X Lo
Analog In X Loss
Anlg Out Config
Anlg Out Absolut
Comm Control
Datalinks
Datalinks
Datalinks
Analog Inputs
Analog Inputs
Analog Inputs
Analog Inputs
Analog Inputs
Analog Outputs
Analog Outputs
Analog Outputs
Analog Outputs
Analog Outputs
Analog Outputs
Digital Inputs
Analog Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Outputs
Digital Inputs
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Speed Feedback
Torq Attributes
459
460
461
462
PI Deriv Time
PI Reference Hi
PI Reference Lo
PI Feedback Hi
463
464
PI Feedback Lo
PI Output Gain
476, 482, 488, 494 ScaleX In Value
601
602
603
604
477, 483, 489, 495 ScaleX In Hi
478, 484, 490, 496 ScaleX In Lo
479, 485, 491, 497 ScaleX Out Hi
480, 486, 492, 498 ScaleX Out Lo
481, 487, 493, 499 ScaleX Out Value
595 Port Mask Act
596 Write Mask Cfg
597
598
600
Write Mask Act
Logic Mask Act
TorqProve Cnfg
TorqProve Setup
Spd Dev Band
SpdBand Integrat
Brk Release Time
Process PI
Process PI
Process PI
Process PI
Process PI
Process PI
Scaled Blocks
Scaled Blocks
Scaled Blocks
Scaled Blocks
Scaled Blocks
Scaled Blocks
Security
Security
Security
Security
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Dig OutX Level
Dig OutX OnTime
Dig OutX OffTime
Dig Out Invert
Dig Out Param
Dig Out Mask
DigIn DataLogic
6.x
Motor Fdbk Type
Encoder PPR
Enc Position Fdbk
Encoder Speed
Fdbk Filter Sel
Notch Filter Freq**
Notch Filter K**
Marker Pulse
Pulse In Scale
Encoder Z Chan
Torque Ref X Sel**
605
606
607
608
609
610
611
612
613
631
632
633
634
635
636
637
ZeroSpdFloatTime
Float Tolerance
Brk Set Time
TorqLim SlewRate
BrkSlip Count
Brk Alarm Travel
MicroPos Scale%
TorqProve Status
Brake Test Torq
6.x
Rod Load Torque
TorqAlarm Level
TorqAlarm Action
TorqAlarm Dwell
TorqAlrm Timeout
TorqAlrm TO Act
PCP Pump Sheave
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Torq Proving
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
Torque Ref X Hi**
Torque Ref X Lo**
Torq Ref A Div**
Torque Ref B Mult**
Torq Attributes
Torq Attributes
Torq Attributes
Torq Attributes
638
639
640
641
Max Rod Torque
Min Rod Speed
Max Rod Speed
OilWell Pump Sel
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
Torque Setpoint**
Pos Torque Limit**
Torq Attributes
Torq Attributes
642
643
Gearbox Rating
Gearbox Sheave
Oil Well Pump
Oil Well Pump
Neg Torque Limit**
Torque Setpoint2**
Control Status**
Mtr Tor Cur Ref**
Torq Attributes
Torq Attributes
Torq Attributes
Torq Attributes
644
645
646
647
Gearbox Ratio
Motor Sheave
Total Gear Ratio
DB Resistor
Oil Well Pump
Oil Well Pump
Oil Well Pump
Oil Well Pump
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
53
54
663
669
670
671
672
675
676
677
700
701
702
Number
648
650
651
652
653
654…660
661
662
Parameter Name
Gearbox Limit
Adj Volt Phase
Adj Volt Select
Adj Volt Ref Hi
Adj Volt Ref Lo
Adj Volt Preset1-7
Min Adj Voltage
Adj Volt Command
MOP Adj VoltRate
Adj Volt TrimSel
Adj Volt Trim Hi
Adj Volt Trim Lo
Adj Volt Trim %
Adj Volt AccTime
Adj Volt DecTime
Adj Volt S Curve
Pos/Spd Prof Sts
Units Traveled
Home Position
6.x
705
707
708
711
713
714
Pos/Spd Prof Cmd
Encoder Pos Tol
Counts Per Unit
Vel Override
Find Home Speed
Find Home Ramp
Pos Reg Filter
Pos Reg Gain
718
719
720, 730, 740, 750,
760, 770, 780, 790,
800, 810, 820, 830,
840, 850, 860, 870
Step x Type
Group
Oil Well Pump
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
Adjust Voltage
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
ProfSetup/Status
Profile Setup
Number Parameter Name
721, 731, 741, 751,
761, 771, 781, 791,
801, 811, 821, 831,
841, 851, 861, 871
Step x Velocity
722, 732, 742, 752,
762, 772, 782, 792,
802, 812, 822, 832,
842, 852, 862, 872
Step x AccelTime
723, 733, 743, 753,
763, 773, 783, 793,
803, 813, 823, 833,
843, 853, 863, 873
Step x DecelTime
724, 734, 744, 754,
764, 774, 784, 794,
804, 814, 824, 834,
844, 854, 864, 874
Step x Value
725, 735, 745, 755,
765, 775, 785, 795,
805, 815, 825, 835,
845, 855, 865, 875
Step x Dwell
726, 736, 746, 756,
766, 776, 786, 796,
806, 816, 826, 836,
846, 856, 866, 876
Step x Batch
727, 737, 747, 757,
767, 777, 787, 797,
807, 817, 827, 837,
847, 857, 867, 877
Step x Next
Group
Profile Setup
Profile Setup
Profile Setup
Profile Setup
Profile Setup
Profile Setup
Profile Setup
* These parameters will only be displayed when parameter 053 [Motor Cntl Sel] is set to option “2” or “3.”
** These parameters will only be displayed when parameter 053 [Motor Cntl Sel] is set to option “4.”
6.x
Firmware 6.002 and later.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Appendix
Specifications
Category
Agency
Certification
Specification
Listed to UL508C and CAN/CSA-C2.2 No. 14-M91.
Marked for all applicable European Directives
EMC Directive (2004/108/EC)
EN 61800-3 Adjustable Speed electrical power drive systems
Low Voltage Directive (2006/95/EC)
EN 50178 Electronic Equipment for use in Power Installations
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
Category
Protection
Specification
AC Input Overvoltage Trip:
AC Input Undervoltage Trip:
Bus Overvoltage Trip:
400V
528V AC
340V AC
815V DC
Bus Undervoltage Shutoff/Fault: 300V DC
Nominal Bus Voltage:
Heat Sink Thermistor:
480V
528V AC
340V AC
815V DC
600V DC
300V DC
700V DC
Monitored by microprocessor overtemp trip
Drive Overcurrent Trip
Software Overcurrent Trip:
Hardware Overcurrent Trip:
200% of rated current (typical)
220…300% of rated current (depending on drive rating)
Line Transients: Up to 6000 volts peak per IEEE C62.41-1991
Control Logic Noise Immunity: Showering arc transients up to 1500V peak
Power Ride-Thru
Logic Control Ride-Thru:
15 milliseconds at full load
0.5 seconds minimum, 2 seconds typical
Ground Fault Trip:
Short Circuit Trip:
Intermittent Overload
Current Limit Capability
Phase-to-ground on drive output
Phase-to-phase on drive output
110% overload capability for up to 1 minute.
150% overload capability for up to 3 seconds.
Proactive Current Limit programmable from
20…160% of rated output current. Independently programmable proportional and integral gain.
Environment
Electronic Motor Overload
Protection
Altitude:
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.
1000 m (3280 ft) maximum without derating. See
Derate Guidelines on page 58 for operation above
1000 m (3280 ft).
Ambient Operating Temperature w/o Derating:
IP20, NEMA 1:
Storage Temperature
(all constructions):
-10…60 °C (14…140 °F)
-40…70 °C (-40…158 °F)
Atmosphere: 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.
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
55
56
Category
Environment
(continued)
Specification
Relative Humidity:
Shock:
Vibration:
Sinusoidal:
Electrical
Control
5…95% non-condensing
40G peak for 6 milliseconds duration (
±
3.0 ms)
Random:
Input Voltage:
Output Voltage Range:
Output Frequency Range:
Frequency Accuracy
Digital Input:
Analog Input:
Frequency Control:
0.35 mm (0.014 in.) constant displacement to a constant acceleration of 5G.
10…500 Hz, 1 octave/minute, 10 sweep cycles,
3 axes
0.05 g
2
/Hz, 10…500 Hz, 3 axes at 30 minutes per axis
480V RMS, +10%, -5% (operate to -50% with reduced power, -30% minimum precharge)
Note: The PowerFlex Frame 1X drive requires a
3% input impedance.
47…63 Hz.
Input Frequency Range:
Line-to-Neutral Phase
Imbalance Tolerance:
Output Voltage:
Output Frequency Range:
Switching Frequency:
Continuous Output Power:
Continuous Output Current:
Peak Output Current:
3 seconds Maximum:
1 minute:
Efficiency at Maximum Power,
Nominal Voltage:
Power Loss at Full Load:
Power Loss to Air:
Method:
Carrier Frequency:
2%
0…460V RMS at nominal 480V RMS input. Output will be 460V RMS.
0…420 Hz
4 kHz base; 2, 4, 8, 10 kHz selectable with derating. Derating at 8 and 10 kHz.
100 kW (150 HP)
180 amps RMS
270 amps RMS (3 seconds per 60 seconds)
198 amps RMS (1 minute per 10 minutes)
> 97.5%
1900 W at 100 kW
200 W at 110 kW
Sine-coded PWM with programmable carrier frequency.
2…10 kHz. Drive rating based on 4 kHz.
for more information.
0…rated motor voltage
0…420 Hz
Within ± 0.01% of set output frequency.
Within ± 0.4% of maximum output frequency
Speed Regulation - with Slip Compensation (Volts per Hertz Mode)
0.5% of base speed across 40:1 speed range
40:1 operating range
10 rad/sec bandwidth
Speed Regulation - with Slip Compensation
(Sensorless Vector Mode)
0.5% of base speed across 80:1 speed range
80:1 operating range
20 rad/sec bandwidth
Speed Regulation - with Feedback (Sensorless
Vector Mode)
0.1% of base speed across 80:1 speed range
80:1 operating range
20 rad/sec bandwidth
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
Category
Control
(continued)
Liquid
Coolant
Encoder
Dynamic
Brake
Resistor
Specification
Speed Control:
Torque Regulation:
Selectable Motor Control:
Speed Regulation - without feedback (Vector
Control Mode)
0.1% of base speed across 120:1 speed range
120:1 operating range
50 rad/sec bandwidth
Speed Regulation - with feedback (Vector Control
Mode)
0.001% of base speed across 120:1 speed range
1000:1 operating range
250 rad/sec bandwidth
Torque regulation without Feedback;
± 5%, 600 rad/sec bandwidth
Torque regulation with Feedback;
± 2%, 2500 rad/sec bandwidth
Sensorless Vector with full tuning. Standard V/Hz with full custom capability and Vector Control with
Force Technology (with and without feedback).
Stop Modes
Accel/Decel
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.
Coolant Type: 50% water / 50% propylene glycol
Max. Particle Size in Coolant: 5 microns
Minimum Flow Rate:
Nominal Flow Rate:
7.57 LPM (2 GPM)
9.46 LPM (2.5 GPM)
Maximum Flow Rate:
Pressure Drop:
22.71 LPM (6 GPM)
< 0.34 bar at 9.46 LPM (5 psi at 2.5 GPM), 20 °C
Maximum Coolant Temperature: 60 °C (140 °F)
Maximum Inlet Pressure: 3.45 bar (50 psi)
Type:
Supply:
Incremental, dual channel
12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter, 250 kHz maximum.
Quadrature:
Duty Cycle:
Requirements:
Regen DC Bus Voltage (V
Resistor d
):
Minimum Ohms, External Brake
90°, ± 27 degrees at 25 °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 of 7.0V
DC (12 volt encoder). Maximum low state voltage is 0.4V DC.
790 volts
8.2 ohms
Heat Dissipation
Table 14 Watts Loss @ Rated Load, Speed, and PWM Carrier Frequency
Voltage
PWM
Freq.
Watts Loss
Into Air Into Liquid Total
480V 4 kHz 200 1700 1900
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
57
58
Derate Guidelines
Altitude
Above 1000 m (3280 ft), derate the output current by 1% for every 100 additional meters (328 additional feet). PowerFlex 700L Frame 1X drives should not be used above 2000 m (6562 ft) due to voltage spacing requirements.
Ambient
Frame 1X drives have a maximum ambient of 60 °C (140 °F). PowerFlex
700L drives cannot be derated to operate at higher temperatures.
Carrier Frequency
For Frame 1X drives, refer to the carrier frequency derating table below.
180
Output
(Amps)
0
2
4
6
Carrier Frequency (kHz)
8
144 Amps
(80%)
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
PowerFlex 700L Frame 1X Drive Installation Instructions – Publication 20L-IN013A-EN-P – June 2009
59
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
www.rockwellautomation.com
Power, Control and Information Solutions Headquarters
*PN-47006*
PN-47006
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Publication 20L-IN013A-EN-P – June 2009
Copyright ® 2009 Rockwell Automation. All rights reserved. Printed in USA.
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Key Features
- Liquid-Cooled
- Adjustable Frequency
- Basic Start-Up Routine
- Cooling Loop Connection
- Wiring Instructions
- Troubleshooting Tips
- CE Compliant
