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Reference Manual

Adjustable Frequency AC DriveVolume 2PowerFlex 700S

www.abpowerflex.com

Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls” (Publication SGI-1.1 available from your local Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will the Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited.

Throughout this manual we use notes to make you aware of safety considerations.

Attentions help you:

• identify a hazard

• avoid the hazard

• recognize the consequences

Important: Identifies information that is especially important for successful application and understanding of the product.

DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.

PLC is a registered trademark of Rockwell Automation.

ControlNet is a trademark of ControlNet International, Ltd.

DeviceNet is a trademark of the Open DeviceNet Vendor Association.

COLOR-KEYED is a registered trademark of Thomas & Betts Corporation.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Shock Hazard labels may be located on or inside the drive to alert people that dangerous voltage may be present.

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 1 Specifications & DimensionsPowerFlex 700S Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Input/Output Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Heat Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Chapter 2 Detailed Drive OperationAccel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Auto/Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Auto Restart (Reset/Run) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Autotune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Bus Regulation/Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16Cable, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21Cable, Motor Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24Cable, Standard I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26Cable Trays and Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27Carrier (PWM) Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28Common Bus Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30ControlNet (20-COMM-C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31Copy Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41Current Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42Datalinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43DC Bus Voltage/Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45Decel Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46DeviceNet (20-COMM-D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54Direction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57Distribution Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58DPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59DriveLogix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62Drive Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63Drive Ratings (kW, Amps, Volts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67Electronic Gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68EMC Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71Flying Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72Friction Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

ii Table of Contents

Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75Grounding, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76HIM Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77HIM Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78Input Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79Input Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81Jog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82Lead/Lag Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86Motor Control Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87Motor Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89Motor Start/Stop Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91Output Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92Output Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93Overspeed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94Owners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95Parameter Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97Permanent Magnet Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98PET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99Position Loop - Follower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100Position Loop - Point to Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105Position Detect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110Position Watch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111Power Loss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112Preset Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113Process PI Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114Process Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115Process Trim Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116Reflected Wave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117Remote I/O Adapter (20-COMM-R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118Reset Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127Reset Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128RFI Filter Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129S-Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130Scaling Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131Shear Pin Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132Skip Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133Speed Control, Speed Mode, Speed Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134Speed Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135Speed Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136Speed Reference Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137Speed PI Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138Start Inhibits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-139Start Permissives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-140Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141

Table of Contents iii

Stop Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-142SynchLink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-143Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157Thermal Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158Torque Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159Torque Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-160Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-161User Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-162Velocity Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-163Velocity Reference Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-164Velocity Feedback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-165Velocity Pl Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-166Voltage Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-167Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-168

Appendix A Dynamic Brake Selection Guide

Table of Contents

Section 1Understanding How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Dynamic Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2Determining Dynamic Brake Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1How to Determine Dynamic Brake Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Determine Values of Equation Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Section 3Evaluating the Internal Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Evaluating the Capability of the Internal Dynamic Brake Resistor . . . . . . . . . . . . . . . . . 3-1PowerFlex 70 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4PowerFlex 700 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Section 4Selecting An External Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1How to Select an External Dynamic Brake Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Appendix A

Index

Chapter 1

Specifications & Dimensions

PowerFlex 700S Specifications

Category SpecificationProtection 200-

208V Drive

240vDrive

380/400VDrive

480VDrive

600V Drive

690VDrive

AC Input Overvoltage Trip: 247VAC 285VAC 475VAC 570VAC 690VACAC Input Undervoltage Trip: 120VAC 138VAC 233VAC 280VAC 345VACBus Overvoltage Trip: 350VDC 405VDC 675VDC 810VDC 1013VDCBus Undervoltage Trip: AdjustableNominal Bus Voltage: 281VDC 324VDC 540VDC 648VDC 810VDCHeat Sink Thermistor: Monitored by microprocessor overtemp tripDrive Overcurrent Trip

Software Current Limit:Hardware Current Limit:Instantaneous Current

Limit:

20-160% of rated current200% of rated current (dependent on drive rating)

220-300% of rated current (dependent on drive rating)Line Transients Up to 6000 Volts peak per IEEE C62.41-1991Control Logic Noise Immunity:

Showering arc transients up to 1500V peak

Power Ride-Thru 15 milliseconds at full loadLogic Control Ride-Thru 0.5 seconds minimum, 2 seconds typical Ground Fault Trip: Phase-to-ground on drive outputShort Circuit Trip: Phase-to-phase on drive output

Environment Altitude: 1000 m (3300 ft.) max. without deratingAmbient Operating Temperature:Without derating:

Open Type:IP20:NEMA Type 1:IP56, NEMA Type 4X:

0 to 50o C (32 to 122o F)0 to 50o C (32 to 122o F)0 to 40o C (32 to 104o F)0 to 40o C (32 to 104o F)

Storage Temperature (all const.):

-40 to 70o C (-40 to 158o F)

Atmosphere Important: Drive must not be installed in an area where the surrounding 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.

Relative Humidity: 5 to 95% non-condensingShock: 15G peak for 11ms duration (+/- 1.0 ms)Vibration: 0.152 mm (0.006 in.) displacement, 1G peak

1-2 Specifications & Dimensions

Agency Certification

The drive is designed to meet the following specifications:NFPA 70 - US National Electric CodeNEMA ICS 3.1 - Safety standards for Construction and Guide for Selection,

Installation and Operation of Adjustable Speed Drive SystemsNEMA 250 - Enclosures for Electrical EquipmentIEC 146 - International Electrical Code

UL and cUL Listed to UL508C and CAN/CSA-C2. No. 14-M91

Marked for all applicable European Directives(1)

EMC Directive (89/336/EEC)Emissions

EN 61800-3 Adjustable Speed electrical power drive systemsPart 3Immunity

EN 61800-3 Second Environment, Restricted Distribution Low Voltage Directive (73-23-EEC)

EN 60204-1 Safety of Machinery - Electrical Equipment ofMachines

EN 50178 Electronic Equipment for use in Power InstallationElectrical Voltage Tolerance: -10% of minimum, + 10% of maximum

Frequency Tolerance: 47-63 HzInput Phases: Three-phase input provides full rating for all drives. Single-phase

operation provides 50% of rated currentDisplacement Power Factor: TBDEfficiency: 97.5% at rated amps, nominal line voltsMax. Short Circuit Current Rating:

Using Recommended Fuse

orCircuit Breaker Type

Maximum short circuit current rating to match specified fuse/circuit breaker capability

Control Method

Induction Motor:

Brushless Motor:

Ratings apply to all drives. The drive can be supplied as 6 pulse or 12 pulse in a configured package.Indirect Self-Organized, Field-Orientated ControlCurrent-regulated, sine-coded PWM with programmable carrier frequency

Carrier Frequency Frames 1, 2, 3, 5

Drive rating: 4 kHz, Range 1 - 12 kHz

Output Voltage Range: 0 to rated motor voltageOutput Frequency Range: 0 - 350 HzSpeed Regulation:

With a Feedback Sensor:Sensorless:

0.001% of Top Speed over a 100:1 Speed Range0.5% of Top Speed Over a 120:1 typical Speed Range

Selectable Motor Contol: Field Orientated Control with and without a feedback device and Brushless motor control

Stop Modes: Multiple programmable stop modes including - Ramp, Coast and Current Limit

Accel/Decel: Independently programmable accel and decel times adjustable from 0 to 6553.5 in. in .01 second increments

S-Curve Time: Adjustable from 0.5 to 4.0 secondsIntermittent Overload: 110% Overload capability for up to 1 minute

150% Overload capability up to 3 secondsCurrent Limit Capability: Independent Motoring and Regenerative Limits programmable to

800% of rated output currentElectronic Motor Overload Protection:

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

Category Specification

Specifications & Dimensions 1-3

Feedback Encoder Inputs Qty (2) Incremental, Dual Channel Quadrature type, Isolated with differential transmitter Output (Line Drive)5V DC or 12V DC (5V DC requires an external power supply)

Hi-Resolution Stegmann Option:

Excitation:Hi-Resolution Feedback:Resolution Feedback:Interface:Maximum Cable Length:

11.5V @ 130mASine/Cosine 1V peak-peak Offset 2.5Up to 1,000,000 linesRS-485 Hiperface Compatible182 meters (600 ft.)

Resolver Option:Excitation Frequency: 2400 HzExcitation Volatage: 26 VrmsOperating Frequency Range:

26 Vrms

Resolver Feedback Voltage:

1 - 10 kHz

Maximum Cable Length: 304.8 meters (1000 ft.)(1) Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high [Pulse Freq]

readings.

Category Specification


Input/Output Ratings Each PowerFlex has heavy duty torque capabilities. The drive ratings can be found in Table 2.E on page 2-64 and Table 2.F on page 2-65


Heat Dissipation See Watts Loss on page 2-168


Mounting Figure 1.1 Minimum Mounting Clearance Requirements

101.6mm(4.0 in.)

101.6mm(4.0 in.)

Refer to the Mounting on page 2-91for detailed dimension

information

With Adhesive Label(see below)

No Adhesive Label (see below)

101.6mm(4.0 in.)

101.6mm(4.0 in.)

50.8mm (2.0 in)

50.8mm (2.0 in)


Derating Guidelines

Frame VoltageND Rating Enclosure Frequency(1) Derate

1 400V 11 kW • Open• NEMA Type1• IP20

2-6kHz

460V 15 HP • Open• NEMA Type1• IP20

2-6kHz

2 400V 15kW • Open• NEMA Type1• IP20


10 kHz

25 HP • Open• NEMA Type1• IP20

6-10 kHz

Max

. Sur

roun

ding

Air

Tem

p, o C

20

25

30

35

40

45

50

40 50 60 70 80 90 100

% of Output FLA

6 kHz

8 kHz

10 kHz

20

25

30

35

40

45

50

40 50 60 70 80 90 100

% of Output FLA

6 kHz

8 kHz

10 kHzMax

. Sur

roun

ding

Air

Tem

p, o

C

40 50 60 70 80 90 100

8 kHz

10 kHz

35

40

45

50

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C

40 50 60 70 80 90 100

10 kHz

40

42

44

46

48

50

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C

40 50 60 70 80 90 1000

10

20

30

40

50

6 kHz

8 kHz

10 kHz

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C


3 400V 18.5 kW • Open• NEMA Type1• IP20

6-10 kHz

400V 22 kW • Open• NEMA Type1• IP20

2-10 kHz None

30 kW • Open• NEMA Type1• IP20

6-10 kHz

37 kW • Open• NEMA Type1• IP20

4-10 kHz

460 V 30 HP • Open• NEMA Type1• IP20

2-10 kHz None


6-10 kHz


6-10 kHz


40 50 60 70 80 90 1000

10

20

30

40

50

6 kHz

8 kHz

10 kHz

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C

10

20

30

40

50

40 50 60 70 80 90 100

6 kHz

8 kHz

10 kHz

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C

40 50 60 70 80 90 1000

10

20

30

40

50

6 kHz

4 kHz

8 kHz10 kHz

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C

10

20

30

40

50

40 50 60 70 80 90 100

6 kHz

8 kHz

10 kHzMax

. Sur

roun

ding

Air

Te

mp,

oC

40 50 60 70 80 90 1000

10

20

30

40

50

6 kHz

8 kHz10 kHz

% of Output FLA

Max

. Sur

roun

ding

Air

Tem

p, o

C


5 400V 55 kW • Open• NEMA Type1• IP20

2-8 kHz None


2-8 kHz None


4 kHz None6-8 kHz

(1) Consult the factory for further derate information at other frequencies.


15

20

25

30

35

40

45

50

40 50 60 70 80 90 100

% of Output FLA

8 kHz

6 kHz

Max

. Sur

roun

ding

Air

Tem

p, o

C


Dimensions The following are the PowerFlex 700S dimensions.

Table 1.A PowerFlex 700S Frames

Frame400V AC Input 480V AC InputND kW HD kW ND HP HD HP

1 0.37 to 11 0.37 to 7.5 0.5 to 15 0.33 to 102 15 11 20 15

18.5 15 25 203 22 18.5 30 25

30 22 40 3037 30 50 40

5 55 45 – –– – 75 60– – 100 75


Figure 1.2 PowerFlex 700S Frame 1-3 (Frame 1 Shown)

Dimensions are in millimeters and (inches)

C

A

D12.5 (0.49)

7.0 (0.28) typ

B E

7.0 (0.28) typ7.0 (0.28)D

Fram

e

A B C D E

Weight(1) kg (lbs.)Drive

1 200.0 (7.87) 389.0 (15.31) 202.8 (7.98) 175.0 (6.89) 375.0 (14.76) 11.3 (24.92)2 285.0 (11.22) 389.0 (15.31) 202.7 (7.98) 250.0 (9.84) 375.0 (14.76) 18.4 (40.57)3 285.0 (11.22) 564.0 (22.20) 202.7 (7.98) 250.0 (9.84) 550.0 (21.65) 26.6 (58.65)

(1) Weights include HIM, DriveLogix controller with ControlNet daughtercard, Hi-Resolution Encoder Option, and 20-COMM-C ControlNet adapter


Figure 1.3 PowerFlex 700S Frame 5


271.1 (10.57)

369.0 (14.53)

349.5 (13.76)

7.5 (0.30)

369.4 (14.54)

225.0 (8.86)

6.50 (0.26)

70.1 (2.76)

6.50 (0.26)

41.9 (1.65)

7.5 (0.30)

625.0 (24.61)

644.5 (25.37)OverallHeight75 HP

Frame 5

689.6 (27.15)OverallHeight100HP

Frame 5

6.50 (0.26)

Conduit BoxNOT PresentOn 75 HP Frame 5

308.9 (12.16)

Weight(1) kg (lbs.)

(1) Weights include HIM, DriveLogix controller with ControlNet daughtercard, Hi-Resolution Encoder Option, and 20-COMM-C ControlNet adapter

Drive42.6 (93.93)


Figure 1.4 PowerFlex 700S Bottom View Dimensions, Frame1 & 2


187.9(7.40)

190.4(7.50)

136.1(5.36)

25.5(1.00)

108.0 (4.25)

140.9 (5.55)

135.0 (5.31)

161.0 (6.34)

173.5 (6.83)152.5 (6.00)

132.5 (5.22)72.5 (2.85)

28.7 (1.13) Dia.3 Places

137.7 (5.42)171.0 (6.73)

201.4 (7.93)242.4 (9.54)

104.3 (4.11)65.0 (2.56)

122.2 (4.81)

153.7(6.05)

160.3(6.31)

114.9(4.52)

187.6(7.39)

22.4 (0.88) Dia.2 Places

Frame 1

Frame 2


Figure 1.5 PowerFlex 700S Frame 3 Bottom View Dimensions


167.9(6.61)

170.3 (6.70)

159.7 (6.29)

153.9(6.06) 130.5

(5.14)

87.7 (3.45)

94.0 (37.0)

131.0 (5.16)

162.0 (6.38)

202.2 (7.96)

252.0 (9.92)

162.9(6.41)

187.3(7.37)

37.3 (1.47) Dia.2 places28.7 (1.13) Dia.

2 places

22.2 (0.87) Dia.

Frame 3 - All Drives, except 50 HP, 480 V

Frame 3 - 50 HP, 480V

Normal Duty Drive

167.9(6.61)

130.5(5.14)

252 (9.92)

202.2 (7.96)

87.7 (3.45)

170.3 (6.70)

159.7 (6.29)

162.9(6.41)

187.3(7.37)

94.0 (3.70)

131.0 (5.16)

28.7 (1.13) Dia.2 Places 46.7 (1.84) Dia.

2 Places

34.9 (1.37) Dia.2 Places


Figure 1.6 PowerFlex 700S Frame 5 Bottom View Dimensions


95.8(3.77)

159.0(6.26)

184.0 (7.24)

229.5 (9.04)

62.7 (2.47) Dia.2 Places

22.2 (0.87) Dia.2 Places

34.9 (1.37) Dia.2 Places

110.0 (4.33)150.0 (5.91)

215.0 (8.46)280.0 (11.02)

320.0 (12.60)

93.0 (3.66)65.0 (2.56)

241.9 (9.52)

220.0 (8.66)

158.2 (6.23)169.0 (6.65)

109 (4.29)131.4 (5.17)

193 (7.60)297.3 (11.70)

93.0 (3.66)65.0 (2.56)

96.0(3.78)

153.7(6.05)

184.3 (7.26)

188.5(7.42)

223.5 (8.80)

241.9(9.52)

62.7 (2.47) Dia.2 Places22.2 (0.87) Dia.

2 Places

34.9 (1.37) Dia.

Removable Junction Box96.9 (3.81)107.6 (4.24)

Frame 5 - 75 HP, 480 V (55kW, 400V)

Frame 5 - 100 HP, 480 V (55kW, 400V)

Chapter 2

Detailed Drive Operation

Accel Time The Accel Time parameter, Parameter 32 [Accel Time], sets the rate at which the drive ramps up its output after a Start command or during an increase in desired speed (speed change).

The rate established is the result of the programmed Accel Time and the programmed motor rated speed, Parameter 4 [Motor NP RPM].

Times are adjustable in 0.1 second increments from 0.0 to 3600.0 seconds.

Programming zero seconds will cause the drive to use .1 seconds.

Parameter 4 [Motor NP RPM]Parameter 32 [Accel Time]

------------------------------------------------------------------------ Accel Rate=

2-2 Detailed Drive Operation

AC Supply Source Considerations

PowerFlex 700S drives are suitable for use on a circuit capable of delivering a maximum of 200,000 RMS symmetrical amperes, 600V. If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.

!To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses and circuit breakers specified in Table 2.E and Table 2.F

Detailed Drive Operation 2-3

Alarms Alarms indicate conditions within the drive that could affect drive operation or application operation. Alarms are selected during commissioning of the drive. Example of alarms include: Encoder loss, Communication loss or other exceptions within the drive. Also see Diagnostics.

[Alarm Status 1][Alarm Status 2]

Two 32 bit words. Indications masked by the setup of each parameter listed in [Exception Event1] and [Exception Event 2]. Exception events consist of Parameters 365 to 394, each of which can be programmed for various responses. Responses include Ignore, Alarm, Fault Coast Stop, Fault Ramp Stop, and Fault Current limit Stop.

Application

[Inv Ol Pend Cnfg] is set to a value of 1. This configure the drive to set the alarm bit, [Alarm Status 1] bit 15, for this when the event occurs. This will allow the drive to continue running. The system controller can make the decision as to what action to take in relation to the alarm.


Analog Inputs Analog Input Specifications

There are 2 analog inputs located on TB1 - Row B (Bottom Terminals). Each input accepts a +/-10V or +/-1V bipolar, differential signal. Dip switches SW1-1 and SW1-2 are used to select whether the analog inputs are +/-10V or +/-1V. The A/D converter is 14 bits including the sign bit (13 bits plus the sign bit).

Analog Outputs

Once the Analog Input is converted, [Anlg Inx Offset] can be applied. [Anlg Inx Offset] has a range of +/-20V. [Anlg Inx Volts] is the sum of the A/D output and [Anlg Inx Offset]. [Anlg Inx Volts] is displayed as +/-10V.

[Anlg Inx Scale] scales [Anlg Inx Volts] to the range of [Anlg Inx Data]. A destination parameter, such as a speed reference can then be linked to [Anlg Inx Data].

[Al x Filt Gain] and [Anlg Inx Filt BW] are used to filter the analog input data.

A/D14bit

803

802804

805

TB1-B11

TB1-B10

-

+

Anlg ln1 Offset

Anlg ln1 Scale

+X

Anlg ln1 Volts

Lead Lag

(kn * s) + wns + wn

800

Anlg ln1 Data

Al 1 Filt Gain

Anlg ln1 Filt BW

801

A/D14bit

809

808810

811

TB1-B8

TB1-B7

-

+

Anlg ln2 Offset

Anlg ln2 Scale

+X

Anlg ln2 Volts

Lead Lag

(kn * s) + wns + wn

806

Anlg ln2 Data

Al 2 Filt Gain

Anlg ln2 Filt BW

807

ShieldTB1-B9


Analog Input Configuration

This example illustrates how to setup a speed reference to follow a 0-10V analog input signal and null out a small amount of offset from the A/D converter on the analog input.

• [Anlg ln1 Offset] = -0.0144V• [Anlg ln1 Scale] = 0.1 per 1V• [Anlg ln1 Filt Gain] = 1• [Anlg ln1Filt BW] = 0• [Spd Ref 1] is linked to [Anlg ln1 Data]

With a desired [Anlg In1 Volts] of 0V, the drive was reading 0.0144V. To null out analog input 1, [Anlg In1 Offset] was set to -0.0144V.

[Spd Ref 1] is a per unit parameter, meaning that a value of 1 equates to base motor RPM. Therefore, to scale [Anlg In1 Data] to give us a value from 0 to 1 for a 0-10V signal, [Anlg In1 Scale] was set to 0.1 per 1V.

[Anlg In1 Filt BW] was set to 0 so that no filtering took place on analog input 1.

Response Time

The response time between a change of an analog speed reference and when a fluxed up motor reacted to that change on a PowerFlex 700S was measured.

Before taking the measurements, motor data was entered and an autotune was performed on the connected motor. The motor was unloaded.

Additionally, the following parameters were set:

• Parameter 89 [Spd Err Filt BW] = 0 Rad/Sec• Parameter 90 [Spd Reg BW] = 40 Rad/Sec• Parameter 151 [Logic Cmd Word] = 0000 0000 0000 0001 (Bit 0 was set

to 1 to disable the speed ramp)

To measure the response time, an analog input was configured as the speed reference. The drive was started with a 0 RPM speed reference. A 0 to 10V supply was wired through a switch to the analog input. Then the time between a 0 to 10V step change on the analog input and the motor current to reach 2/3 of its peak was measured with an oscilloscope.

20 trials were performed with the following results:

• Average time = 2.2 ms• Worst case response time = 3.4 ms

The response times can be broken down as follows:

• Analog input delay time = 0.8 ms• VPL (velocity processor loop) time = 0.5 ms• Time to ramp Iq to 2/3 = remaining time


So the variable in the response time is the time to ramp Iq to 2/3. From our testing, we can see that Parameter 89 [Spd Err Filt BW] and Parameter 90 [Spd Reg BW] affect how fast the drive responds to a step change in the speed reference, and therefore how fast Iq is ramped up. Decreasing Parameter 354 [Iq Rate Limit] will tend to make the Iq ramp time longer. Setting Parameter 153 [Control Options] bit 11 will also make the Iq ramp time longer.


Analog Outputs Analog Output Specifications

There are 2 analog outputs located on TB1 - Row B (Bottom Terminals). Each output outputs a +/-10V bipolar, differential signal. The D/A converter is 12 bits including the sign (11 bits plus the sign bit).

Analog Output Configuration

The analog outputs can be linked to either an integer parameter or a real parameter. Use [Anlg Out Real] when you are linking to a real parameter and use [Anlg Outx Integer] when you are linking to an integer parameter.

[Anlg Outx Offset] is added to [Anlg Outx Real] or [Anlg Outx Integer] before the scaling and limiting blocks. [Anlg Outx Offset] has a range of +/-20V.

The result of [Anlg Outx Offset] plus [Anlg Outx Real] or [Anlg Outx Integer] is limited by 10 times the value of [Anlg Outx Scale].

Then that limited value is divided by the value of [Anlg Outx Scale].

[Anlg Outx Zero] is added after the scaling and limiting of the analog output value. [Anlg Outx Zero] can be used to null out any offset from the D/A converter.

TB1-B5

TB1-B6

-

+

816

X

Anlg Out1 Volts

818

812

814

815

817

+

Anlg Out1 Zero

Anlg Out1 Offset

Anlg Out1 Integer

Anlg Out1 Real

Anlg Out1 Scale

D/A12bit

1[x]

Limit

+

10 [x]

TB1-B5

TB1-B6

-

+

816

X

Anlg Out1 Volts

823

813

819

820

822

+

Anlg Out1 Zero

Anlg Out2 Offset

Anlg Out2 Integer

Anlg Out2 Real

Anlg Out2 Scale

D/A12bit

1[x]

Limit

+

10 [x]

TB1-B4Shield


Configuration Example 1:

This configuration sends motor speed feedback to a 0-10V analog output.

• [Motor NP RPM] is 1755 RPM• [Anlg Out1 Real] is 1755 RPM• [Anlg Out1 Scale] is set to 175.5 per Volt

[Anlg Out1 Real] is used because [Motor NP RPM] is a real parameter. [Anlg Out1 Scale] is set to 175.5 per Volt, so that the analog output will give -10V when the motor speed is -1755 RPM and will give +10V when the motor speed is +1755 RPM.


This configuration sends the motor torque current reference value to a 0-10V analog output signal.

• [Anlg Out1 Real] is linked to [Mtr TrqCurr Ref]• [Anlg Out1 Scale] = 0.1 per Volt

[Mtr TrqCurr Ref] is a real parameter expressed in per unit. Therefore a value of 1 corresponds to 100% motor torque. [Anlg Out1 Real] is used because [Mtr TrqCurr Ref] is a real parameter.

[Anlg Out1 Scale] is set to 0.1 per 1V so that when [Mtr TrqCurr Ref] = 1p.u., the analog output = 1 / 0.1 = 10V.


This configuration sends [Position Error] out to a 0-10V analog output signal.

• [Anlg Out1 Integer] is linked to [Position Error]• [Anlg Out1 Scale] is set to 214748664.8 per Volt

[Position Error] is an integer parameter with a range from -2147483648 to +2147483648. [Anlg Out1 Integer] is used because [Position Error] is an integer parameter.

[Anlg Out1 Scale] is set to 214748364.8 per Volt so the analog output will give -10V when the position error is -2147483648 and will give +10V when the position error is +2147483648.


Auto/Manual Information not available at time of publication


Auto Restart (Reset/Run) Information not available at time of publication


Autotune Auto-tuning is a procedure that involves running a group of tests on the motor/drive combination. Some tests are checking the drive hardware while others configure the drive parameters to maximize the performance of the attached motor.

The auto-tuning procedure can be done using the Start-Up menu of the HIM.

Autotune - Start-Up Menu

The Start-Up menu prompts the User for information and yes/no responses as required. Figure 2.1 is a flow chart of the Start-Up Menu. The “Motor Control,” “Motor Data,” “Feedback Configuration,” “Power Circuit Test,” “Direction Test,” “Motor Tests,” and “Inertia Measure” submenus of the Start-Up Menu are all related to the autotuning of the drive/motor combination and will be covered in this section.

Figure 2.1 Start-Up Menu Flow Chart

PowerFlex 700SStart-Up

Motor Control Motor DataFeedback

ConfigurationPower Circuit Test Direction Test

Motor Tests Inertia Measure Speed Limits Speed Control Start / Stop / I/O

Select Motor ControlMode

Select DB Resistor

Enter Motor NP DataPower & Units

FLAVoltsHertzRPMPoles

Setup / SelectEncoderResolver

Hi-Res EncoderLinear Sensor

Diagnostic Check forDrive Power Circuit

Verify Direction

Field OrientedControl: MeasureStator Resistance,Leakage Inductance,MagnetizingInductancePMag Motor: EncoderOffset, StatorResistance, StatorInductance, Back EMF

Measure SystemInertia

Select DirectionControl

Set FWD, REV andABS Speed Limits

Select Sources For AllSpeed References

Configure:Digital Inputs, Digital

Outputs, AnalogInputs, Analog Outputs

Done /Exit

Esc

Down 1 level or Select

Back 1 level or 1 selection

Scroll all choices


Motor Control

The Motor Control submenu asks you to select the motor control operating mode which sets the parameter [MC Operate Mode]. Choices are “FOC,” “FOC2,” “Pmag Motor” and “Test.”

• “FOC” selects field oriented control. This should be the selection for AC squirrel cage induction motors

• “FOC2” selects field oriented control and is only used for a specific type of AC induction motor with motor thermal feedback.

• “Pmag Motor” selects control for permanent magnet motors• “Test” puts the drive in a test mode to perform the direction test. “Test” is

automatically selected during the direction test portion of the Start-Up routine, and does not need to be set manually by the user.

Next, the motor control submenu asks you to select whether you have no dynamic braking, an internal resistor for dynamic braking, or an external resistor for dynamic braking. When no dynamic braking is selected, the bus regulator is turned on (see Bus Regulation/Braking of this manual for more details).

Motor Data

This submenu asks you to enter whether the motor power is in units of kW or HP. Then you are prompted to enter the motor nameplate data. Accurate motor nameplate data is important for tuning the drive to the connected motor.

Feedback Configuration

The Feedback Configuration submenu asks you to select the feedback device type. Possible selection are “Encoder 0,” “Encoder 1,” “Aux Speed,” “Motor Sim,” or “Option Card.” Encoder 0 and Encoder 1 are for the encoders on the I/O board. When “Encoder 0” or “Encoder 1” are selected, you must also enter the encoder ppr. “Motor Sim” is to simulate a motor when there is no motor connected to the drive. “Option Card” can be chosen when either the Resolver or Hi-Resolution Encoder option cards are installed.

Power Circuit Test

This submenu allows you to perform a diagnostic check to check the output section of the drive power circuit for shorts or open circuits.

Direction Test

The direction test checks the actual direction relative to the commanded, and checks for proper encoder feedback. The test prompts you to answer if


the motor direction is correct. When it is not you can either power down and swap 2 of the motor leads, or the drive can change its logic to change the motor direction. Then the test is performed again. The test then checks if the feedback is positive. When it is not you can either power down and swap 2 of the encoder signals, or the drive can change its logic to change the sign of the feedback. Then the test is performed again.


Motor Tests

This submenu performs the tests to measure the motor characteristics. These tests can be performed with the motor coupled or uncoupled to the load, but be aware that the motor will rotate during some of the tests.

For Field Oriented Control the following motor tests are performed:

For Permanent Magenet Control the following motor tests are performed:

Inertia Test

The final test is the inertia calculation. The motor and load (machine) inertia is used to set the bandwidth of the speed regulator. During the test the motor will accelerate to the speed set in [Atune Spd Ref] at a specified torque set by [Atune Torq Ref]. The test then calculates the time in seconds to accelerate the motor at rated torque from zero to base speed and stores that value in [Total Inertia].

Stator Resistance TestThis test identifies the motor stator resistance and stores the value into [Stator Resistnce]. The motor should not rotate during this test.

Stator Inductance Test This test identifies the motor stator inductance and stores the value into [Stator Inductnce]. The motor should not rotate during this test.

Leakage Inductance TestThis test measures the inductance characteristics of the motor. A measurement of the motor inductance is required to determine references for the regulators that control torque. The motor should not rotate during this test. The test runs for approximately 1 minute and then stores the calculated value into [Leak Inductance]. A typical value is between 15 and 25%.

Flux Current TestThis test is used to identify the value of motor flux current required to produce rated motor torque at rated current. When the flux test is performed, the motor will rotate. The drive accelerates the motor to the speed set in [Atune Spd Ref] (default is 85% of base speed) and then coasts for several seconds. This cycle may repeat several times, then decelerate to a low speed and shut off. This test stores the value for flux current in [Flux Current].

Stator Resistance TestInformation not available at time of publication

Stator Inductance TestInformation not available at time of publication

Encoder OffsetThe absolute position sensor counter offset from the rotor flux center position for a Permanent Magnet (PM) motor. This value is determined by an automated measurement procedure, which uses Parameter 505 [PM TestWait Time], 506 [PM Test Idc Ramp], 507 [PM Test FreqRamp], 508 [PM Test Freq Ref] and 509 [PM Test I Ref]. First, the Flux Producing (d-axis) current is applied to the stator, starting with 0A and with 0 Hz. Current increases with the ramp rate defined by Parameter 506 [PM Test Idc Ramp] to the peak current value defined by Parameter 509 [PM Test I Ref]. The current is continuously applied at this level for the time interval defined by Parameter 505 [PM TestWait Time]. Then, the DC excitation position will be changed by 90 electrical degrees with the frequency defined by Parameter 508 [PM Test Freq Ref] and the rate change of the frequency defined by Parameter 507 [PM Test FreqRamp]. The 90 degree phase shifted d-axis current with the current value defined by Parameter 509 [PM Test I Ref] is continuously applied for the time interval defined by Parameter 505 [PM TestWait Time] The value of Parameter 504 [PM AbsEnc Offst] is determined by value in the absolute position sensor counter.

Back EMFInformation not available at time of publication


Manual Autotune - Logic Command

To perform a motor rotation test manually, set [MC Operate Mode] to “Test.” Then start the drive and verify motor direction and check [Motor Spd Fdbk]. When the motor direction is backwards, power must be removed and two motor leads should be swapped. When the feedback is negative, power must be removed and two encoder leads should be swapped. After direction and feedback are verified, press stop and set [MC Operate Mode] back to “FOC,” “FOC2,” or “Pmag Motor” according to your configuration.

Bits 4 through 9 in [Logic Command] can be used to manually perform the power circuit test and motor tests instead of through the HIM Startup routine. To select a test, the corresponding bit must be set to a 1. Then the drive must be started.

Troubleshooting an “MC Commissn Fail” Fault during Autotune

The “MC Commissn Fail” fault occurs when either the Power Circuits diagnostics test fails or one of the Motor Tests fails. To find out specifically why the fault occurred, before clearing the fault, check the bits in the following parameters: [MC Diag Error 1], [MC Diag Error 2], or [MC Diag Error 3].

Bit 4 “MC Atune En”Selects the motor tests described on the previous page that measure stator resistance, stator inductance, leakage inductance, and flux current.

Bit 5 “Pwr Diag En”Selects the power circuit tests described on the previous page.

Bit 6 “Dir Sel En”Information not available at time of publication

Bit 7 “PM Offset En”Information not available at time of publication

Bit 8 “Mtr Inert EnMeasures the value for [Motor Inertia]. This test is similar to the inertia test that measures [Total Inertia], except the motor must be uncoupled from the load.

Bit 9 “Sys Inert En”Performs the inertia test described to set the value for [Total Inertia]


Bus Regulation/Braking Description

This information serves as a supplement to the PowerFlex 700S Users Manual, publication 20D-UM001B-EN-P, addressing items specific to the PowerFlex 700S bus regulation and dynamic braking. Please refer to the Users Manual for details on the PowerFlex 700S dynamic braking wiring and setup and the PowerFlex Dynamic Braking Resistor Calculator for application techniques on dynamic braking.

Technical Information

The bus regulator limits the maximum bus voltage for systems that do not have (or have limited) braking or regenerative capabilities. The bus regulator limits the bus voltage by comparing the DC bus voltage feedback to a DC bus voltage reference. It then limits the regenerative power allowed back onto the DC bus to keep the DC bus voltage at or below the reference value and prevent a “DC Bus Overvolt” fault.

Dynamic braking uses a 7th IGBT and braking resistor to dissipate regenerative energy. The drive switches the 7th IGBT on and off to keep the DC bus voltage at or below the dc bus voltage reference. Parameters in the PowerFlex 700S specify whether the resistor is an internal or external resistor. For an external resistor, the user can program the resistor specifications for protection of the resistor.

The PowerFlex 700S allows the user to select bus regulation, dynamic braking, or a combination of bus regulation and dynamic braking.

Bus/Reg Brake Ref

Rated Volts

415

401

414 00

02

306

414 03

300127

128

125

-1

123

124

DC Bus Voltage

Brake/Bus Confg (Brake Enable) (BusRef Hi/Lo)

100

Brake/Bus Cnfg (Bus Reg En)

XX

X +

&

/

+

-

Bus Volt Regulator

Limit0.045

2

Motor Spd Fdbk

Mtring Power LimRegen Power Lim

Power Limit Calc

+

Iq Actual Lim

Torque Neg Limit

Min

Max

Torque PosLim Actl

Torque NegLim Actl

Torque Pos Limit

126

353


Bus Regulator/Braking Configuration

Parameter 414 [Bus/Brake Cnfg] determines the configuration of bus regulation and dynamic braking. Parameter 414 is broken down into the following bits:

Set the appropriate [Bus/Brake Config] your configuration. The following is a summary of possible settings for [Bus/Brake Config]:

Parameter 415 [Bus Reg/Brake Ref] sets the turn-on bus voltage threshold for the bus regulator and the dynamic brake. Actual values are modified by the configuration selected in [Bus/Brake Config]. When using common DC bus drives, adjustment of [Bus Reg/Brake Ref] allows, a limited coordination of brake operation with other drives. For example, when you have 2 common bus drives, and one drive is larger than the other, set the larger drive to turn on at a lower voltage than the smaller drive. In this manner, the smaller drive does not try to dissipate all of the dynamic braking energy.

Bit 0 - Brake EnableWhen this bit is set to 1 it enables the internal brake transistor (7th IGBT). When this bit is set to 0 then the internal brake transistor is disabled.

Bit 1 - Brake ExternWhen this bit is set to a 1 it configures the brake operation for an external resistor. Then the external brake resistor protection is based on the peak watts entered into [Brake PulseWatts] and the continuous watts entered in [Brake Watts]. When this bit is set to 0 it configures the brake operation for an internal resistor. Then [Brake PulseWatts] and [Brake Watts] are not active.

Bit 2 - BusRef Hi/LoThis bit configures whether bus regulation or dynamic braking turns on first. This bit is only active when Parameter 414 [Bus/Brake Cnfg] bits 0 and 3 are both set to one. When this bit is set to 1 the dynamic braking turns on first (at the dc bus voltage set by Parameter 415 [Bus Reg/Brake Ref]), and then the bus regulator turns on if the dc bus voltage continues to rise (at the dc bus voltage set by Parameter 415 plus 4.5%). When this bit is set to 0 the bus regulator turns on first (at the dc bus voltage set by Parameter 415) and then the dynamic braking turns on when there are any transients above Parameter 415.

Bit 3 - Bus Reg EnWhen this bit is set to 1, bus regulation is enabled. When this bit is set to 0, bus regulation is disabled.

Desired Operation[Bus/Brake Config]

SettingDynamic braking with internal resistor 0001Dynamic braking with external resistor 0011Bus regulation only 1000Bus regulation first, then dynamic braking with internal resistor 1001Dynamic braking with internal resistor first, then bus regulation 1101Bus regulation first, then dynamic braking with external resistor 1011Dynamic braking with external resistor first, then bus regulation 1111


NOTE: Actual bus voltage reference values are determined as a percentage of Parameter 401 [Rated Volts] and selected voltage class.

For example, with a 480V rated drive and [BusReg/Brake Ref]=111%:

NOTE: When the low voltage class is selected an additional multiplier of 1.2 is used. For example P401 [Rated Volts] = 400 then P401 * 1.2 = 480 is used. In this case, if a drive has a selected low voltage class, but is run on a high voltage class AC line, the dynamic brake will not automatically turn on.

Parameter 416 [Brake PulseWatts] sets the peak power reference for determining the protection for an external brake resistor. Parameter 416 is active only if the configuration is selected for an external brake (Parameter 414 bit 1, Bus/Brake Cnfg). When the internal brake resistor is used then the protection is determined from drive internal values. Normally this value is specified by the resistor vendor as the peak power rating or a 1 second power rating with typical values in the range of 30 to 100 times higher than the resistor continuous power rating. A simple estimate for the peak power of the resistor can be made from the brake elements' mass, specific heat and an assumed element temperature of 375oC.

Where 75,000 represents a specific heat of 0.11 cal/Kg C (steal or nichrome) and a temperature rise of 350C (approximation).

For example, a resistor with a nichrome element that weighs 10 lbs. would have a Brake Pulse Watts of:

When the resistor package's peak energy rating cannot be obtained, there are a few other ways to approximate [Brake PulseWatts]:

bus voltage reference 2 Par 401 [Rated Volts] Par 415 [Bus Reg/Brake Ref]××100

-------------------------------------------------------------------------------------------------------------------------------------------------=

bus voltage reference 2 480 111××100

--------------------------------------- 753.5 VDC= =

Par 416 [Brake Pulse Watts] 75,000 (watts/lbs) element weight (lbs)×=

75,000 10× 750,000 watts=


1. [Brake PulseWatts] = 75,000 x (Resistor element weight); where the resistor element weight is the total weight of the resistor wire element in pounds (not the entire weight of the resistor cage).

2. [Brake Pulse Watts] = (Time constant) x [Brake Watts]; where the Time constant equals the amount of time for the resistor to reach 63% of its rated temperature with applied rated watts ([Brake Watts]).

[Brake Watts] sets the continuous watts for determining the protection for an external brake. Enter the continuous watt rating of the resistor cage (found on the resistor cage nameplate or from the resistor manufacturer) for this parameter. This parameter is active only if the configuration is selected for an external brake ([Bus/Brake Cnfg] bit 1 set to 1). When the internal brake resistor is used then the protection is determined from drive internal values.

Parameter 369 [Brake OL Cnfg] determines how the drive reacts when the brake protection is exceeded. Some possible settings for this parameter are:

Parameter 418 [Brake TP Sel] selects a value to monitor for diagnostics of the dynamic brake protection. Possible selections for Parameter 418 [Brake TP Sel] are:

Parameter 369 [Brake OL Cnfg] Setting Drive Operation0 - “Ignore” The drive ignores the brake protection was exceeded and does

not generate the fault 38 “Brake OL Trip” or alarm “Brake OL Trip.”1 - “Alarm” The drive generates an alarm “Brake OL Trip,” but does not

generate the fault 38 “Brake OL Trip.”2 - “FltCoastStop” The drive generates the fault 38 “Brake OL Trip” and issues a

coast stop.3 - “FltRampStop” The drive generates the fault 38 “Brake OL Trip” and issues a

ramp stop.4 - “FltCurLimStop” The drive generates the fault 38 “Brake OL Trip” and issues a

current limit stop.

Parameter 418 [Brake TP Sel] Setting Description0 - “Zero” Do not monitor any test point for the brake protection.1 - “Duty Cycle” Duty cycle of the internal resistor or calculated duty cycle of external

resistor based on Parameter 416 [Brake PulseWatts] and Parameter 417 [Brake Watts].

2 - “Power Actual” Information not available at time of publication3 - “Max BodyTemp” Maximum temperature that the resistor body can handle.4 - “Max ElemTemp Act” Maximum temperature that the resistor element can handle.5 - “BodyTemp Act” Predicted temperature of the resistor body.6 - “ElemTemp Act” Predicted temperature of the resistor element.7 - “BTmpTrip Stat” Information not available at time of publication8 - “ETmpTripStat” Information not available at time of publication9 - “Int DB Ohms” Ohm rating of internal resistor when internal resistor is installed10 - “Data State” Information not available at time of publication11 - “MC BrakeEnbl” Information not available at time of publication12 - “1/rdb” Information not available at time of publication13 - “1/th_eb” Information not available at time of publication


Parameter 419 [Brake TP Data] displays the data selected in Parameter 418 [Brake TP Sel].

14 - “1/ce” Information not available at time of publication15 - “tamax” Information not available at time of publication16 - “1/th_ba” Information not available at time of publication17 - “1/cb” Information not available at time of publication18 - “DB IGBT Amp” Information not available at time of publication


Cable, Control Table 2.A Analog and Encoder Inputs

Signal Type Wire Type DescriptionMinimum

Insulation RatingStandard Analog I/O Belden 8760/9460 (or

equiv.)0.750 mm2 (18AWG), twisted pair, 100% shield with drain

300 V, 75-90o C(167 - 194o F)

Belden 8770 (or equiv.) 0.750 mm2 (18AWG), 3 cond., shielded for remote pot only

Encoder/Pulse I/O Less then or equal to 30m (98 ft.) - Belden 9773 (or equiv.)

0.196 mm2 (24AWG), individually shielded

Greater then 30m (98 ft.) - Belden 9773 (or equiv.)

0.750 mm2 (18AWG), twisted pair, shielded

Stegman Encoder Stegmann 6-411682-XX cables with C12 FUR connectors

ResolverSynchLink Versalink V-System

Lucent TechnologiesSpeciality Fibers Technology Division 1403-CF BLK

200/230 micron HCS (Hard Clad Silica)Operating Wavelength - 650 nm (Red)Data Rate - 5 Mbps

EMC Compliance Refer to EMC Instructions


Cable, Motor Lengths The length of cable between the drive and motor may be limited by various application parameters. The 2 primary areas of concern are Reflected Wave and Cable charging. The Reflected Wave phenomenon, also known as transmission line effect, can produce very high peak voltages on the motor due to voltage reflection. Allen-Bradley drives have patented software that limits the voltage peak to 2 times the DC bus voltage or 1600 volts, whichever is greater, and reduce the number of occurrences, but many motors have inadequate insulation systems to tolerate these peaks.

See Reflected Wave for more details.

Refer to Table 2.B for measuring cable lengths when concerned about Reflected Wave. The actual lead length for each motor must be measured or calculated based on the lead length for that motor only. Figure 2.2 shows 2 motors, each 300 feet from the drive. Motor protection decisions are based on 300 feet cable length (not 600 ft.). If the motors need protection at this distance, then both motors must be dealt with individually. In some cases, a single device placed at the drive output or near the motors may protect both motors. Figure 2.2 shows 1 motor at 50 feet and one at 550 feet. The motor that is close to the drive (50 ft.) may not need protection, but the motor farther from the drive (550 ft.) may need protection. Again, each motor must be considered individually based on its distance from the drive. Cable charging occurs because of the capacitance, phase-to-phase or phase-to-ground, inherent in the length of cable. The current that is used to charge the cable capacitance detracts from the overall current capability of the drive and reduces the availability of torque producing current for the motor. This can result in poor motor performance, motor stalls under full load and nuisance drive overcurrent tripping. In general, shielded cable has higher cable capacitance and will require higher cable charging current.

Refer to Table 2.B for measuring cable lengths when concerned about cable charging. In this case, it is the total amount of cable connected to the drive that must be considered. Figure 2.2 shows 2 motors, each 300 feet from the drive. The drive must be capable of supplying enough current to charge the total length (600 ft.) plus the needed current to produce necessary torque in the motors. If a drive is unable to provide sufficient current for both cable charging and motor torque, then a larger drive with adequate current rating should be substituted. Figure 2.2 shows 1 motor at 50 feet and one at 550 feet. Again, the drive must be capable of supplying enough current to charge the total length (600 ft.), plus the needed current to produce desired torque in the motors. In fact, diagrams A, B, C and D will all require the same cable charging installation guidelines because they all have total cable lengths of 600 feet. Listed below are the maximum cable lengths recommended for PowerFlex drives. Distances listed consider both reflected wave amplitude and cable charging current. These distances are advisory only and are not intended to guarantee a trouble free installation. Differences in the cable chosen and other factors can affect maximum distance.


Table 2.B Motor Cable Length Restrictions

�Assumes 4 kHz carrier frequency, NEMA MG1 motor and no external devices. Consult factory for longer distances.

Figure 2.2 Motor Cable Lengths

Catalog No.Drive ND HP @ 480V AC

Maximum Motor Lead Length - Unshielded

Cable m (ft.)�

Maximum Motor Lead Length-Shielded

Cable m (ft.)�

20DD1P1A0EYNANNNN 0.5 98 (320) 67 (220)20DD2P1A0EYNANNNN 1 98 (320) 67 (220)20DD3P4A0EYNANNNN 2 128 (420) 98 (320)20DD5P0A0EYNANNNN 3 128 (420) 98 (320)20DD8P0A0EYNANNNN 5 158 (520) 128 (420)20DD011A0EYNANNNN 7.5 158 (520) 128 (420)20DD014A0EYNANNNN 10 158 (520) 128 (420)20DD022A0EYNANNNN 15 189 (620) 128 (420)20DD027A0EYNANNNN 20 189 (620) 158 (520)20DD034A0EYNANNNN 25 189 (620) 189 (620)20DD040A0EYNANNNN 30 189 (620) 189 (620)20DD052A0EYNANNNN 40 189 (620) 189 (620)20DD065A0EYNANNNN 50 189 (620) 189 (620)20DD096A0EYNBNNNN 75 189 (620) 189 (620)20DD125A0EYNBNNNN 100 189 (620) 189 (620)

182.9 (600)

91.4 (300)

91.4 (300) 15.2 (50) 167.6 (550)

152.4 (500)

15.2 (50)15.2 (50)

All examples represent motor cable length of 182.9 meters (600 feet)


Cable, Power

A variety of cable types are acceptable for drive installations.

Unshielded

For many installations, unshielded cable or loose conductors are adequate, provided they can be separated from sensitive circuits. As an approximate guide, allow a minimum spacing of 0.3 meters (1 foot). Avoid long parallel runs. It is recommended that individual wires have XLPE insulation. As a minimum, any insulation must be at least 15 mils thick. Wire with PVC insulation (i.e. THHN, see more below) is acceptable if no moisture is present and the PVC insulation meets the 15 mil minimum. Recommended tray cable has XLPE for individual conductors and a PVC outer jacket.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001A-EN-P.

Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has 4 XLPE insulated conductors with a 100% coverage

!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.


foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.

Table 2.C Recommended Shielded Power Wire

Based on field and internal testing, Rockwell Automation/Allen-Bradley has determined conductors manufactured with Poly Vinyl Chloride (PVC) wire insulation are subject to a variety of manufacturing inconsistencies which can lead to premature insulation degradation when used with IGBT drives that produce the reflected wave phenomena. Flame-retardant heat-resistant thermoplastic insulation is the type of insulation listed in the NEC code for the THHN wire designation. This type of insulation is commonly referred to as PVC. In addition to manufacturing inconsistencies, the physical properties of the cable can change due to environment, installation and operation, which can also lead to premature insulation degradation.

Location Rating/Type Description

Standard (Option 1)

600V, 90° C (194° F)XHHW2/RHW-2Anixter B209500-B209507, Belden® 29501-29507, or equivalent

• Four tinned copper conductors with XLPE insulation.• Copper braid/aluminum foil combination shield and tinned

copper drain wire.• PVC jacket.

Standard (Option 2)

Tray rated 600V, 90° C (194° F) RHH/RHW-2Anixter OLF-7xxxxx or equivalent

• Three tinned copper conductors with XLPE insulation.• 5 mil single helical copper tape (25% overlap min.) with three

bare copper grounds in contact with shield.• PVC jacket.

Class I & II;Division I & II

Tray rated 600V, 90° C (194° F) RHH/RHW-2Anixter 7V-7xxxx-3G or equivalent

• Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor.

• Black sunlight resistant PVC jacket overall.• Three copper grounds on #10 AWG and smaller.


Cable, Standard I/O For analog and encode input cable refer Cable, Control

For digital input cable, refer to Cable, Power.


Cable Trays and Conduit

When laying cable in cable trays, do not randomly distribute them. Cables for each drive should be bundled together and anchored to the tray. See Figure 2.3. A minimum separation of one cable width should be maintained between bundles to reduce overheating and cross-coupling. Current flowing in one set of cables can induce a hazardous voltage and / or excessive noise on the cable set of another drive, even when no power is applied to the second drive.

Dividers also provide excellent separation.

Figure 2.3 Cable Tray

Conduit must be magnetic steel and be installed so as to provide a continuous electrical path through the conduit itself. Care must be taken when pulling wire to avoid nicking the wire. Nylon-coated wire such as THHN or THWN is subject to insulation damage when it is pulled through conduit, particularly if 90º bends are present. Nicking can significantly reduce or remove the insulation. Use great care when pulling nylon coated. Water based lubricants should not be used with nylon coated wire such as THHN.

Important: Because of the nature of the drive PWM output and the reflected wave phenomenon, it is preferable to have each set of drive motor/power cables in an individual conduit. If this is not possible, do not route more than 3 sets of drive cables in one conduit. it is important that the allowable fill rates specified in the applicable national or local codes NOT be exceeded.

!ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” motor leads.

R W B

Random -Not Recommended

B

R

G

W

B

R

G

W

B

R

G

Wor

Recommended


Carrier (PWM) Frequency See Chapter 1 for derating guidelines as they travel to carrier frequency.

In general, the lowest possible switching frequency that is acceptable for any particular application is the one that should be used. There are several benefits to increasing the switching frequency. Refer to Figure 2.4 and Figure 2.5. Note the output current at 2 kHz and 4kHz. The “smoothing” of the current waveform continues all the way to 10 kHz.

Figure 2.4 Current at 2kHz PWM Frequency

Figure 2.5 Current at 4kHz PWM Frequency

The benefits of increased carrier frequency include less motor heating and lower audible noise. An increase in motor heating is considered negligible and motor failure at lower switching frequencies is very remote. The higher switching frequency creates less vibration in the motor windings and laminations making lower audible noise. This may be desirable in some applications. Some undesirable effects of higher switching frequencies include derating ambient temperature vs. load characteristics of the drive, higher cable charging currents and higher potential for common mode noise.

A very large majority of all drive applications will perform adequately at 2-4 kHz.


Common Bus Systems Information not available at time of publication


Communications See individual adapters - ControlNet (20-COMM-C), DeviceNet (20-COMM-D), Remote I/O Adapter (20-COMM-R), etc.


ControlNet(20-COMM-C)

This information serves as a supplement to the PowerFlex ControlNet Adapter Users Manual, publication 20COMM-UM003A-EN-P, addressing items specific to the PowerFlex 700S. Please refer to the Users Manual for details on 20-COMM-C set-up, configuration, I/O messaging, and explicit messaging. This document does not apply to the DriveLogix communications to the 700S.

Setup Information

Parameters 25 [M-S Input] and 26 [M-S Output] of the 20-COMM-C must be configured for the Datalinks that are to be used. If changes are made to these parameters or others, Parameter 9 [Reset Module] must be set to reset module for the change to take effect. Set rotary switches to the correct node address. Node 02 all Datalinks in this example.

To use the 20-COMM-C on the PowerFlex 700S with ControlLogix use following setup when adding to the ControlNet device list. Use the values from Table 1 for the input and output sizes. Configuration Assembly Instance = 6 and Configuration Size = 0.

Node Configured for: Input Size Output SizeLogic Command / Reference and Logic Status / Feedback only 3 2

Plus Datalink A 5 4Plus Datalink B 7 6Plus Datalink C 9 8Plus Datalink D 11 10


The following data structures will be added to the ControlLogix Processor for the communications with the 20-COMM-C module and drive.

Example:Tag namesOutputs to the Drive - PowerFlex700S_02:O[0] … [9]Inputs from the Drive - PowerFlex700S_02:I[0] … [10] word [0] reserved


Figure 2.6 is an example using Bits in the ControlLogix to write to the output bits associated to Parameter 158 [Drive Logic Rslt]

PowerFlex700S_02:O[0].0 -.9 map to Parameter 158 [Drive Logic Rslt]

Figure 2.6 Using Bits in ControlLogix


To use the 20-COMM-C with the PowerFlex 700S, the 20-COMM-C must be v1.003 firmware or later.

The Logic Command and Logic Status are 32 bit data, but only the first 16 are used. The bit definitions of the Logic Command word follow the same pattern as Parameter 158 [Drive Logic Rslt]. The bit definitions of the Logic Status word follow the same pattern as bits 0-15 of Parameter 155 [Logic Status].

Reference and Feedback are 16 bit unsigned integer data. Datalinks are 32 bit data. Figure 2.7 shows I/O Image table for a ControlLogix system.

PF700S_Coast Stop

PF700S_CurrLim_Stop

PF700S_Clear_Fault

PF700S_UniPol_Fwd

PF700S_UniPol_Rev

PF700S_Jog2

PF700S_Jog1

PF700S_Start

PF700S_Normal_Stop

PowerFlex700S_02:0.Data[0].1










Figure 2.7 ControlLogix I/O

ControlLogix Adapter PowerFlex 700S

Output ImageO.Data[0] DINT

O.Data[1] DINT

O.Data[2] DINT

O.Data[3] DINT

O.Data[4] DINT

O.Data[5] DINT

O.Data[6] DINT

O.Data[7] DINT

O.Data[8] DINT

O.Data[9] DINT

0 Logic Cmd (16-

1 Reference (16

2 Datalink A1

3 Datalink A2

4 Datalink B1

5 Datalink B2

6 Datalink C1

7 Datalink C2

8 Datalink D1

9 Datalink D2

P158 Drive Logic

P20 SpeedRef DPI

P707 Data In A1 Int P708 Data In A1P709 Data In A2 IntP710 Data In A2P711 Data In B1 IntP712 Data In B1P713 Data In B2 Int P714 Data In B2P715 Data In C1 IntP716 Data In C1P717 Data In C2 IntP718 Data In C2 P719 Data In D1 IntP720 Data In D1P721 Data In D2 IntP722 Data In D2

ControlNet DPI


1 Bits 0 - 152 Not affected by Parameter 73 [Spd Fdbk Scale]I.Data[0] is reserved


Output ImageI.Data[1] DINT

I.Data[2] DINT

I.Data[3] DINT

I.Data[4] DINT

I.Data[5] DINT

I.Data[6] DINT

I.Data[7] DINT

I.Data[8] DINT

I.Data[9] DINT

I.Data[10] DINT

0 Logic Status (16

1 Feedback (16

2 Datalink A1

3 Datalink A2

4 Datalink B1

5 Datalink B2

6 Datalink C1

7 Datalink C2

8 Datalink D1

9 Datalink D2

P158 Drive Logic

P722 SpeedRef DPI

P707 Data In A1 Int P708 Data In A1P709 Data In A2 IntP710 Data In A2P711 Data In B1 IntP712 Data In B1P713 Data In B2 Int P714 Data In B2P715 Data In C1 IntP716 Data In C1P717 Data In C2 IntP718 Data In C2 P719 Data In D1 IntP720 Data In D1P721 Data In D2 IntP722 Data In D2

ControlNet DPI

CIP Generic Message Source and Destination

TagsBuffer

Message

Handler

Message


Parameter 723 [Dlink OutDataType] needs to be set for the type of data used. The most common will be Real Data (i.e. Current, Voltage, Torque are all Real Values in the drive). The 700S drive default for this parameter is all is all Datalinks set for Integer. If the check mark is not set then datalink is not set for Integer (From DriveExecutive).


ControlLogix Programming

To setup the PowerFlex 700S to follow a speed reference from the 20-COMM-C, Parameter 691 [DPI Ref Select] must be set to “Port 5.” Parameter 16 [Speed Ref Sel] must be set to “Speed Ref DPI.”

Reference and Feedback values are floating point values in the PowerFlex 700S. Use the following logic to transmit and receive reference and feedback data as unsigned integer data.

Reference to 700S (Commanded RPM Base Motor Speed)⁄32767

------------------------------------------------------------------------------------------------------=

MOV

CPT

MOV

Speed Reference Via ControlNet to a PowerFlex 700S using a 20-COMM-C module.

The first move instruction is only for visual indication of the speed reference.

MoveSource CNet_Ref_RPM 1200.0Dest CNet_Ref_RPM 1200.0

ComputeDest CNet_700S_Ref_Float 22114.959 Expression (CNet_Ref_RPM/Motor_Base_Speed)*Speed_Conversion_Constant

MoveSource CNet_Ref_Float 22114.959 Dest PowerFlex700S_02:0.Data(1) 22115


Feedback RPM (700S Feedback 32767) Base Motor Speed×⁄=

CPT

MOV

Convert Speed Feedback from 700S via 20-COMM-CFeedback is returned as a 0 to 32767 number for 0 to Base Speed

ComputeDest CNet_700S_Fdbk 1897Expression (CNet_700S_Fdbk_Float/Speed_Conversion_Constant)*Motor_Base_Speed

MoveSource PowerFlex700S_02:1.Data[2] 22114.959 Dest CNet_700S_Fdbk_Float 34969.0


Datalinks Programming

In the ControlLogix system, Datalinks are transmitted over ControlNet as 32 bit integers (DINT). In order to send or receive floating point a COP (copy) instruction must be utilized. The copy instruction in ControlLogix performs a bitwise copy. Set the length of the copy instruction to a value appropriate for the destination data type. For example, when copying a DINT data type to a REAL data type, the length would be one since both data types contain 32 bits of data.

Figure 2.8 is for all Datalinks selected.

Figure 2.8 All Datalinks Selected

COP

Copy data from ControlLogix Processor to 20-COMM-C for 700S Data Links

Copy FileSource PF700_Float_Data[10]Dest PowerFlex700S_02:O.Data[2] Length 8

COPCopy FileSource PowerFlex700S_02:I.Data[3]Dest PF700_Float_Data[0] Length 8

Copy data from 20-COMM-C to Floating Point data file.Parameter 723 must be set to real data links on the 700S


Explicit Messaging

When using explicit messaging in the ControlLogix system, the message type CIP Generic is used. The data is transferred over ControlNet in the same data type as the parameter in the PowerFlex 700S. Make sure the data type for the Source and Destination tags in your ControlLogix message instruction matches the data type in the PowerFlex 700S. Also, the Number of Elements in the ControlLogix message instruction must match the size of the Source data. For example, to send an explicit message to write to Parameter 12 [Speed Ref 2], which is a floating point:

1. The Source and Destination tags would be of type REAL.

2. The Number of Elements would be 4 bytes since a REAL data type takes up 4 bytes of data.

For other types of messages refer to the 20-COMM-C user manual.


Copy Cat Information not available at time of publication


Current Limit Information not available at time of publication


Datalinks Datalinks are used to transfer I/O data from a communication adapter, i.e. ControlNet (20-COMM-C), DeviceNet (20-COMM-D), to a controller. Datalinks allow parameter values to be changed without using messaging.

Configuring Datalinks

This section contains information on configuring the Datalink parameters for the PowerFlex 700S. There are also parameters in the communication adapters that must be configured to use Datalinks. See the ControlNet (20-COMM-C) and DeviceNet (20-COMM-D) section on the individual adapters for more information on setting up the Datalinks in the adapter.

“Data In” Parameters

[Data In x Int] and [Data In Real] parameters are inputs to the drive from the controller and are used to write to parameters. A total of 8 parameters can be written with the “Data In” parameters. In the 700S, each parameter is either a 16 bit integer, a 32 bit integer or a 32 bit floating point (real). This means the datalinks parameters are 32 bits.

To write to a 16 bit or 32 bit integer parameter, that parameter must be linked to one of the [Data In x Int] parameters.

To write to a real parameter, that parameter must be linked to one of the [Data In x Real] parameters.

“Data Out” Parameters

[Data Out x Int] and [Data Out Real] parameters are outputs from the drive to the controller and are used to read parameters. A total of 8 parameters can be read with the “Data Out” parameters. In the 700S, each parameter is either a 32 bit integer or a 32 bit floating point (real). This means that the datalink parameters are 32 bits. [Dlink OutDataType] is used to select whether each of the 8 “Data Out” data is an integer or real.

To read a 16 bit or 32 bit integer parameter, one of the [Data Out x Int] parameters must be linked to the desired integer parameter. Then the bit corresponding to the [Data In x Int] parameter in [Dlink OutDataType] is set to 0.

Example Configuration #1 - Writing an Integer Parameter using a Datalink• [Position Control] is linked to [Data In A1 Int]

The value that is sent to [Data In A1 Int] from the controller will show up in [Postion Control]. [Data In A1 Int] is used because [Position Control] is an integer parameter.

Example Configuration #2 - Writing a Real Parameter using a Datalink• [Torque Ref 1] is linked to [Data In A1 Real]

The value that is sent to [Data In A1 Real] from the controller will show up in [Torque Ref 1]. [Data In A1 Real] is used because [Torque Ref 1] is a real integer parameter.


To read to a real parameter, one of the [Data In x Real] parameters must be linked to the desired real parameter. Then bit corresponding to the [Data In x Real] parameter in [Dlink OutData Type] is set to 1.

Example Configuration #3 - Reading an Integer Parameter using a Datalink• [Data Out A1 Int] is linked to [Position Status]• [Dlink OutData Type] bit 0 is set to 0

The value from [Data Out A1 Int] to the controller contains the value of [Position Status]. [Data Out A1 Int] is used and [Dlink OutDataType] bit 0 is set to 0 because [Position Status] is an integer parameter.

Example Configuration #4 - Reading a Real Parameter using a Datalink• [Data Out A1 Real] is linked to [Output Current]• [Dlink OutDataType] bit 1 is set to 1

The value from [Data Out A1 Real] to the controller contains the value of [Output Current]. [Data Out A1 Real] is used and [Dlink OutDataType] bit 0 is set to 1 because [Output Current] is a real parameter.


DC Bus Voltage/Memory Information not available at time of publication


Decel Time The Decel Time parameter Parameter 33 [Decel Time] sets the rate at which the drive ramps down its output during a ramp Stop command or during an decrease in commanded speed (speed change).

The rate established is the result of the programmed Decel Time and the programmed motor rated speed Parameter 4 [Motor NP RPM] as follows:

Times are adjustable in 0.1 second increments from 0.0 to 3600.0 seconds. Programming zero seconds will cause the drive to use .1 second.

Motor RPM (Parameter 4)Decel Time (Parameter 33)----------------------------------------------------------------- Decel Rate (RPM/sec)=


DeviceNet(20-COMM-D)

This serves as a supplement to the PowerFlex DeviceNet Adapter Users Manual, publication 20COMM-UM002A-EN-P, addressing items specific to the PowerFlex 700S. Please refer to the user manual for details on 20-COMM-D set-up, configuration, I/O messaging, and explicit messaging.


To use the 20-COMM-D with the PF700S, the 20-COMM-D must be v1.005 firmware or later.

The Logic Command and Logic Status are 16 bits plus a 16 bit pad word for a total of 32 bit data. The bit definitions of the Logic Command word follow the same pattern as Parameter158 [Drive Logic Rslt]. The bit definitions of the Logic Status word follow the same pattern as bits 0-15 of Parameter155 [Logic Status]. Reference, Feedback, and Datalinks are 32 bit data. This means with just the Logic Command/Status and Speed Ref/Fdbk I/O enabled in the 20-COMM-D, would map 8 bytes of I/O in the DeviceNet Scanner. With the Logic Command/Status, Speed Ref/Fdbk and all of the Datalinks enabled would have a total of 40 bytes of I/O mapped in the DeviceNet scanner. The I/O Image table for a ControlLogix system is shown.


Output ImageO.Data[0] DINT

O.Data[1] DINT

O.Data[2] DINT

O.Data[3] DINT

O.Data[4] DINT

O.Data[5] DINT

O.Data[6] DINT

O.Data[7] DINT

O.Data[8] DINT

O.Data[9] DINT

0 Logic Command 1 Pad Word2 Reference3 Reference4 Datalink A15 Datalink A16 Datalink A27 Datalink A28 Datalink B19 Datalink B11 Datalink B21 Datalink B21 Datalink C11 Datalink C1 1 Datalink C2 1 Datalink C2 1 Datalink D1 1 Datalink D1 1 Datalink C2 1 Datalink C2

P158 Drive Logic

P20 SpeedRef DPI

P707 Data In A1 Int P708 Data In A1P709 Data In A2 IntP710 Data In A2P711 Data In B1 IntP712 Data In B1713 Data In B2 Int P714 Data In B2P715 Data In C1 IntP716 Data In C1P717 Data In C2 IntP718 Data In C2 P719 Data In D1 IntP720 Data In D1P721 Data In D2 IntP722 Data In D2

DPIDeviceNet


1 Bits 0-152 Not affected by Parameter 73 [Spd Fdbk Scale]I.Data[0] is reserved

To setup the PowerFlex 700S to follow a speed reference from the 20-COMM-D, Parameter691 [DPI Ref Select] must be set to “Port 5.” Parameter 16 [Speed Ref Sel] must be set to “Speed Ref DPI.”

Reference and Feedback values are floating point values in the PowerFlex 700S. Use the following logic to transmit and receive reference and feedback data as integer data.


Input ImageI.Data[0] DINT

I.Data[1] DINT

I.Data[2] DINT

I.Data[3] DINT

I.Data[4] DINT

I.Data[5] DINT

I.Data[6] DINT

I.Data[7] DINT

I.Data[8] DINT

I.Data[9] DINT

0 Logic Status 1 Pad Word2 Feedback (LSW) 3 Feedback4 Datalink A15 Datalink A16 Datalink A27 Datalink A28 Datalink B19 Datalink B11 Datalink B21 Datalink B21 Datalink C11 Datalink C11 Datalink C21 Datalink C21 Datalink D11 Datalink D11 Datalink D21

P155 Logic Status

P72 Speed Ref DPI

P724 Data Out A1 P725 Data Out A1P726 Data Out A2 P727 Data Out A2P728 Data Out B1 P729 Data Out B1P730 Data Out B2 P731 Data Out B2P732 Data Out C1 P733 Data Out C1P734 Data Out C2 P735 Data Out C2 P736 Data Out D1 P737 Data Out D1P738 Data Out D2 P739 Data Out D2

CIP Generic MessageSource and Destination

Tags

MessageBuffer

MessageHandler

2

DPIDeviceNet

Transmitted Reference Floating Point Reference (RPM) 32768×Base Motor RPM

----------------------------------------------------------------------------------------------------=

Floating point Feedback (RPM) Feedback received Base Motor RPM×32768

----------------------------------------------------------------------------------------------=


In the ControlLogix system, Datalinks are transmitted over DeviceNet as 32 bit integers (DINT). In order to send or receive floating point a COP (copy) instruction must be used. The copy instruction in ControlLogix performs a bitwise copy. Set the length of the copy instruction to a value appropriate for the destination data type. For example, when copying a DINT data type to a REAL data type, the length would be one since both data types contain 32 bits of data.

When using explicit messaging in the ControlLogix system, the message type CIP Generic is used. The data is transferred over DeviceNet in the same data type as the parameter in the PowerFlex 700S. Make sure that the data type for the Source and Destination tags in your ControlLogix message instruction matches the data type in the PowerFlex 700S. Also, the Number of Elements in the ControlLogix message instruction must match the size of the Source data. For example, to send an explicit message to write to Parameter12 [Speed Ref 2], which is a floating point:

1. The Source and Destination tags would be type REAL.

2. The Number of Elements would be 4 bytes since a REAL data type takes up 4 bytes of data.


Diagnostics Information not available at time of publication


Digital Inputs Technical Information

There are 4 digital inputs on the I/O board. One of the inputs is dedicated for the Enable and cannot be configured. The other 3 inputs can be configured. Digital Input 1 is 24VDC and Digital Inputs 2 and 3 can accept a 12-24VDC signal. There is a 24VDC power supply on the I/O board to supply power for those inputs.

Digital Inputs 2 and 3 have are high speed digital inputs with a maximum input frequency of 350 kHz.

Digital Input Configuration

826

827

BitCombine

828

DigIn1 User DataLocal I/O Status

(DigIn 1)

DigIn1 Data

DigIn1 Bit

838

Selector

0101

DigIn 1 Sel

830

831

BitCombine

836

DigIn2 User DataLocal I/O Status

(DigIn 2)

DigIn2 Data

DigIn2 Bit

840

Selector

824 02824 02

DigIn 2 SelSelections per Par 839

TB1-T10

TB1-T11

24 VDC

24 VDC Common

Debounce

Debounce

{Logic Common}

824 00Local I/O Status (Enable In)

En In Debounce

TB1-T9

TB1-T8

TB1-T7DigIn 1 Debounce

Debounce

TB1-T5

TB1-T6

Bit Filter

236

SyncLink

08

09

10

11

DigIn 2 Debounce

{Return "Common"}

Port0 Regis

(Ext Filt 0)

(Ext Filt 1)

Cnfg

(Ext Filt 3)

(Ext Filt 2)

236

236

236

833

825

829

Debounce

TB1-T3

TB1-T4

Bit Filter

SyncLink

DigIn 3 Debounce

{Return "Common"}

837834

835

BitCombine

836

DigIn3 User Data

DigIn3 Data

DigIn3 Bit

840

Selector

824 03

246 08

09

10

11

Port0 Regis

(Ext Filt 0)

(Ext Filt 1)

Cnfg

(Ext Filt 3)

(Ext Filt 2)

246

246

246

824 03

DigIn 3 SelSelections per Par 840

824 824


[DigIn x Sel] can be set to the following values:

[DigIn x Debounce] sets a delay time to allow any bounce in the digital input to settle out. This parameter has a range of 0 to 15.5 milliseconds.

When [DigIn x Sel] is set to “User Select,” the function of the digital input is determined by the following:

• [DigIn x Data] determines any bits that should be permanently set. [DigIn x Data] sets value of [DigIn x User Data] except for the bit chose in [DigIn x Bit]

• [DigIn x Data] determines the bit you wish to toggle based on whether the digital input is on or off

• [DigIn x User Data] will have the same bits that are set in [DigIn x Data]. Then the bit that was chosen in [Digin x Bit] will toggle based on whether the digital inputs is on or off. A designation (sink) parameter is then linked to [DigIn x User Data] so that it determines the value of that sink parameter

Configuration Example

DigIn 1 will be setup to determine the value of [Speed Ref Sel]. DigIn 1 will toggle [Speed Ref Sel] between a value of 1 “Speed Ref 1” and 5 “Speed Ref 5.”

• [DigIn 1 Sel] = “User Select”• [DigIn 1 Data] = 0000 0000 0000 0000 0000 0000 0000 0001• [DigIn 1 Bit] = 2. This means when we toggle Digital Input 1, bit 2 of

[DigIn 1 User Data] will toggle.

When Digital Input 1 is off [DigIn 1 User Data] will be equal to [DigIn 1 Data]. In other words, [DigIn 1 User Data] will equal 0000 0000 0000 0000 0000 0000 0000 0001 (a value of 1).

When Digital Input 1 is on [DigIn 1 User Data] will be equal to [DigIn 1 Data] plus whatever bit was set in [DigIn 1 Bit]. In other words [DigIn 1 User Data] will equal 0000 0000 0000 0000 0000 0000 0000 0101 (a value of 5).

[Speed Ref Sel] is linked to [DigIn 1 User Data]. Now [Speed Ref Sel] will toggle between a value of 1 and 5.

Value Description Value Description0 Not Used 8 Fwd/Reverse1 Normal Stop 9 Cur Lim Stop2 Start 10 Coast Stop3 Run 11 Aux Fault4 Clear Faults 12 Aux Fault Inv5 Stop - CF 13 Position EN6 Jog 1 14 User Select7 Jog 2 15 Precharge/Disc


Digital Input Status Bits

[Local I/O Status], bits 0-4 give the status of the digital inputs and can be used for troubleshooting the digital inputs. The bits are broken down as follows:

• Bit 0 - “Enable Input”• Bit 1 - “Digital Input 1”• Bit 2 - “Digital Input 2”• Bit 3 - “Digital Input 3”

When the bit in [Local I/O Status] associated with the digital input is on, this means the PowerFlex 700S sees that the digital input is on. When the bit associated with the digital input is off, this means the PowerFlex 700S sees the digital input is off.


Digital Outputs Technical Information

There are 3 digital outputs on the I/O board.

Digital Outputs 1 and 2 are 24VDC open collector (sinking logic). They are rated 25mA maximum. Figure 2.9 is an example of how Digital Outputs 1 and 2 would be used with a light.

NOTE: The transistor in the diagram is the internal circuitry of the Digital Output. When the logic for Digital Output 1 becomes true, the transistor turns on, tying the transistor's collector to ground and completing the circuit. Then the light will turn on.

Figure 2.9 Digital Outputs

Digital Output 3 is a relay output rated for 24VDC. The relay output is rated 5A @ 24VDC for a resistive load, and 2A @ 24VDC for an inductive load.

Digital Output

Common (Return)

T6Sinking Ouput

G + 24V DC

Digital Output Logic

T4


Digital Output Configuration

The [Relay x Data] parameter and [Dig Out x Data] parameters are linked to a parameter used to turn on the digital output.

The [Relay x Bit] parameter and [Dig Out x Bit] parameters select which bit of the data you wish to use to turn on the digital output.

Configuration Example

This example configures Digital Output 1 for “Enabled.” “Enabled” indicates the inverter section of the drive is active (IGBTs switching).

• [Dig Out 1 Data] is linked to [Logic Status]• [Dig Out 1 Bit] is set to 0

When the “Enabled” bit of [Logic Status] turns on, Digital Output 1 turns on.

Digital Output Status Bits

[Local I/O Status], bits 16-18 give the status of the digital outputs and can be used for troubleshooting the digital outputs. The bits are broken down as follows:

• Bit 16 - “Digital Output 3” (Output Relay)• Bit 17 - “Digital Output 1” (Aux Out 1)• Bit 18 - “Digital Output 2” (Aux Out 2)

When the bit in [Local I/O Status] associated with the digital output is on, this means that the logic in the PowerFlex 700S is telling that digital output

841

842

Relay Out Data

Relay Out Bit

16Local I/O Status(Output Relay)

TB2-B5

TB2-B4

843

844

Dig Out 1 Data

Data Out 1 Bit

17Local I/O Status(Aux Out 1)

TB1-T6

TB1-T5

845

846

Dig Out 2 Data

Data Out 2 Bit

Local I/O Status(Aux Out 2)18

TB1-T4

{Return "Common"}

824

824

824


to turn on. When the bit associated with the digital input is off, this means that the logic in the PowerFlex 700S is telling that digital output to turn off.


Direction Control Information not available at time of publication


Distribution Systems Information not available at time of publication


DPI DPI is an enhancement to SCANport that provides more functions and better performance. SCANport was a CAN based, Master-Slave protocol, created to provide a standard way of connecting motor control products and optional peripheral devices together. It allows multiple (up to 6) devices to communicate with a motor control product without requiring configuration of the peripheral. SCANport and DPI both provide two basic message types called Client/Server (C/S) and Producer/Consumer (P/C). Client/Server messages are used to transfer parameter and configuration information in the background (relative to other message types). Producer/Consumer messages are used for control and status information. DPI adds a higher baud rate, brand specific enabling, Peer-to-Peer (P/P) communication, and Flash Memory programming support. PowerFlex drives support the existing SCANport and Drive Peripheral Interface (DPI) communication protocols. Multiple devices of each type (SCANport or DPI) can be attached to and communicate with the drive at the same time. This communication interface is the primary way to interact with, and control the drive.

Client/Server

Client/Server messages operate in the background (relative to other message types) and are used for non-control purposes. The Client/Server messages are based on a 10ms “ping” event that allows peripherals to perform a single transaction (i.e. one C/S transaction per peripheral per time period). Message fragmentation (because the message transaction is larger than the standard CAN message of eight data bytes) is automatically handled by Client/Server operation. The following types of messaging are covered:

• Logging in peripheral devices • Read/Write of parameter values• Access to all parameter information (limits, scaling, default, etc.)• User set access• Fault/Alarm queue access• Event notification (fault, alarm, etc.)• Access to all drive classes/objects (e.g. Device, Peripheral, Parameter,

etc.)

Producer/Consumer Operation Overview

Producer/Consumer messages operate at a higher priority than Client/Server messages and are used to control/report the operation of the drive (e.g. start, stop, etc.). A P/C status message is transmitted every 5ms (by the drive) and a command message is received from every change of state in any attached DPI peripheral. Change of state is a button being pressed or error detected by a DPI peripheral. SCANport devices are slightly different in that those peripherals transmit command messages upon reception of a drive status message rather than on detection of a change of state. Producer/Consumer


messages are of fixed size, so support of message fragmentation is not required. The following types of messaging are covered:

• Drive status (running, faulted, etc.)• Drive commands (start, stop, etc.)• Control logic parsing operations (e.g., mask and owner parameters)• Entering Flash programming mode• “Soft” login and logout of peripheral devices (enabling/disabling of

peripheral control)

Peer-to-Peer Operation

Peer-to-Peer messaging allows two devices to communicate directly rather than through the master or host (i.e. drive). They are the same priority as C/S messages and will occur in the background. In the PowerFlex 70 drive, the only Peer-to-Peer functionality supports proxy operations for the LED HIM. Since the PowerFlex 700 drive does not support an LED HIM, it will not support Peer-to-Peer proxy operations. The Peer-to-Peer proxy operation is only used so that the LED HIM can access parameters that are not directly part of the regulator board (e.g. DeviceNet baud rate, etc.). The LED HIM is not attached to a drive through a CAN connection (as normal DPI or SCANport devices are), so a proxy function is needed to create a DPI message to access information in an off-board peripheral. If an LCD HIM is attached to the PowerFlex 70 or 700 drive, it will be able to directly request off-board parameters using Peer-to-Peer messages (i.e. no proxy support needed in the drive). Because the PowerFlex 70 supports the LED HIM, only 4 communication ports can be used. PowerFlex 700 drives can use all 6 communication ports because Peer-to-Peer proxy operations are not needed. All Peer-to-Peer operations occur without any intervention from the user (regardless whether proxy or normal P/P operation), no setup is required. No Peer-to-Peer proxy operations are required while the drive is in Flash mode.

All the timing requirements specified in the DPI and SCANport System, Control, and Messaging specifications are supported. Peripheral devices will be scanned (“pinged”) at a 10ms rate. Drive status messages will be produced at a 5ms rate, while peripheral command messages will be accepted (by the drive) as they occur (i.e. change of state). Based on these timings, the following worst case conditions can occur (independent of the baud rate and protocol):

• Change of peripheral state (e.g. Start, Stop, etc.) to change in the drive - 10ms

• Change in reference value to change in drive operation - 10ms• Change in Datalink data value to change in the drive - 10ms• Change of parameter value into drive - 20ms times the number of

attached peripherals

The maximum time to detect the loss of communication from a peripheral device is 500ms.


Table 2.D Timing Specifications contained in DPI and SCANport

The Minimum Update Time (MUT), is based on the message type only. A standard command and Datalink command could be transmitted from the same peripheral faster than the MUT and still be O.K. However, two successive Datalink commands will have to be separated by the MUT.

DPI Host status messages only go out to peripherals once they log in and at least every 125ms (to all attached peripherals). Periphals time out if more than 250ms. Actual time dependent on number of peripherals attached. Minimum time goal of 5ms (may have to be dependent on Port Baud Rate). DPI allows minimum 5ms status at 125k and 1ms status at 500k.

SCANport Host status messages only go out to the peripherals once they log in. Peripherals time out if more than 500ms. If peripheral receives incorrect status message type, peripheral generates an error. Actual time dependent on number of peripherals attached. SCANport allows minimum rate of 5ms.

DPI Host determines MUT based on number of attached peripherals. Range of values from 2 to 125ms. Minimum goal time of 5ms. DPI allows 2ms at 500k and 5ms minimum at 125k.

SCANport No Minimum Update Time (MUT).DPI Peripheral command messages (including Datalinks) generated on change-of-state, but not faster than Host MUT and at

least every 250ms. Host will time out if it is more then 500ms.SCANport Command messages produced as a result of Host status message. If no command response to Host status within 3

status scan times, Host will time out on that peripheral.DPI Peer messages requests cannot be sent any faster than 2x of MUT.SCANport No peer message support.DPI Host must ping every port at least every 2 seconds. Peripherals time if more then 3 seconds pass. Host will wait a

maximum of 10ms (125k) or 5ms (500k) for peripheral response to ping. Peripherals typical response time is 1ms. Periphals allow only one pending explicit message (i.e. ping response or peer request) at a time.

SCANport Host waits at least 10ms for response to ping. Host cannot send more then 2 event messages (including ping) to a peripheral within 5ms. Periphals typical response time is 1ms.

DPI Response to an explicit request or fragment must occur within 1 second or device will time out (applies to Host or Peripheral). Time-out implies retry from beginning. Maximum number of fragments per transaction is 16. Flash memory is exception with 22 fragments allowed.

SCANport Assume same 1 second time-out. Maximum number of fragments is 16.DPI During Flash mode, host stops ping, but still supports status/command messages at a 1-5 second rate. drive will use 1

second rate. Data transfer occurs via explicit message as fast as possible (i.e. peripheral request, host response, peripheral request, etc.) but only between two devices.

SCANport No Flash mode support.


DriveLogix Information not available at time of publication


Drive Overload Information not available at time of publication


Drive Ratings (kW, Amps, Volts)

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bina

tion

Mot

or C

ontr

olle

r, U

L lis

ted

for

208

Wye

or

Del

ta, 2

40 W

ye o

r D

elta

, 480

Y/2

77 o

r 60

0Y/ 3

47.

Not

UL

liste

d fo

r us

e on

480

V o

r 60

0V D

elta

/Del

ta s

yste

ms.

�T

he A

IC r

atin

gs o

f the

Bul

letin

140

M M

otor

Pro

tect

or m

ay v

ary.

See

pub

licat

ion

140M

-SG

001B

-EN

-P.

�20

DC

205

curr

ent r

atin

g is

lim

ited

to 4

0o C s

urro

undi

ng a

ir te

mpe

ratu

re.

Driv

e C

atal

og

Num

ber

FramekW/H

PRa

ting

Inpu

t Ra

tings

Out

put A

mps

Dua

l Ele

men

t Ti

me

Dela

y Fu

seNo

n-Ti

me

Dela

y Fu

seC

ircui

t B

reak

er�

Mot

or

Circ

uit

Prot

ecto

r�14

0M M

otor

Sta

rter

with

Adj

usta

ble

Curr

ent R

ange

��

ND

HD

Amps

kVA

Con

t.1

Min

.3

Sec.

Min

.�M

ax.�

Min

.�M

ax.�

Amps

Amps

Avai

labl

e C

atal

og N

umbe

rs�

400

Volt

AC In

put

20D

C1P

31

0.37

0.25

1.1

0.77

1.3

1.4

1.9

33

36

123

140M

-C2E

-B16

--

-20

DC

2P1

10.

750.

551.

81.

32.

12.

43.

23

63

815

314

0M-C

2E-B

2514

0M-D

8E-B

25-

-20

DC

3P5

11.

50.

753.

22.

23.

54.

56.

06

76

1215

714

0M-C

2E-B

4014

0M-D

8E-B

40-

-20

DC

5P0

12.

21.

54.

63.

25.

05.

58.

56

106

2020

714

0M-C

2E-B

6314

0M-D

8E-B

63-

-20

DC

8P7

14

2.2

7.9

5.5

8.7

9.9

13.2

1517

.515

3030

1514

0M-C

2E-C

1014

0M-C

2E-C

1014

0M-F

8E-C

10-

20D

C01

11

5.5

470

.57.

511

.513

17.4

1525

1545

4515

140M

-C2E

-C16

140M

-D8E

-C16

140M

-F8E

-C16

-20

DC

015

17.

55.

514

.410

.015

.417

.223

.120

3020

6060

2014

0M-C

2E-C

2014

0M-D

8E-C

2014

0M-F

8E-C

20-

20D

C02

21

117.

520

.614

.322

24.2

3330

4530

8080

3014

0M-C

2E-C

2514

0M-D

8E-C

2514

0M-F

8E-C

25-

20D

C03

02

1511

28.4

19.7

3033

4535

6035

120

120

50-

-14

0M-F

8E-C

32-

20D

C03

73

18.5

1535

.024

.337

4560

4580

4512

512

550

--

140M

-F8E

-C45

-20

DC

043

322

18.5

40.7

28.2

4356

7460

9060

150

150

60-

--

-20

DC

056

330

2253

36.7

5664

8670

125

7020

020

010

0-

--

-20

DC

072

337

3068

.947

.872

8411

290

150

9025

025

010

0-

--

-20

DC

105

5-

4581

.456

.485

128

170

110

175

110

300

300

150

--

--

55-

100.

569

.610

511

615

812

512

512

540

030

015

0-

--

-20

DC

125

5-

4591

.963

.796

144

168

125

200

125

375

375

150

--

--

55-

121.

183

.912

513

816

315

027

515

050

037

525

0-

--

-20

DC

140

6-

5510

176

105

158

210

150

225

150

400

300

150

--

--

75-

136

103

140

154

210

200

300

200

550

400

250

--

--

20D

C17

06

-75

136

103

140

1028

020

030

020

055

040

025

0-

--

-90

-16

412

617

018

725

525

037

525

060

050

025

0-

--

-20

DC

205�

6-

9016

412

617

025

531

325

037

525

060

050

025

0-

--

-11

0-

199

148

205

220

289

275

450

275

600

600

400

--

--


Table 2.F 480 Volt AC Input Recommended Protection Devices

480

Volt

AC In

put R

ecom

men

ded

Prot

ectio

n De

vice

s

�M

inim

um p

rote

ctio

n de

vice

siz

e is

the

low

est r

ated

dev

ice

that

sup

plie

s m

axim

um p

rote

ctio

n w

ithou

t nui

sanc

e tr

ippi

ng.

�M

axim

um p

rote

ctio

n de

vice

siz

e is

the

high

est r

ated

dev

ice

that

sup

plie

s dr

ive

prot

ectio

n. F

or U

S N

EC

, min

imum

siz

e is

125

% o

f mot

or F

LA.

Rat

ings

sho

wn

are

max

imum

.�

Circ

uit B

reak

er -

inve

rse

time

brea

ker.

For

US

NE

C, m

inim

um s

ize

is 1

25%

of m

otor

FLA

. Rat

ings

sho

wn

are

max

imum

.�

Mot

or C

ircui

t Pro

tect

or -

inst

anta

neou

s tr

ip c

ircui

t bre

aker

. For

US

NE

C m

inim

um s

ize

is 1

25%

of m

otor

FLA

. Rat

ings

sho

wn

are

max

imum

.�

Bul

letin

140

M w

ith a

djus

tabl

e cu

rren

t ran

ge s

houl

d ha

ve th

e cu

rren

t trip

set

to th

e m

inim

um r

ange

that

the

devi

ce w

ill n

ot tr

ip.

�M

anua

l Sel

f-P

rote

cted

(T

ype

E)

Com

bina

tion

Mot

or C

ontr

olle

r, U

L lis

ted

for

208

Wye

or

Del

ta, 2

40 W

ye o

r D

elta

, 480

Y/2

77 o

r 60

0Y/ 3

47.

Not

UL

liste

d fo

r us

e on

480

V o

r 60

0V D

elta

/Del

ta s

yste

ms.

�T

he A

IC r

atin

gs o

f the

Bul

letin

140

M M

otor

Pro

tect

or m

ay v

ary.

See

pub

licat

ion

140M

-SG

001B

-EN

-P.

�20

BC

205

curr

ent r

atin

g is

lim

ited

to 4

0o C s

urro

undi

ng a

ir te

mpe

ratu

re.

Driv

e C

atal

og

Num

ber

FramekW/H

PRa

ting

Inpu

t Ra

tings

Out

put A

mps

Dual

Ele

men

t Ti

me

Dela

y Fu

seNo

n-Ti

me

Dela

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seC

ircui

t B

reak

er�

Mot

or

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uit

Prot

ecto

r�14

0M M

otor

Sta

rter

with

Adj

usta

ble

Cur

rent

Ran

ge�

�

ND

HD

Amps

kVA

Con

t.1

Min

.3

Sec.

Min

.�M

ax.�

Min

.�M

ax.�

Amps

Amps

Avai

labl

e C

atal

og N

umbe

rs�

400

Volt

AC In

put

20D

C1P

31

0.37

0.25

1.1

0.77

1.3

1.4

1.9

33

36

153

140M

-C2E

-B16

– –

–20

DC

2P1

10.

750.

551.

81.

32.

12.

43.

23

63

815

314

0M-C

2E-B

2514

0M-D

8E-B

25 –

–20

DC

3P5

11.

50.

753.

22.

23.

54.

56.

06

76

1215

714

0M-C

2E-B

4014

0M-D

8E-B

40 –

–20

DC

5P0

12.

21.

54.

63.

25.

05.

57.

56

106

2020

714

0M-C

2E-B

6314

0M-D

8E-B

63 –

–20

DC

8P7

14

2.2

7.9

5.5

8.7

9.9

13.2

1517

.515

3030

1514

0M-C

2E-C

1014

0M-D

8E-C

1014

0M-F

8E-C

10 –

20D

C01

11

5.5

410

.87.

511

.513

17.4

1525

1545

4515

140M

-C2E

-C16

140M

-D8E

-C16

140M

-F8E

-C16

–20

DC

015

17.

55.

514

.410

.015

.417

.223

.120

3020

6060

2014

0M-C

2E-C

2014

0M-D

8E-C

2014

0M-F

8E-C

20 –

20D

C02

21

1511

28.4

19.7

3033

4535

6035

120

120

5014

0M-C

2E-C

2514

0M-D

8E-C

2514

0M-F

8E-C

2520

DC

030

215

1128

.419

.730

3345

3560

3512

012

050

– –

140M

-F8E

-C32

20D

C03

73

18.5

1535

.024

.338

4560

4580

4512

512

550

– –

140M

-F8E

-C45

20D

C04

33

2218

.540

.728

.243

5674

6090

6015

015

060

– –

20D

C05

63

3022

5336

.756

6486

7012

570

200

200

100

– –

–20

DC

072

337

3068

.947

.872

8411

290

150

9025

025

010

0 –

– –

20D

C10

55

--45

81.4

56.4

8512

817

011

017

511

030

030

015

0 –

– –

55--

100.

569

.610

511

615

812

522

512

540

030

015

0 –

– –

–20

DC

125

5–

5510

176

105

158

210

150

225

150

400

300

150

– –

– –

5545

91.9

63.8

9614

416

812

520

012

537

537

515

0 –

– –

–20

DC

140

6--

5510

176

105

158

210

150

225

150

400

300

150

– –

– –

75--

136

103

140

154

210

200

300

200

550

400

250

– –

– –

20D

C17

06

--75

135

103

140

210

280

200

300

200

550

400

250

– –

– –

90--

164

126

170

187

255

250

375

250

600

500

250

– –

– –

20D

C20

56

--90

164

126

170

255

313

250

375

250

600

500

250

– –

– –

110

--19

914

820

522

028

275

450

275

600

600

400

– –

– –


Dynamic Braking See Bus Regulation/Braking

For resistor sizing, See Appendix A. This module contains a second order thermal model of the internal


Efficiency See Chapter 1


Electronic Gearing Information not available at time of publication


EMC Instructions CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User and Reference Manual.

Declarations of Conformity are available online at:http://www.ab.com/certification/ce/docs.

Low Voltage Directive (73/23/EEC)• EN50178 Electronic equipment for use in power installations.• EN60204-1 Safety of machinery - Electrical equipment of machines.

EMC Directive (89/336/EEC)

EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods.

General Notes• If the adhesive label is removed from the top of the drive, the drive must

be installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV Directive.

• The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents.

• Use of line filters in ungrounded systems is not recommended.• PowerFlex drives may cause radio frequency interference if used in a

residential or domestic environment. The user is required to take measures to prevent interference, in addition to the essential requirements for CE compliance listed below, if necessary.

• Conformity of the drive with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance.


Essential Requirements for CE Compliance

Conditions 1-6 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3.

1. Standard PowerFlex 700S CE compatible Drive.

2. Review important precautions/attentions statements throughout this document and the PowerFlex 700S User Manual, publication 20D-UM001B-EN-P before installing drive.

3. Grounding as described on page 1-4 of the user manual.

4. Output power, control (I/O) and signal wiring must be braided, shield cable with a coverage of 75% or better, metal conduit or equivalent attenation.

5. All shielded cables should terminate with proper shielded connector.

6. Conditions in Table 2.G

Table 2.G PowerFlex 700S EN61800-3 EMC Compatibility

Fram

e

Second EnvironmentRestrict Motor Cable to 30 m (98 ft.)

First Environment Restricted Distribution

Any Drive and Option1 ✔

Not available at time of publication

2 ✔

3 ✔

5 ✔


Faults Information not available at time of publication


Flying Start Information not available at time of publication


Friction Compensation Information not available at time of publication


Function Blocks Information not available at time of publication


Fuses and Circuit Breakers Tables Table 2.E and Table 2.F provide drive ratings (including continuous, 1 minute and 3 second) and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40o C and the U.S. N.E.C. Other country, state or local codes may require different ratings.

Fusing

If fuses are chosen as the desired protection method, refer to the recommended types listed below. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen. IEC - BS88 (British Standard) Parts 1 & 2 (1), EN60269-1, Parts 1 & 2, type gG or equivalent should be used.

UL - UL Class CC, T, RK1 or J must be used.

Circuit Breakers

The “non-fuse” listings in the following tables include both circuit breakers (inverse time or instantaneous trip) and 140M Self-Protecting Motor Starters. If one of these is chosen as the desired protection method, the following requirements apply. IEC and UL - Both types of devices are acceptable for IEC and UL installations.


Grounding, General Refer to Grounding and Wiring for Pulse Width Modulated Drives, publication DRIVES-IN001A-EN-P. Available online at:

www.theautomationbookstore.com


HIM Memory See Copy Cat


HIM Operations Information not available at time of publication


Input Devices See Motor Start/Stop Precautions


Input Modes Information not available at time of publication


Input Power Conditioning Refer to Chapter 2 of Grounding and Wiring for Pulse Width Modulated Drives, publication DRIVES-IN001A-EN-P. Available online at:

www.theautomationbookstore.com


Jog Information not available at time of publication


Lead/Lag Filters Information not available at time of publication


Limits Information not available at time of publication


Links Information not available at time of publication


Masks A mask is a parameter that contains one bit for each of the possible adapters. Each bit acts like a valve for issued commands. Closing the valve (setting a bit value to 0) stops the command from reaching the DriveLogix. Opening the valve (setting a bit value to 1) allows the command to pass through the mask into the DriveLogix.

Table 2.H Mask Parameters and Functions

The bits for each parameter are broken down as follows:

• Bit 0 - “Digital Input”• Bit 1 - “Adapter 1”• Bit 2 - “Adapter 2”• Bit 3 - “Adapter 3”• Bit 4 - Not Used• Bit 5 - “Adapter 5”• Bit 6 - Not Used• Bit 7 - “DriveLogix”

Example: A customer's process is normally controlled by a remote PLC, but the drive is mounted on the machine. The customer does not want anyone to walk up to the drive and reverse the motor because it would damage the process. The local HIM (drive mounted Adapter 1) is configured with an operator's panel that includes a “REV” Button. To assure that only the PLC (connected to Adapter 5) has direction control, the [Direction Mask] can be set as follows:

This “masks out” the reverse function from all adapters except Adapter 5, making the local HIM (Adapter 1) REV button inoperable. Also see PowerFlex 700S Users Manual.

Parameter Function[Logic Mask] Determines which adapters can control the drive. When the bit for an adapter

is set to “0,” the adapter will have no control functions except for stop.[Start Mask] Controls which adapters can issue start commands.[Jog Mask] Controls which adapters can issue jog commands.[Direction Mask] Controls which adapters can issue forward/reverse direction commands.[Fault Clr Mask] Controls which adapters can clear a fault.

Direction Mask 0 1 0 0 0 0 0Adapter # X 6 5 4 3 2 1 0


Motor Control Select Information not available at time of publication


Motor Nameplate

The 700S also uses two additional pieces of motor information:

• The number of motor poles - only even numbers are allowed (this may or may not appear on the nameplate)

• Motor rotor inertia - time (seconds) for an uncoupled motor to accelerate from zero to base speed, at rated motor torque. Calculated during auto-tune.

[Motor NP Volts]The motor nameplate base voltage defines the output voltage, when operating at rated current, rated speed, and rated temperature.

[Motor NP FLA]The motor nameplate defines the output amps, when operating at rated voltage, rated speed, and rated temperature. It is used in the motor thermal overload, and in the calculation of slip.

[Motor NP Hz]The motor nameplate base frequency defines the output frequency, when operating at rated voltage, rated current, rated speed, and rated temperature.

[Motor NP RPM]The motor nameplate RPM defines the rated speed, when operating at motor nameplate base frequency, rated current, base voltage, and rated temperature. This is used to calculate slip.

[Motor NP Power]The motor nameplate power is used together with the other nameplate values to calculate default values for motor parameters to and facilitate the commissioning process. This may be entered in horsepower or in kilowatts as selected in the previous parameter or kW for certain catalog numbers and HP for others.

[Motor NP Pwr Units]The rated power of the motor may be entered in horsepower or in kilowatts. This parameter determines the units on the following parameter.


Motor Overload Information not available at time of publication


Motor Start/Stop Precautions

Information not available at time of publication


Mounting Refer to the Chapter 1 of the PowerFlex 700S User Manual for mounting instructions and limitations. As a general rule, drives should be mounted on a metallic flat surface in the vertical orientation. If considering other orientation, contact the Factory for additional data.


Output Devices Drive Output Disconnection

Allen-Bradley Drives can be used with an output contactor between the drive and motor. This contactor can be opened under load without damage to the drive. It is recommended, however, that the drive have a programmed “Enable” input and that this input be opened at the same time as the output contactor.

Cable Termination

Voltage doubling at motor terminals, known as reflected wave phenomenon, standing wave or transmission line effect, can occur when using drives with long motor cables. Inverter duty motors with phase-to-phase insulation ratings of 1200 volts or higher should be used to minimize effects of reflected wave on motor insulation life.

Applications with non-inverter duty motors or any motor with exceptionally long leads may require an output filter or cable terminator. A filter or terminator will help limit reflection to the motor, to levels which are less than the motor insulation rating.

Cable length restrictions for undetermined cables are discussed in Table 2.B. Remember the voltage doubling phenomenon occurs at different lengths for different drive ratings. If your installation requires longer motor cable lengths, a reactor or cable terminator is recommended.

Output Reactor

Bulletin 1321 Reactors can be used for drive input and output. These reactors are specifically constructed to accommodate IGBT inverter applications with switching frequencies up to 20 kHz. They have a UL approved dielectric strength of 4000 volts, opposed to a normal rating of 2500 volts. The first two and last two turns of each coil are triple insulated to guard against insulation breakdown resulting from high dv/dt. When using motor line reactors, it is recommended that the drive PWM frequency be set to its lowest value to minimize losses in the reactors.

By using an output reactor the effective motor voltage will be lower because of the voltage drop across the reactor - this may also mean a reduction of motor torque.

!ATTENTION: Any disconnecting means wired to the drive output terminals U, V and W must be capable of disabling the drive if opened during drive operation. If opened during drive operation, the drive will continue to produce output voltage between U, V, W. An auxiliary contact must be used to simultaneously disable the drive.


Output Display Output Current

Displays measured RMS drive output current. Parameter 297 [Output Curr Disp] which is the integer equivalent of Parameter 308 with * internal storage in 1/10 Amps (10 = 1.0amp).

Output Frequency

This parameter displays the actual output frequency of the drive. The output frequency is created by a summation of commanded frequency and any active speed regulator such as slip compensation, PI Loop, bus regulator. The actual output may be different than the commanded frequency.

Output Power

This parameter displays the output kW of the drive. Motor Power is the calculated product of the torque reference and motor speed feedback. A 125ms filter is applied to this result. Positive values indicate motoring power; negative values indicate regenerative power. The output power is a calculated value and tends to be inaccurate at lower speeds. It is not recommended for use as a process variable to control a process.

Output Voltage

Displays RMS line-to-line fundamental output voltage at the drive output terminals. This data is averaged and updated every 50 milliseconds. The actual output voltage may be different than that determined by the sensorless vector or V/Hz algorithms because it may be modified by features such as the Auto-Economizer.


Overspeed Limit Information not available at time of publication


Owners An owner is a parameter that contains one bit for each of the possible adapters. The bits are set high (value of 1) when its adapter is currently issuing that command, and set low when its adapter is not issuing that command.

Table 2.I Owner Parameters and Functions

The bits for each parameter are broken down as follows:

• Bit 0 - “Digital Input”• Bit 1 - “Adapter 1”• Bit2 - “Adapter 2”• Bit 3 - “Adapter 3”• Bit 4 - Not Used• Bit 5 - “Adapter 5”• Bit 6 - Not Used• Bit 7 - “DriveLogix”

Ownership falls into two categories:

1. Exclusive: Only one adapter at a time can issue the command and only one bit in the parameter will be high.

2. Non Exclusive: Multiple adapters can simultaneously issue the same command and multiple bits may be high.

Some ownership must be exclusive; that is, only one Adapter at a time can issue certain commands and claim ownership of that function. For example, it is not allowable to have one Adapter command the drive to run in the forward direction while another Adapter is issuing a command to make the drive run in reverse. Direction Control, therefore, is exclusive ownership.

Conversely, any number of adapters can simultaneously issue Stop Commands. Therefore, Stop Ownership is not exclusive.

Example: The operator presses the Stop button on the Local HIM to stop the drive. When the operator attempts to restart the drive by pressing the HIM Start button, the drive does not restart. The operator needs to determine why the drive will not restart.

Parameter Function[Stop Owner] Indicates the adapters that are presently issuing a valid stop command.[Start Owner] Indicates the adapters that are presently issuing a valid start command.[Jog Owner] Indicates the adapters that are presently issuing a valid jog command.[Direction Owner] Indicates the adapter that currently has exclusive control of direction changes.[Fault Clr Owner] Indicates the adapters that are presently issuing a valid start command.


The operator first views the Start owner to be certain that the Start button on the HIM is issuing a command.

When the local Start button is pressed, the display indicates that the command is coming from the HIM.

The [Start Owner] indicates that there is not any maintained Start commands causing the drive to run.

The operator then checks the Stop Owner. Notice that bit 0 is a value of “1,” indicating that the Stop device wired to the Digital Input terminal block is open, issuing a Stop command to the drive.

Until this device is closed, a permanent Start Inhibit condition exists and the drive will not restart.

Driv

eLog

ixN

ot U

sed

Adap

ter 5

Not

Use

dAd

apte

r 3Ad

apte

r 2Ad

apte

r 1Te

rmin

al B

lcok

-D

igita

l Inp

ut

Start Owner Bit 7 6 5 4 3 2 1 0Adapter # 0 0 0 0 0 0 1 0

Driv

eLog

ixN

ot U

sed

Adap

ter 5

Not

Use

dAd

apte

r 3Ad

apte

r 2Ad

apte

r 1Te

rmin

al B

lcok

-D

igita

l Inp

ut

Start Owner Bit 7 6 5 4 3 2 1 0Adapter # 0 0 0 0 0 0 1 0

Driv

eLog

ixN

ot U

sed

Adap

ter 5

Not

Use

dAd

apte

r 3Ad

apte

r 2Ad

apte

r 1Te

rmin

al B

lcok

-D

igita

l Inp

ut

Stop Owner Bit 7 6 5 4 3 2 1 0Adapter # 0 0 0 0 0 0 1 0


Parameter Access Level Information not available at time of publication


Permanent Magnet Motors Information not available at time of publication


PET Pulse Elimination Technique - See Reflected Wave.


Position Loop - Follower This information serves as a supplement to the PowerFlex 700S Users Manual, publication 20D-UM001B-EN-P, addressing items specific to the PowerFlex 700S. Please refer to the Users Manual for details on Position Loop configuration parameters. The position loop in the 700S drive can be used in place of an additional motion controller for simple positioning applications. The most common configuration will be in conjunction with PLC control. This example uses an encoder from the lead drive to send position/speed information to the PowerFlex700S position and speed loops.

XXXTechnical Information

General facts about the Point to Point Position Loop in the 700S:

1. Uses only Parameter 768 [PositReg P Gain] for tuning, Parameter 770 [Posit I Gain]

2. Uses quadrature encoder counts for positioning. i.e. 1024 encoder = 4096 counts per rev.

3. Speed loop tuning directly affects the position loop tuning and should be tuned first

4. Position loop tuned independently of the speed loop

5. For best performance, use with Dynamic brake or Regenerative system

Figure 2.10 Position Loop

Overview

The Aux XRref positioning feature in the PowerFlex 700S gives the user the ability to follow the position of a master motor without an external position controller. The position loop can be scaled to different units other than feedback counts, EGR (Electronic Gear Ratio). The position loop works as an outer loop to the speed reference in the Aux XRef mode. The function of the Aux XRef loop is to close the postion error of the follower in relation to the master position. This allows position following of the master during

318PI

770768

+

755

740

7404

5

754753

[N][D]

746745

742

758

743

0

2

1

Offset


accel/decel and steady state operation. Also allows for correction moves to match position of the master via an offset.

Mode Select

Parameter 742 [Posit Ref Sel] = 1, Select Aux XRef operation. This uses counts from a linked source for the position reference to the position loop.

For this example shown below Parameter 240 [Encdr1 Position] is linked to Parameter 743 [Aux Posit Ref]. This is the position command for the loop.

Speed Reference Select

For the position following mode to work properly, there needs to be a speed reference to the speed loop of the drive to follow.

0

2

1

position ref to EGR

742xref select

743

742 10 p to p reref

4

758 reref

xpp ref

aux xref

ptptRRef_Act741

0

2

1

16

5

4

3

6

0

20

15

14

x

/

14

12

11

10

++

Speed Ref Sel

Speed Ref1


For this example Parameter 10 [Speed Ref 1] is linked to Parameter 241 [Encdr1 Spd Fdbk]. Speed Ref 1 is selected in Parameter 16 [Speed Ref Sel].This generates the speed command from the master encoder input. If EGR is used, Parameter 11 [Spd Ref1 Divide] must be used to match the gear ratio set in the next step.

Position Reference Scaling

Position reference can be entered in user units by using the EGR scaling. Parameter 745 [PositRef EGR Mul] and Parameter 746 [PositRef EGR Div] are used to scale the position reference. For this example EGR is not used for a 1:1 ratio.

EGR example: Assuming a 1024 encoder on the motor which translates to 4096 counts per rev quadrature position counts.Parameter 745 [PositRef EGR Mul] = 1Parameter 746 [PositRef EGR Div] = 4Translates the position command to a gear ratio of 4:1 Master Revs to Follower Revs. Also Parameter 11 [Spd Ref1 Divide] needs to be set to 4 for the EGR to function properly.

Position Offset

Offsets can be added to the position reference. Offsets are used to make a correction move to sync the follower to the master position. There are two

elec GR

[N][D]

745 746egr num egr denom

pos ref

744

egr out

+

*

756

X Offset SpdFlt

LPass

Rate Lim

+753

754

755

740

740

4

5


offsets, Parameter 753[Posit Offset 1] and Parameter 754 [Posit Offset 2]. Offset speed must be entered in Parameter 755, if this is left at zero the move will not occur. Offsets to position must be entered in counts of feedback as it is added to the position reference after the EGR scaling. Offsets must be maintained to keep the position, for example if you enter a 300 in the offset the position loop will move 300 counts extra. If you zero the offset command the motor will return to the previous position. Offsets can be added to or zeroed.

To zero the offset after a move, set Parameter 740 bit 5 =1 then set offset value = 0 then set Parameter 740 bit 5 = 0. The system will not make an offset move when Parameter 740 bit 5 is set.

Positions Loop

Logic Setup

Parameter 151 [Logic Command] = Bit 13 “PositionEnbl” = 1

Parameter 740 [Position Control] = Bit 1 “Posit Spd Output” =1

Initial Tuning

The speed loop of the drive must be tuned prior to tuning the Position Loop.

++

744

+-

load GR

[N][D]

766

767

+-

764

762 select

222

+-

x droop

771

kxis

AND

3 2 740

kx ++

774

772770 741 0 1

773

768

pos ctrl

lim lo

lim hi

x load fbk

mtr fbk dev select

intg hold intg enable

motor fbk


Parameter 768 [PositReg P Gain] = 4 (Default)

Parameter 775 [Xreg Spd LoLim] Negative speed limit at which the position regulator will output. Default = -1750

Parameter 776 [Xreg Spd HiLim] Positive speed limit at which the position regulator will output. Default = 175

Tuning TipsTIP: Do not attempt to set the accel/decel rates of the point to point position loop faster than can be accomplished by the speed loop bandwidth. Attempting to set the accel/decel rates faster than the speed loop can handle will cause instability in the position loop.

TIP: Do not attempt to operate at the torque limits of the drive motor combination.

TIP: Typical Parameter 768 [PositReg P Gain] is set between 1/5 to 1/3 of the velocity BW, but may be set higher using lead compensation on the Position Regulator Output. Lead/Lag filtering of the position regulator output is accomplished via the speed trim 2 filter. Parameter 25 [Strim2 Filt Gain] and Parameter 26 [Strim2 Filt BW]. Making the Lead filter = 1/BW. Example: BW = 40 r/s Setting Parameter 25 [Strim2 Filt Gain] = 5 and Parameter 26 [Strim2 Filt BW] = 200 will effectively cancel the 1/40 sec. lag. This will allow a higher position gain for increased stability.

TIP: Parameter 770 [PositReg Integ] can be used but is disabled by default. If used Parameter 772 [XReg Integ LoLim] and Parameter 773 [XReg Integ HiLim] should be set with narrow limits.


Position Loop - Point to Point

This information serves as a supplement to the PowerFlex 700S Users Manual addressing items specific to the PowerFlex 700S. Please refer to the Users Manual for details on Position Loop configuration parameters. The position loop in the 700S drive can be used in place of an additional motion controller for simple positioning applications. The most common configuration will be in conjunction with PLC control. This example uses PLC control to send position references, position offsets, position redefines, starts, and stops to the 700S.


First a few general facts about the Point to Point Position Loop in the 700S:

1. Uses only Parameter 768 [PositReg P Gain] for tuning, no integral gain.

2. Uses quadrature encoder counts for positioning. i.e. 1024 encoder = 4096 counts per rev.

3. Position loop tuned independently of the speed loop.

4. Speed loop tuning directly affects the position loop tuning.

5. For best performance, should be used with Dynamic brake or Regenerative system.

Figure 2.11 shows a block diagram of the Point to Point Position Loop.

Figure 2.11 Point to Point Position Loop

0

2

1

742xref select

743load GR

[N][D]

3157

Deriv

740 10 p to p reref

758 reref

xpp ref

744

+

LPass

Rate Lim

+753

754

755

740

740

4

5

Posit Offset 1

X Offset Ref

X Offset Pol

Posit Offset Speed

Posit Offset 2

747

+

-

Deriv

3157

Position ErrorPoint to Point Pos

762

769

Limit

768

761

759

760

775

776

XReg Spd LoLim

XReg Spd HiLim

PositReg P Gain

Pt-Pt Filt BW

Pt-Pt Accel Time

Pt-Pt Decel Time

pos enable

00

&740 4

157 4

318Posit Spd OutputTo Speed ControlRegulator

Position Control(Speed Out En)

Logic Ctrl State(Position En)

pos enable745 746

egr num egr denom

Position Cmmd

1


Overview

The Point to Point positioning feature in the PowerFlex 700S gives the user the ability to position the load without an external position controller. The Point to Point function of the position loop moves from current location to commanded location then holds that position until given a new reference or a stop command. The position is not maintained when the drive is stopped or the position loop is not enabled. When the position loop is enabled, the value at Parameter 758 [Pt-Pt Posit Ref] is the current position. A position ReRef needs to be used to establish the correct position for meaningful operation. The position loop can be scaled to different units other than feedback counts, i.e. degrees or inches.

Setup

Links

• Parameter 740 [Position Control] Parameter 707 [Data In A1 Int]

• Parameter 22 [Speed Trim 2] Parameter 318 [Posit Spd Output] Position Regulator Speed Command Output for use by the Speed Loop.

• Parameter 151 [Logic Command] Parameter 709[Data In A2 Int]

• Parameter 758 [Pt-Pt Posit Ref] Parameter 711 [Data In B1 Int]

Mode Select and Referencing

0

2

1

position ref to EGR

742xref select

743

742 10 p to p reref

4

758 reref

xpp ref

aux xref

ptptRRef_Act741


Parameter 742 [Posit Ref Sel] = 2, Select Point to Point operation.

Parameter 758 [Pt-Pt Posit Ref] Point to Point Position Reference. This value comes to the drive via a PLC.

Parameter 740 bit 10 [Pt-Pt ReRef] This does a position redefine when active. When this bit is set, the position reference in Parameter 758 [Pt-Pt Posit Ref] can be changed to the position desired for the current location. This can be used as a home zero setup by moving the load to the home position. Example: setting Parameter 740 bit 10 =1 and then setting Parameter 758 = 0, this will set Parameter 747 [Position Command] value to be the position command for zero. Also if Parameter 758 is set to a different number, that will become the new position value. After setting Parameter 758 to the desired value Parameter 740 bit 10 can be set = 0.

Parameter 16 [Speed Ref Sel] = 0 (Zero Speed)

Position Reference Scaling

Position reference can be entered in user units by using the EGR scaling. Parameter 745 [PositRef EGR Mul] and Parameter 746 [PositRef EGR Div] are used to scale the position reference. If you would like to use degrees of motor revolution for the positioning units, scale as follows.

Assuming a 1024 encoder on the motor which translates to 4096 counts per rev quadrature position counts.Parameter 745 [PositRef EGR Mul] = 4096Parameter 746 [PositRef EGR Div] = 360

Translates the position command of 0-360o to 0-4096 position counts. This will allow you to enter degrees of motor rotation for the position command.

elec GR

[N][D]

745 746egr num egr denom

pos ref

744

egr out

+

*


Position Offset

Offsets can be added to the position reference. Offset can be used to offset the commanded position or to make a correction move. There are two offset, Parameter 753[Posit Offset 1] and Parameter 754 [Posit Offset 2]. Offset speed must be entered in Parameter 755, if this is left at zero the move will not occur. Offsets to position must be entered in counts of feedback. Offsets must be maintained to keep the position, for example if you enter a 300 in the offset, the position loop will move 300 counts extra. If you zero the offset command the motor will return to the previous position. Offsets can be added to or zeroed. To zero the offset after a move:

• Set Parameter 740 bit 5 =1 • Then set offset value = 0 • Next set Parameter 740 bit 5 = 0

The system will not make an offset move when Parameter 740 bit 5 is set.

Point to Point Control

756

X Offset SpdFlt

LPass

Rate Lim

+753

754

755

740

740

4

5

Position ErrorPoint to Point Pos

769

Limit

768

761

759

760

775

776

XReg Spd LoLim

XReg Spd HiLim

PositReg P Gain

Pt-Pt Filt BW

Pt-Pt Accel Time

Pt-Pt Decel Time

00

318Posit Spd OutputTo Speed ControlRegulator

1


Logic Setup

Parameter 151 [Logic Command] = Bit 13 “PositionEnbl” = 1

Parameter 740 [Position Control] = Bit 1 “Posit spd Output” =1

Initial TuningTIP: The speed loop of the drive must be tuned prior to tuning the Position Loop.

Parameter 768 [PositReg P Gain] = 4 (Default)

Parameter 761 [Pt-Pt Filt BW] sets the bandwidth of a low pass filterwhich affects smoothness at the start of deceleration in the point to point mode. A high filter bandwidth will produce a more square deceleration torque, one with a higher level of jerk. Typical values are 5 to 100 (rad/sec.). A zero value will bypass the filter. Tail-out is influenced mainly by Parameter 768. Too high of a value in this parameter will cause unstable operation at the end of the move. Default = 25

Parameter 759 [Pt-Pt Accel Time] Acceleration time from zero to Base Speed of the motor. This is only active in Point to Point mode. Default = 10

Parameter 760 [Pt-Pt Decel Time] Deceleration time from Base Speed of the motor to zero. This is only active in Point to Point mode. Default = 10

Parameter 775 [Xreg Spd LoLim] Negative speed limit at which the position regulator will output. Default = -1750

Parameter 776 [Xreg Spd HiLim] Positive speed limit at which the position regulator will output. Default = 175

Tuning TipsTIP: Do not attempt to set the accel/decel rates of the point to point position loop faster than can be accomplished by the speed loop bandwidth. Attempting to set the accel/decel rates faster than the speed loop can handle will cause instability in the position loop.

TIP: Do not attempt to operate at the torque limits of the drive motor combination.

TIP: Typical Parameter 768[PositReg P Gain] is set between 1/5 to 1/3 of the velocity BW, but may be set higher using lead compensation on the Position Regulator Output. Lead/Lag filtering of the position regulator output is accomplished via the speed trim 2 filter of Parameter 25 [Strim2 Filt Gain] and Parameter 26 [Strim2 Filt BW]. Making the Lead filter = 1/BW. Example: BW = 40 r/s Setting Parameter 25 [Strim2 Filt Gain] = 5 and Parameter 26 [Strim2 Filt BW] = 200 will effectively cancel the 1/40 sec. lag. This will allow a higher position gain for increased stability.


Position Detect Information not available at time of publication


Position Watch Information not available at time of publication


Power Loss Information not available at time of publication


Preset Speeds There are no “Preset Speed” parameters. However, the Speed Reference parameters can be used as set speeds. See the Speed Reference for more information.


Process PI Loop Information not available at time of publication


Process Trim Information not available at time of publication


Process Trim Regulator Information not available at time of publication


Reflected Wave Information not available at time of publication


Remote I/O Adapter(20-COMM-R)

This serves as a supplement to the PowerFlex Remote I/O Adapter Users Manual, publication 20COMM-UM004B-EN-P addressing items specific to the PowerFlex 700S. Please refer to the Users Manual for details on 20-COMM-R set-up, configuration, rack configurations, and block transfers.


First a few general facts about the 20-COMM-R (refer to Chapter 4 of the PowerFlex Remote I/O Adapter Users Manual for details):

1. Can only be configured as a 1/4 or1/2 rack

2. Remote I/O (RIO) is based on 16-bit integer values

3. Datalinks are transferred to and from the drive by block transfers

ControlLogix System

Here is the I/O image table for the ControlLogix system and a 20-COMM-R configured as a ¼ rack. Notice that the first 2 words of the image table are Discrete I/O, the rest of the data comes across as Block Transfer I/O.



OutpO.Data[0] INTO.Data[1] INT BT_Out[0] INT BT_Out[1] INTBT_Out[2] INTBT_Out[3] INTBT_Out[4] INT BT_Out[5] INT BT_Out[6] INT BT_Out[7] INTBT_Out[8] INTBT_Out[9] INTBT_Out[1 INTBT_Out[1 INTBT_Out[1 INT BT_Out[1 INT BT_Out[1 INT BT_Out[1 INTBT_Out[1 INTBT_Out[1 INT

0 BT Control1 Logic Command2 Reference3 Reference4 Datalink A15 Datalink A16 Datalink A27 Datalink A28 Datalink B19 Datalink B11 Datalink B21 Datalink B21 Datalink C11 Datalink C1 1 Datalink C2 1 Datalink C2 1 Datalink D1 1 Datalink D1 1 Datalink C2 1 Datalink C2

P158 Drive Logic

P20 SpeedRef DPI

P707 Data In A1 Int P708 Data In A1P709 Data In A2 IntP710 Data In A2P711 Data In B1 IntP712 Data In B1713 Data In B2 Int P714 Data In B2P715 Data In C1 IntP716 Data In C1P717 Data In C2 IntP718 Data In C2 P719 Data In D1 IntP720 Data In D1P721 Data In D2 IntP722 Data In D2

RIO DPI


When the 20-COMM-R is configured as a ½ rack, the Reference and Feedback values become words 2 and 3 in the Discrete I/O. The mapping for the Datalinks sent over block transfer I/O stays the same. Words 0 and 1 in the block transfer I/O become buffers.

Reference/Feedback Programming

Because the PowerFlex 700S is based on 32-bit and floating-point parameters, some special data handling is required when using Remote I/O.

To setup the PowerFlex 700S to follow a speed reference from the 20-COMM-R, Parameter 691 [DPI Ref Select] must be set to “Port 5.” Parameter16 [Speed Ref Sel] must be set to “Speed Ref DPI.”

Reference and Feedback values are floating point values in the PowerFlex 700S. Use the following logic to transmit and receive reference and feedback data as integer data.


P155 Logic Status

P72 Speed Ref DPI

P724 Data Out A1 P725 Data Out A1P726 Data Out A2 P727 Data Out A2P728 Data Out B1 P729 Data Out B1P730 Data Out B2 P731 Data Out B2P732 Data Out C1 P733 Data Out C1P734 Data Out C2 P735 Data Out C2 P736 Data Out D1 P737 Data Out D1P738 Data Out D2 P739 Data Out D2

BT MessageSource and Destination

Tags

MessageBuffer

MessageHandler

2

OutpO.Data[0] INTO.Data[1] INT BT_Out[0] INT BT_Out[1] INTBT_Out[2] INTBT_Out[3] INTBT_Out[4] INT BT_Out[5] INT BT_Out[6] INT BT_Out[7] INTBT_Out[8] INTBT_Out[9] INTBT_Out[1 INTBT_Out[1 INTBT_Out[1 INT BT_Out[1 INT BT_Out[1 INT BT_Out[1 INTBT_Out[1 INTBT_Out[1 INT

0 BT Control1 Logic Command2 Reference3 Reference4 Datalink A15 Datalink A16 Datalink A27 Datalink A28 Datalink B19 Datalink B11 Datalink B21 Datalink B21 Datalink C11 Datalink C1 1 Datalink C2 1 Datalink C2 1 Datalink D1 1 Datalink D1 1 Datalink C2 1 Datalink C2

RIO DPI


Transmitted Reference (counts) [Floating point Reference (RPM)32768

Base motor RPM[ ]----------------------------------------------×=

COP

Speed Reference Via Remote I/O to a PowerFlex 700S using a 20-COMM-R module.

The first move instruction is only for visual indication of the speed reference. Calculate the reference as a DINT based on 32768 = base motor speed.

Then copy the DINT into 2, 16 bit tags sent over Remote I/O.

MoveSource RIO_700S_Ref_RPM 1765.0Dest RIO_700S_Ref_RPM 1765.0

ComputeDest RIO_700S_Ref_DINT 32768 Expression (RIO_700S_Ref_RPM/RIO_700S_Base_Motor_Speed)*32768

Copy FileSource RIO_700S_Ref_DINT Dest RIO_700S_BT_0[0]Length 2

MOV

CPT

Floating point Feedback (RPM) [Feedback received (counts)Base Motor RPM

32768------------------------------------------×=

COP

Speed Reference Via Remote I/O to a PowerFlex 700S using a 20-COMM-R module.

The first move instruction is only for visual indication of the speed reference. Calculate the reference as a DINT based on 32768 = base motor speed.

Then copy the DINT into 2, 16 bit tags sent over Remote I/O.

MoveSource RIO_700S_Ref_RPM 1765.0Dest RIO_700S_Ref_RPM 1765.0

ComputeDest RIO_700S_Ref_DINT 32768 Expression (RIO_700S_Ref_RPM/RIO_700S_Base_Motor_Speed)*32768

Copy FileSource RIO_700S_Ref_DINT Dest RIO_700S_BT_0[0]Length 2

MOV

CPT


Datalink Programming

To read datalinks, the bits in Parameter 723 [Dlink OutDataTyp] must be set appropriately for each Datalink to select whether the data is floating point or DINT.

Because the datalinks are transmitted and received through block transfers, the data type in the controller is limited to 16-bit integers. To write or read floating point or 32-bit integers the COP (copy) instruction must be utilized. The copy instruction in ControlLogix performs a bitwise copy. Set the length of the copy instruction to a value appropriate for the destination data type.

For example:

1. When copying a floating-point value into an integer register, the length will be 2. A single precision IEEE floating point value uses 32-bits. This means (2) 16-bit integers are required to properly transmit the data.

2. When copying (2) integer values (the low and high word of 32-bit data) into a floating-point register, the length will be 1.

SLC/PLC-5 SystemReference/Feedback Programming

The reference is scaled so that base motor speed = 32768. The SLC/PLC-5 does not use DINT, and only handle 16 bit integers, so the reference has to be handled differently to account for references above 32767 or below -32768. The following example shows how to transmit references less than twice base motor speed.


ComputeDest F12:0 0.0Expression (F12:1 I F12:4) * 32768.0

CPT

LES ADD

MOV

Less Than (A<B)Source A

Source B

F12:00.0

-32768.0 -32768.0

Less Than (A<B)Source A

Source B

Dest

F12:00.0

-65536.0 -65536.0

N10:100

MoveSource A

Dest

-1-1

N10:100

EQU MOV

MOV

EqualSource A

Source B

F12:00.0

-32768.0 -32768.0

MoveSource A

Dest

F12:00.0

N10:100

MoveSource A

Dest

-1-1

N10:110

LIM MOV

MOV

Limit TestLow Lim

Test

High Lim

-32767.0-32767.0

F12:00.0

-1.0-1.0

MoveSource

Dest

F12:00.0

N10:100

MoveSource A

Dest

-1-1

N10:110

GRT SUB

MOV

Greater Than (A>B)Source A

Source B

F12:00.0

32767.032767.0

SubtractSource A

Source B

Dest

F12:00.0

65536.0 65536.0N10:10

0

MoveSource A

Dest

-1-1

N10:110

Convert the 32 bit floating point speed reference into 2, 16 bit intergers to send over RIO.F12:0 = 32 bit floating point speed reference (counts)N10:10 = LSW of speed reference to send over RIO (counts)N10:11 = MSW of speed reference to send over RIO (counts)

Calculate a speed reference based on 32768 = base motor speed.F12:0 = 32 bit floating point speed reference (counts)F12:1 = speed reference (RPM) F12:4 = base motor speed (RPM)

0

1


The feedback is also scaled so that base motor speed = 32768. The SLC/PLC-5 does not use DINT, and only handle 16 bit integers, so the feedback has to be handled differently to account for references above 32767 or below -32768. The following example shows how to read feedback values less than twice base motor speed.

EQU SUBEqualSource A

Source B

N11:111 0

-1 -1

SubtractSource A

Source B

Dest

N11:1100

65536.0 65536.0

F12:20.0

EQU MOVEqualSource A

Source B

N11:1110

-1 -1

MoveSource

Dest

-32768.0-32768.0

F12:2 0.0

MOVMoveSource

Dest

N11:1100

F12:20.0

LIMLimit TestLow Lim

Test

High Lim

-32767.0-32767.0 N11:110

0-1.0-1.0

Convert the speed feedback that comes over RIO as 2, 16 bit intergers into a 32 bit floating feedback.N11:10 = LSW of speed feedback from RIO (counts)N11:111 = MSW of speed feedback from RIO (counts)F12:2 = 32 bit floating point speed feedback (counts)

0002GRT

Greater Than (A>B)Source A

Source B

N11:110 00 0

EQUEqualSource A

Source B

N11:1100

-32768.0 -32768.0

EQUEqualSource A

Source B

N11:1110

-1 -1

MOVMoveSource

Dest

N11:1100

F12:20.0

LIMLimit TestLow Lim

Test

High Lim

0.00.0

N11:1100

32767.032767.0

EQUEqualSource A

Source B

N11:11100 0

ADDAddSource A

Source B

Dest

N11:1100

65536.0 65536.0

F12:20.0

EQUEqualSource A

Source B

N11:11100 0

LESGreater Than (A<B)Source A

Source B

N11:110 00 0

ComputeDest F12:3 0.0Expression (F12:2 I 32768.0) * F12:4

CPT

Convert the speed feedback into an RPM value.F12:3 = speed feedback (RPM)F12:2 = 32 bit floating point speed feedback (counts)F12:4 = base motor speed (RPM)

0003


Datalink Programming

Datalinks are transmitted and received through block transfers. The SLC/PLC-5 is limited to 16 bit integers and floating point. In order to send or receive floating point Datalinks we have to swap the LSW and MSW and utilize the COP (copy) instruction. Because the SLC/PLC-5 does not support 32-bit integers, 32-bit Datalinks remain split into 2, 16 bit integers. The following examples are for transmitting and receiving the different types of Datalinks.

Figure 2.12 Reading DINT datalinks in an SLC/PLC-5

Figure 2.13 Writing DINT Datalinks in an SLC/PLC-5

Figure 2.14 Reading Floating point Datalinks in an SLC/PLC-5

Copy FileSource #N11:114Dest #N13:114Length 2

A DINT datalink is sent across RIO as 2, 16 bit intergers. There is no DINT datatype in the SLC, so to read the data we will copy the DINT into 2, 16 bit intergers.N11:114 = LSW Datalink A2 Out from RIO BT ReadN11:115 = MSW Datalink A2 Out from RIO BT ReadN13:114 = LSW Datalink A2 OutN13:115 = MSW Datalink A2 Out

0004

Copy FileSource #N13:14Dest #N10:14Length 2

A DINT datalink is sent across RIO as 2, 16 bit intergers. There is no DINT datatype in the SLC, so to write the data we use 2, 16 bit intergers in the SLC.N13:14 = LSW Datalink A2 InN13:15 = MSW Datalink A2 InN10:14 = LSW Datalink A2 in for RIO BT Write N10:15 = MSW Datalink A2 in for RIO BT Write

0005

A floating point datalink is sent across RIO as 2, 16 bit intergers. To read a floating point datalink correctly in the SLC, you must firstswap the high and low 16 bit intergers, and then copy the 2, intergers into a floating point address.N11:112 = LSW Datalink A1 Out from RIO BT ReadN11:111 = MSW Datalink A1 Out from RIO BT ReadN13:112 = MSW Datalink A1 OutN13:113 = LSW Datalink A1 OutN12:5 = Datalink A1 Out

0006

MOVMoveSource

Dest

N11:11221158

F13:113 23873

MOVMoveSource

Dest

N11:11317447

F13:112 17447

COPCopy FileSource #N13:112Dest #N12:5Length 1


Figure 2.15 Writing Floating point Datalinks in an SLC/PLC-5

A floating point datalink is sent across RIO as 2, 16 bit intergers. To write a floating point datalink correctly in the SLC, you must firstcopy the floating point into 2 intergers, then swap the high and low 16 bit intergers.F12:6 = Datalink A1 InN13:12 = MSW Datalink A1 InN13:13 = LSW Datalink A1 In N10:12 = LSW Datalink A1 In from RIO BT WriteN10:13 = MSW Datalink A1 In from RIO BT Write

0007

MOVMoveSource

Dest

N13:13 0

F10:12 0

MOVMoveSource

Dest

N13:1216800

N10:1316800

COPCopy FileSource #F12:6Dest #F13:12 Length 2


Reset Meters Information not available at time of publication


Reset Run Information not available at time of publication


RFI Filter Grounding Information not available at time of publication


S-Curve Information not available at time of publication


Scaling Blocks Information not available at time of publication


Shear Pin Fault Information not available at time of publication


Skip Frequency Information not available at time of publication


Speed Control, Speed Mode, Speed Regulation

See Speed Feedback section for information about feedback devices and speed regulation with and without a speed feedback device.

See the Speed PI Regulator section for information about the speed regulator.

See the Torque Select section for information about choosing the output of the speed regulator as the reference to the torque loop.


Speed Feedback Information not available at time of publication


Speed Reference Information not available at time of publication


Speed Reference Select Information not available at time of publication


Speed PI Regulator Information not available at time of publication


Start Inhibits Information not available at time of publication


Start Permissives Information not available at time of publication


Start-Up Information not available at time of publication


Stop Modes Information not available at time of publication


SynchLink This section contains information specific to PowerFlex 700S SynchLink parameters and gives an example of setting up the PowerFlex 700S SynchLink using DriveExecutive. Please refer to the SynchLink System Design Guide, publication 1756-TD008A-EN-P, for PowerFlex 700S SynchLink topologies, hardware and wiring details.


SynchLink data is transmitted as a combination of direct and buffered data. The following table shows the different formats for transmit/receive data and the respective SynchLink fiber update rates for the direct and buffered data.

SynchLink Configuration

Parameter 1000 [SL Node Cnfg] is broken down into 3 bits:

• Bit 1 - “Time Keeper” - This bit is turned on and all other bits turned off in the SynchLink master. Only one drive in a SynchLink network can be the time keeper.

• Bit 2 - “Reserved” - Not used.• Bit 3 - “Synch Now” - This bit is turned on and all other bits off in the

SynchLink slaves.

Parameter 1010 [SL Rx Comm Frmt] selects the format of data to be received. It can be set to:

• “0A, 0D, 0B”- No data.• “0A, 2D, 18B” - 2 direct words and 18 buffered words.• “0A, 4D, 8B” - 4 direct words and 8 buffered words.• “0A, 4D, 18B” - 4 direct words and 18 buffered words.

Parameters 1011 [SL Rx DirectSel0] through 1014 [SL Rx DirectSel3] select what you want to do with received data. The most common settings for these parameters are:

• “No Data” - SynchLink received data is passed straight through.• “SL Multiply” - See details on multiply block.

Parameters 1021 [SL Tx DirectSel0] through 1024 [SL Tx DirectSel3] select what transmit data you wish to send. The most common settings for these parameters are:

• “No Data” - No data is selected for that transmit word.• “Dir Tx Data” - Use this selection to transmit a parameter.

# of Direct Words Direct Word Update # of Buffered Words Buffered Word Update2 50 µSec 18 0.5 ms4 50 µSec 18 1 ms4 50 µSec 8 0.5 ms


SynchLink Direct Data

Direct Data Transmit Parameters (Master)

Even Parameters 1054 [SL Dir Int Rx0] through 1060 [SL Dir Int Rx3] contain the integer values for data received from SynchLink. An integer destination parameter can be linked to these parameters.

Odd Parameters 1055 [SL Dir Real Rx0] through 1061 [SL Dir Real Rx3] contain the floating point values for data received from SynchLink. A real destination parameter can be linked to these parameters.

Direct Data Receive Parameters (Slave)

Parameter 1140 [Tx Dir Data Type] bits 0 through 3 select whether the direct data words transmitted over SynchLink will be integer or real. When the bit is turned off, it means the data transmitted will be integer. When the bit is turned on, it means the data transmitted will be real.

Odd Parameters 1141 [SL Dir Int Tx0] through 1147 [SL Dir Int Tx3] contain the integer values for data transmitted to SynchLink. These parameters can be linked to integer source parameters.

Even Parameters 1142 [SL Dir Real Tx0] through 1148 [SL Dir Real Tx3] contain the floating point values for data transmitted to SynchLink. These parameters can be linked to real source parameters.

Multiply Block:

SynchLink has the ability to take one of the direct data words and multiply it by a constant or parameter value for features such as draw control. Parameters for the multiply block must be setup in the master as well as the slave.

Multiply Block Transmit Parameters (Master)

SynchLink sends across the multiply data as an integer, so floating point values are converted to integer.

Parameter 1032 [SL Mult Base] sets the value to multiply Parameter 1035 [Real to Int In] before sending it out SynchLink. Make sure this parameter is set appropriately so that the integer value sent across SynchLink has enough resolution.

Parameter 1034 [SL Mult State] contains overflow bits if the data for the multiply block is too large. It is broken down into the following bits:

• Bit 0 - “Local Ovflow” - The result of the multiply function is too large.• Bit 1 - “Rx Ovflow” - The data received from SynchLink is too large.• Bit 2 - Not used• Bit 3 - “FtoI Ovflow” - In the master, the data converted from floating

point to integer is too large.


Parameter 1035 [Real to Int In] is linked to the parameter that you want to multiply.

Parameter 1036 [Real to Int Out] contains the integer value sent over SynchLink. One of the SynchLink direct integer transmit words (Parameter 1141, 1143, 1145, or 1147) must be linked to Parameter 1036 to send the value over SynchLink.

For example, to use the multiply block to scale the s-curved speed reference and send it over SynchLink, link Parameter 1035 [Real to Int In] to Parameter 43 [S Curve Spd Ref]. Set Parameter 1032 [SL Mult Base] to 10,000. Then link Parameter 1141 [SL Dir Int Tx0] to Parameter 1036 [Real to Int Out].

Multiply Block Receive Parameters (Slave)

Select which direct word to use the multiply block on by setting one of the following parameters: Parameter 1011 [SL Rx DirectSel0], Parameter 1012 [SL Rx DirectSel1], Parameter 1013 [SL Rx DirectSel2], or Parameter 1014 [SL Rx DirectSel4] to “SL Multiply.” Note that the receive parameter selected to use the multiply block in the slave must correspond to the transmit parameter selected to use the multiply block in the master.

Parameter 1030 [SL Mult A In] contains the value received from SynchLink, after it was divided by Parameter 1032 [SL Mult Base].

Parameter 1031 [SL Mult B In] contains the multiply scale factor to multiply by the value received from SynchLink. Note that Parameter 1031 could be a constant or linked to a source parameter.

Parameter 1032 [SL Mult Base] contains the base to convert integer data received from SynchLink back to real data. Usually, Parameter 1032 [SL Mult Base] will be set the same in the master and slave.

Parameter 1033 [SL Mult Out] contains the result of the multiply block. A destination parameter can be linked to Parameter 1033 [SL Mult Out].

Parameter 1034 [SL Mult State] contains overflow bits if the data for the multiply block is too large. It is broken down into the following bits:

• Bit 0 - “Local Ovflow” - The result of the multiply function is too large.• Bit 1 - “Rx Ovflow” - The data received from SynchLink is too large.• Bit 2 - Not used• Bit 3 - “FtoI Ovflow” - In the master, the data converted from floating

point to integer is too large.

For example, to receive the S-curved speed reference from the master and scale it by 0.5, set Parameter 1011 [SL Rx DirectSel 0] to “SL Multiply.” Set Parameter 1031 [SL Mult B In] to 0.5. Set Parameter 1032 [SL Mult Base] to 10,000. Link Parameter 37 [Spd Ref Bypass] to Parameter 1033 [SL Mult Out].


Buffered Data

Buffered Data Transmit Parameters (Master)

Parameter 1160 [Tx Buf Data Type], bits 0 through 29, select whether each word of buffered data that is transmitted is integer or real. When the bit is turned off, it means the data transmitted will be integer. When the bit is turned on, it means the data transmitted will be real.

Odd Parameters 1161 [SL Buf Int Tx00] through 1219 [SL Buf Int Tx29] are linked to integer parameters that you want to send out SynchLink as buffered data. Note that at this time, the maximum number of buffered words that can be sent over SynchLink is 18, so only odd Parameters 1161 [SL Buf Int Tx00] through 1195 [SL Buf Int Tx17] would be used.

Even Parameters 1162 [SL Buf Real Tx00] through 1220 [SL Buf Real Tx29] are linked to real parameters that you want to send out SynchLink as buffered data. Note that at this time, the maximum number of buffered words that can be sent over SynchLink is 18, so only odd Parameters 1162 [SL Buf Real Tx00] through 1196 [SL Buf Real Tx17] would be used.

Buffered Data Receive Parameters (Slave)

Odd Parameters 1073 [SL Buf Int Rx00] through 1131 [SL Buf Int Rx29] contain integer values that you receive from SynchLink as buffered data. Destination parameters that are integers can be linked to this buffered data. Note that at this time, the maximum number of buffered words that can be received over SynchLink is 18, so only odd Parameters 1073 [SL Buf Int Rx00] through 1107 [SL Buf Int Rx17] would be used.

Even Parameters 1074 [SL Buf Real Rx00] through 1132 [SL Buf Real Rx29] contain real values that you receive from SynchLink as buffered data. Destination parameters that are real values can be linked to this buffered data. Note that at this time, the maximum number of buffered words that can be received over SynchLink is 18, so only even Parameters 1074 [SL Buf Real Rx00] through 1108 [SL Buf Real Rx17] would be used.


Table 2.J SynchLink Transmit Block Diagram

1033

TxDirect Data

SelectorTx FormatSelector

1021 102010241022 10230 1 2 3Direct Tx Data Select

(0-26) (0-17)Tx Port Comm Format

235

245

Event DataRegistration Latches (Local)

P0 Regis Latch

P1 Regis Latch

253

XXX

Opt 0 Regis Ltch

Opt 1 Regis Ltch

(Select = 2)

(Select = 3)

(Select = 8)

1140

(Select = 9) "Not Used"

DirectTransmit

Data

1147 1148

1145 1146

1143 1144

1141 1143Int Real

(Select = 21)SL Dir (type) Tx0

SL Dir (type) Tx1

SL Dir (type) Tx2

SL Dir (type) Tx3

3 2 1 0

Tx Dir Data Type (1=Real)

(Select = 22)

Direct'passthrough'Data from Rx

230Encoder 0 Accum

240Encoder 1 Accum

250Opt 0 Accum

XXXOpt 1 Accum

(Select = 23)

(Select = 24)

(Select = 25)

(Select = 26) "Not Used"

CoordinatedSystem

Time

BufferedTransmit

Data

1160 31 0

1161 1162Int Real

1020

1219 1220

Axis an

dB

uf co

nfig.

SL Buf (type) Tx02

SL Buf (type) Tx31

Tx Port Comm Format

Tx Buf Data Type (1 = real)

Buffered Transmit Data

1226 1227SL Comm TP Sel

SL Comm TP Data

Direct D

ata

15

16

17

18

19

20

21

22

Tx Axis Size

Tx Index 1

Tx Index 0

Tx Seq Cnt

Tx Pkg Size

Tx Buff Size

Tx Dir Size

Tx Index 2

SynchlinkTransmit PortData (Tx) to

Downstream Node

SycnhLink Fiber


Figure 2.16 SynchLink Receive Block Diagram

5

Rx FormatSelector

1010 (0-17)Rx Port Comm Format

SynchlinkReceive PortData (Rx) to Upstream

Node

SycnhLink Fiber

6

7

8

9

10

11

12

Rx DirectData

Selector

1011 10141012 10130 1 2 3Direct Rx Data Select

(0-10)

1030

(sel = 1)

SL Mult A In

(sel = 2-10) EventLatches

(Upstream)

1040

2

10

9

8

7

6

5

4

3

Rx P0 Register

Rx Opt 1 Regis

Rx Opt 0 Regis

Rx D3 Latch

Rx D2 Latch

Rx D1 Latch

Rx D0 Latch

Rx P1 Register

Receive Events

1031

SL Mult B In

1033

(sel = 1)

SL Mult A In

Tx Multiply Data

(sel = 2-10)

BufferedReceive

Data

CoordinatedSystem

Time

1054

1058

1060

1055

1059

1061

SL Dir (type) Rx 0

SL Dir (type) Rx 3

SL Dir (type) Rx 2

SL Dir (type) Rx 1

Int Real

1070

1072

1069

1071

SL Buf (type) Rx 00

SL Buf (type) Rx 01

Int Real

1074

1132

1073

1131

SL Buf (type) Rx 02

SL Buf (type) Rx 31

Int Real

64 Parameters

1226SL Comm TP Sel

SL Comm TP Data

Available forTx

"passthroughdata"

10 Local Overflow

Rx Overflow

AxB

SynchLinkMultipy

1032SL Mult Base

Rx Axis Size

Rx Index 1

Rx Index 0

Rx Seq Cnt

Rx Pkg Size

Rx Buff Size

Rx Dir Size

Rx Index 2

1227

1041

1042

1045

1043

1044

1046

1047

1048

1034

1056 1057


Speed Synchronization Example:

This example will go through how to setup SynchLink to synchronize the ramped, s-curved speed reference for 2 PowerFlex 700S drives using DriveExecutive. Note that the “Peer Communication” setup in DriveExecutive configures the appropriate SynchLink parameters for you as you go through the setup.

Once connected to the drive, click on “Drive, and then “Peer Communication” to get to the SynchLink configuration dialog box.

A dialog box similar to the one shown will appear. This is the dialog box used to setup SynchLink communication.


Master PowerFlex 700S Drive Setup

In the master, or transmitting drive, select the SynchLink Transmit format. For this example, select “4 Direct Words, 8 Buffered Words.”


For Transmitted Direct Word 0, select “Drive Parameter” for the Source and Parameter 43[S Curve Spd Ref] for the Item.

Click and a dialog box will appear.

Uncheck “Sync Now” and check the “Time Keeper” box. The master drive is now the Time Keeper for SynchLink.


Click “OK” twice to accept the settings and close the dialog boxes for Peer Communication.

To synchronize the speed references, we must add a time delay to the S-Curve Spd Ref of the master. To do this link Parameter 37 [Spd Ref Bypass] to Parameter 45 [Delayed Spd Ref].


Slave PowerFlex 700S Setup

In the slave drive, select the SynchLink Receive Format to match the size of the data transmitted from the master. For this example, select “4 Direct Words, 8 Buffered Words.”

If desired, the multiply block can be used to change the scaling of one of the Direct Words coming from the master to the slave. For example, the multiply might be used to enter a gear ratio for the speed reference.


Click and a dialog box appears.

Verify that only the “Sync Now” box is checked (this is factory default).


Click “OK” twice to accept the settings and close the dialog boxes for Peer Communication.

Now we must link the Spd Ref Bypass of the slave to Word 0 of Direct Data coming over SynchLink. To do this, link Parameter 37 [Spd Ref Bypass] to Parameter 1055 [SL Dir Real Rx0].


Note that by linking to Spd Ref Bypass of the slave, we bypassed the ramp and S-Curve of the slave. This is because the reference is already ramped and S-Curved by the master. This way, both drives follow exactly the same ramp.

Cycle Power

• You must power down all drives before SynchLink changes take effect.• First apply power to the Master. The SynchLink LED should be solid

green. The SynchLink LED is on the top right of the MCB and is visible through the window on the control assembly.

• When power is applied to the slave(s), the LED should be a solid light in about 1 minute.


Test Points Information not available at time of publication


Thermal Regulator Information not available at time of publication


Torque Reference Information not available at time of publication


Torque Select Information not available at time of publication


Troubleshooting Information not available at time of publication


User Sets Information not available at time of publication


Velocity Feedback Refer to Speed Feedback


Velocity Reference Control Information not available at time of publication


Velocity Feedback Control Information not available at time of publication


Velocity Pl Control Information not available at time of publication


Voltage Class Information not available at time of publication


Watts Loss Description

This information serves as a supplement to the PowerFlex 700S Users Manual, publication 20D-UM001B-EN-P, addressing items specific to the PowerFlex 700S heat dissipation.


The following table lists watts loss data for PowerFlex 700S drives running at full load, full speed, and factory default PWM frequency of 4kHz.

Table 2.K 480V Watts Loss at Full Load/Speed, 4kHz�

� Includes HIM� Information not available at time of publication

Drive ND HP @ 480V AC Total Watt Loss

0.5 921 1032 1173 1355 210

7.5 24310 27115 38920 46725 51930 54340 70850 �

60 �

75 �

100 �

125 �

150 �

Appendix A

Dynamic Brake Selection Guide

The Dynamic Braking Selection Guide provided on the following pages contains detailed information on selecting and using dynamic brakes.

Dynamic Braking

Selection Guide

www.abpowerflex.com

A-2 Dynamic Brake Selection Guide

Dynamic Braking Resistor Calculator

www.abpowerflex.com

Important User InformationSolid state equipment has operational characteristics differing from those of electromechanical equipment. “Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls” (Publication SGI-1.1 available from your local Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will the Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, the Allen-Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Allen-Bradley Company with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of the Allen-Bradley Company is prohibited.

Throughout this manual we use notes to make you aware of safety considerations.

Attentions help you:

• identify a hazard• avoid the hazard• recognize the consequences

Important: Identifies information that is especially important for successful application and understanding of the product.

DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.

PLC is a registered trademark of Rockwell Automation.

ControlNet is a trademark of ControlNet International, Ltd.

DeviceNet is a trademark of the Open DeviceNet Vendor Association.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Shock Hazard labels may be located on or inside the drive to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the drive to alert people that surfaces may be at dangerous temperatures.

Table of Contents

Section 1 Understanding How Dynamic Braking Works This section provides an overview of the components required to do Dynamic Braking and their functionality.

How Dynamic Braking Works . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Dynamic Brake Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2 Determining Dynamic Brake Requirements This section steps you through the calculations necessary to determine the amount of Dynamic Braking required for your application.

How to Determine Dynamic Brake Requirements . . . . . . . . . . . 2-1Determine Values of Equation Variables . . . . . . . . . . . . . . . . . . 2-4Example Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Section 3 Evaluating the Internal Resistor This section steps you through the process to determine whether or not the available PowerFlex internal resistors are adequate for your application.

Evaluating the Capability of theInternal Dynamic Brake Resistor . . . . . . . . . . . . . . . . . . . . . . . . 3-1PowerFlex 70 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4PowerFlex 700 Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Section 4 Selecting An External ResistorThis section steps you through the process of selecting an external resistor when the internal resistors prove to be insufficient for your application.

How to Select an External Dynamic Brake Resistor . . . . . . . . . 4-1

Appendix A

ii Table of Contents

Section 1

Understanding How Dynamic Braking Works

When an induction motor’s rotor is turning slower than the synchronous speed set by the drive’s output power, the motor is transforming electrical energy obtained from the drive into mechanical energy available at the drive shaft of the motor. This process is referred to as motoring. When the rotor is turning faster than the synchronous speed set by the drive’s output power, the motor is transforming mechanical energy available at the drive shaft of the motor into electrical energy that can be transferred back to the drive. This process is referred to as regeneration.

Most AC PWM drives convert AC power from the fixed frequency utility grid into DC power by means of a diode rectifier bridge or controlled SCR bridge before it is inverted into variable frequency AC power. Diode and SCR bridges are cost effective, but can only handle power in the motoring direction. Therefore, if the motor is regenerating, the bridge cannot conduct the necessary negative DC current, the DC bus voltage will increase and cause an overvoltage fault at the drive. More complex bridge configurations use SCRs or transistors that can transform DC regenerative electrical power into fixed frequency utility electrical energy. This process is known as line regeneration.

A more cost effective solution can be provided by allowing the drive to feed the regenerated electrical power to a resistor which transforms it into thermal energy. This process is referred to as dynamic braking.

How Dynamic Braking Works

1-2 Understanding How Dynamic Braking Works

A Dynamic Brake consists of a Chopper (the chopper transistor and related control components are built into PowerFlex drives) and a Dynamic Brake Resistor.

Figure 1.1 shows a simplified Dynamic Braking schematic.

Figure 1.1 Simplified Dynamic Brake Schematic

Chopper

The Chopper is the Dynamic Braking circuitry that senses rising DC bus voltage and shunts the excess energy to the Dynamic Brake Resistor. A Chopper contains three significant power components:

The Chopper Transistor is an Isolated Gate Bipolar Transistor (IGBT). The Chopper Transistor is either ON or OFF, connecting the Dynamic Brake Resistor to the DC bus and dissipating power, or isolating the resistor from the DC bus. The most important rating is the collector current rating of the Chopper Transistor that helps to determine the minimum resistance value used for the Dynamic Brake Resistor.

Dynamic Brake Components

SignalCommon

DynamicBrake

Resistor

ChopperTransistor

Chopper TransistorVoltage Control

ToVoltageControl

ToVoltageControl

– DC Bus

+ DC Bus

ToVoltage Dividers

VoltageDivider

VoltageDivider

FWD

FWD

Understanding How Dynamic Braking Works 1-3

Chopper Transistor Voltage Control regulates the voltage of the DC bus during regeneration. The average values of DC bus voltages are:

• 395V DC (for 240V AC input)• 658V DC (for 400V AC input)• 790V DC (for 480V AC input)• 987V DC (for 600V AC input)

Voltage dividers reduce the DC bus voltage to a value that is usable in signal circuit isolation and control. The DC bus feedback voltage from the voltage dividers is compared to a reference voltage to actuate the Chopper Transistor.

The Freewheel Diode (FWD), in parallel with the Dynamic Brake Resistor, allows any magnetic energy stored in the parasitic inductance of that circuit to be safely dissipated during turn off of the Chopper Transistor.

Resistor

The Resistor dissipates the regenerated energy in the form of heat. The PowerFlex Family of Drives can use either the internal dynamic brake resistor option or an externally mounted dynamic brake resistor wired to the drive.

1-4 Understanding How Dynamic Braking Works

Notes:

Section 2

Determining Dynamic Brake Requirements

When a drive is consistently operating in the regenerative mode of operation, serious consideration should be given to equipment that will transform the electrical energy back to the fixed frequency utility grid.

As a general rule, Dynamic Braking can be used when the need to dissipate regenerative energy is on an occasional or periodic basis. In general, the motor power rating, speed, torque, and details regarding the regenerative mode of operation will be needed in order to estimate what Dynamic Brake Resistor value is needed.

The Peak Regenerative Power and Average Regenerative Power required for the application must be calculated in order to determine the resistor needed for the application. Once these values are determined, the resistors can be chosen. If an internal resistor is chosen, the resistor must be capable of handling the regenerated power or the drive will trip. If an external resistor is chosen, in addition to the power capabilities, the resistance must also be less than the application maximum and greater than the drive minimum or the drive will trip.

The power rating of the Dynamic Brake Resistor is estimated by applying what is known about the drive’s motoring and regenerating modes of operation. The Average Power Dissipation must be estimated and the power rating of the Dynamic Brake Resistor chosen to be greater than that average. If the Dynamic Brake Resistor has a large thermodynamic heat capacity, then the resistor element will be able to absorb a large amount of energy without the temperature of the resistor element exceeding the operational temperature rating. Thermal time constants in the order of 50 seconds and higher satisfy the criteria of large heat capacities for these applications. If a resistor has a small heat capacity (defined as thermal time constants less than 5 seconds) the temperature of the resistor element could exceed its maximum.

Peak Regenerative Power can be calculated as:

• Horsepower (English units)

• Watts (The International System of Units, SI)

• Per Unit System (pu) which is relative to a value

The final number must be in watts of power to estimate the resistance value of the Dynamic Brake Resistor. The following calculations are demonstrated in SI units.

How to Determine Dynamic Brake Requirements

2-2 Determining Dynamic Brake Requirements

Gather the Following Information

• Power rating from motor nameplate in watts, kilowatts, or horsepower

• Speed rating from motor nameplate in rpm or rps (radians per second)

• Required decel time (per Figure 2.1, t3 – t2). This time is a process requirement and must be within the capabilities of the drive programming.

• Motor inertia and load inertia in kg-m2 or lb.-ft.2

• Gear ratio (GR) if a gear is present between the motor and load

• Motor shaft speed, torque, and power profile of the drive application

Figure 2.1 shows typical application profiles for speed, torque and power. The examples are for cyclical application that is periodic over t4 seconds. The following variables are defined for Figure 2.1:

ω(t) = Motor shaft speed in radians per second (rps)

N = Motor shaft speed in Revolutions Per Minute (RPM)

T(t) = Motor shaft torque in Newton-meters1.0 lb.-ft. = 1.355818 N-m

P(t) = Motor shaft power in watts1.0 HP = 746 watts

ωb = Rated angular rotational speed

ωo = Angular rotational speed less than ωb (can equal 0)

-Pb = Motor shaft peak regenerative power in watts

ω 2πN60

----------=

Rads

---------

Rads

---------

Determining Dynamic Brake Requirements 2-3

Figure 2.1 Application Speed, Torque and Power Profiles

0 t1 t2 t3 t4 t1 + t4 t

0 t1 t2 t3 t4 t1 + t4 t

0 t1 t2 t3 t4 t1 + t4 t

ω(t)

T(t)

P(t)

0 t1 t2 t3 t4 t1 + t4 t

-Pb

Prg

ωo

ωb

Speed

Torque

Power

Drive RatedRegen Power


Step 1 Total Inertia

JT = Total inertia reflected to the motor shaft (kg-m2 or lb.-ft.2)

Jm = Motor inertia (kg-m2 or lb.-ft.2)

GR = Gear ratio for any gear between motor and load (dimensionless)

JL = Load inertia (kg-m2 or lb.-ft.2)1.0 lb.-ft.2 = 0.04214011 kg-m2

Calculate Total Inertia:

Record Total Inertia:

Determine Values of Equation Variables

JT =

JT Jm GR2 JL×( )+=

JT oooooooooo[ ] oooooooooo oooooooooo×( )+=


Step 2 Peak Braking Power

Pb = Peak braking power (watts)1.0 HP = 746 watts

JT = Total inertia reflected to the motor shaft (kg-m2)


ωo = Angular rotational speed,less than rated speed down to zero

Nb = Rated motor speed (RPM)

t3 – t2 = Deceleration time from ωb to ωo (seconds)

Calculate Peak Braking Power:

Record Peak Braking Power:

Compare the peak braking power (Pb) to the drive rated regenerative power (Prg). If the peak braking power is greater than the drive rated regenerative power, the decel time will have to be increased so that the drive does not enter current limit. Drive rated regenerative power (Prg) is determined by:

Prg = Drive rated regenerative power

V = DC bus regulation voltage from Table A.A

R = Minimum brake resistance from Table A.A

Record Rated Regenerative Power:

Pb =

Prg =

PbJT ωb ωb ωo–( )[ ]

t3 t2–( )-------------------------------------=

Rads

---------2πNb

60------------=

Rads

---------

Pbooooooooo[ ] ooooooooo[ ] ooooooooo ooooooooo–( )××

ooooooooo ooooooooo–( )-------------------------------------------------------------------------------------------------------------------------------------------------=

PrgV2

R-----=

Prgooooooooo[ ]2

ooooooooo( )----------------------------------=


For the purposes of this document, it is assumed that the motor used in the application is capable of producing the required regenerative torque and power.

Step 3 Minimum Power Requirements for the Dynamic Brake Resistors

It is assumed that the application exhibits a periodic function of acceleration and deceleration. If (t3 – t2) equals the time in seconds necessary for deceleration from rated speed to ωo speed, and t4 is the time in seconds before the process repeats itself, then the average duty cycle is (t3 – t2)/t4. The power as a function of time is a linearly decreasing function from a value equal to the peak regenerative power to some lesser value after (t3 – t2) seconds have elapsed. The average power regenerated over the interval of (t3 – t2) seconds is:

Pav = Average dynamic brake resister dissipation (watts)

t3 – t2 = Deceleration time from ωb to ωo (seconds)

t4 = Total cycle time or period of process (seconds)

Pb = Peak braking power (watts)


ωo = Angular rotational speed,less than rated speed down to zero

The Average Power in watts regenerated over the period t4 is:

Calculate Average Power in watts regenerated over the period t4:

Record Average Power in watts regenerated over the period t4:

Pav =

Pb

2-----

ωb ωo+( )ωb

---------------------×

Rads

---------

Rads

---------

Pav

t3 t2–( )t4

------------------Pb

2-----

ωb ωo+( )ωb

---------------------=

Pavoooooo oooooo–( )

oooooo[ ]----------------------------------------------- oooooo[ ]

2-----------------------× oooooo oooooo+( )

oooooo[ ]-----------------------------------------------×=


Step 4 Percent Average Load of the Internal Dynamic Brake Resistor

Skip this calculation if an external dynamic brake resistor will be used.

AL = Average load in percent of dynamic brake resistor

Pav = Average dynamic brake resistor dissipation calculated in Step 3 (watts)

Pdb = Steady state power dissipation capacity of dynamic brake resistors obtained from Table A.A (watts)

Calculate Percent Average Load of the dynamic brake resistor:

Record Percent Average Load of the dynamic brake resistor:

The calculation of AL is the Dynamic Brake Resistor load expressed as a percent. Pdb is the sum of the Dynamic Brake dissipation capacity and is obtained from Table A.A. This will give a data point for a line to be drawn on one the curves provided in Section 3.

AL =

ALPav

Pdb-------- 100×=

ALoooooooooo[ ]oooooooooo[ ]

----------------------------------- 100×=


Step 5 Percent Peak Load of the Internal Dynamic Brake Resistor

Skip this calculation if an external dynamic brake resistor will be used.

PL = Peak load in percent of dynamic brake resistor

Pav = Peak braking power calculated in Step 2 (watts)

Pdb = Steady state power dissipation capacity of dynamic brake resistors obtained from Table A.A (watts)

Calculate Percent Peak Load of the dynamic brake resistor:

Record Percent Average Load of the dynamic brake resistor:

The calculation of PL in percent gives the percentage of the instantaneous power dissipated by the Dynamic Brake Resistors relative to the steady state power dissipation capacity of the resistors. This will give a data point to be drawn on one of the curves provided in Section 3.

PL =

PLPb

Pdb-------- 100×=

PL oooooooooo[ ]oooooooooo[ ]

----------------------------------- 100×=


A 10 HP, 4 Pole, 480 Volt motor and drive is accelerating and decelerating as depicted in Figure 2.1.

• Cycle period t4 is 40 seconds

• Rated speed is 1785 RPM and is to be decelerated to 0 speed in 15.0 seconds

• Motor load can be considered purely as inertia, and all power expended or absorbed by the motor is absorbed by the motor and load inertia

• Load inertia is 4.0 lb.-ft.2 and is directly coupled to the motor

• Motor rotor inertia is 2.2 lb.-ft.2

• A PowerFlex 70, 10 HP 480V Normal Duty rating is chosen.

Calculate the necessary values to choose an acceptable Dynamic Brake.

This information was given and must be known before the calculation process begins. This can be given in HP, but must be converted to watts before it can be used in the equations.

This information was given and must be known before the calculation process begins. This can be given in RPM, but must be converted to radians per second before it can be used in the equations.

This value can be in lb.-ft.2 or Wk2, but must be converted into kg-m2 before it can be used in the equations.

Example Calculation

Rated Power 10 HP= 746 watts 7.46 kW=×

Rated Speed ωb 1785= RPM 2π= =178560

----------× 186.98 Rads

-------------------------=

Lower Speed ωo 0= RPM 2π 060-----× 0 Rad

s-------------= = =

Total Inertia JT 6.2= lb.-ft.2 0.261 kg-m2= =

Deceleration Time t3 t2–( ) 15 seconds= =

Period of Cycle t4 40 seconds= =


This was known because the drive is rated at 480 Volts rms. If the drive were rated 230 Volts rms, then Vd = 395 Volts.

All of the preceding data and calculations were made from knowledge of the application under consideration. The total inertia was given and did not need further calculations as outlined in Step 1.

Note that this is 8.1% of rated power and is less than the maximum drive limit of 150% current limit. This calculation is the result of Step 2 and determines the peak power that must be dissipated by the Dynamic Brake Resistor.

This is the result of calculating the average power dissipation as outlined in Step 4. Verify that the sum of the power ratings of the Dynamic Brake Resistors chosen in Step 3 is greater than the value calculated in Step 4.

Refer to Table A.A to determine the continuous power rating of the resistor in the given drive you are using. You will need this number to determine the Percent Average Load and the Percent Peak Load.

This is the result of the calculation outlined in Step 5. Record this value on page 3-1.

Vd 750 Volts=

Peak Braking Power PbJT ωb ωb ωo–( )[ ]

t3 t2–( )-------------------------------------= =

Pb0.261 186.92 186.92 0–( )[ ]

15------------------------------------------------------------- 608.6 watts= =

Average Braking Power Pav

t3 t2–( )t4

------------------Pb

2-----

ωb ωo+( )ωb

---------------------= =

Pav1540-----

608.62

------------ 186.92 0+

186.92------------------------

114.1 watts= =

Percent Average Load AL 100Pav

Pdb--------×= =

AL 100 114.140

------------ 285%=×=


This is the result of the calculation outlined in Step 5. Record this value on page 3-1.

Now that the values of AL and PL have been calculated, they can be used to determine whether an internal or external resistor can be used. Since the internal resistor package offers significant cost and space advantages, it will be evaluated first.

Percent Peak Load PL 100Pb

Pdb--------×= =

PL 100608.6

40------------× 1521%= =


Notes:

Section 3

Evaluating the Internal Resistor

To investigate the capabilities of the internal resistor package, the values of AL (Average Percent Load) and PL (Peak Percent Load) are plotted onto a graph of the Dynamic Brake Resistor’s constant temperature power curve and connected with a straight line. If any portion of this line lies to the right of the constant temperature power curve, the resistor element temperature will exceed the operating temperature limit.

Important: The drive will protect the resistor and shut down the Chopper transistor. The drive will then likely trip on an overvoltage fault.

1. Record the values calculated in Section 2.

Evaluating the Capability of the Internal Dynamic Brake Resistor

AL =

PL =

t3 – t2 =

3-2 Evaluating the Internal Resistor

2. Find the correct constant temperature Power Curve for your drive type, voltage and frame.

Power Curves for PowerFlex 70 Internal DB Resistors

OR

Power Curves for PowerFlex 700 Internal DB Resistors

3. Plot the point where the value of AL, calculated in Step 4 of Section 2, and the desired deceleration time (t3 – t2) intersect.

4. Plot the value of PL, calculated in Step 5 of Section 2, on the vertical axis (0 seconds).

5. Connect AL at (t3 – t2) and PL at 0 seconds with a straight line. This line is the power curve described by the motor as it decelerates to minimum speed.

Drive Voltage Drive Frame(s) Figure Number240 A and B 3.1240 C 3.3240 D 3.4

400/480 A and B 3.5400/480 C 3.6400/480 D 3.7

Drive Voltage Drive Frame Figure Number400/480 0 3.8400/480 1 3.9400/480 2 3.10400/480 3 Uses external DB resistors

only. Refer to Section 4

Evaluating the Internal Resistor 3-3

If the line connecting AL and PL lies entirely to the left of the Power Curve, then the capability of the internal resistor is sufficient for the proposed application.

Figure 3.1 Example of an Acceptable Resistor Power Curve

If any portion of the line connecting AL and PL lies to the right of the Power Curve, then the capability of the internal resistor is insufficient for the proposed application.

• Increase deceleration time (t3 – t2) until the line connecting AL and PL lies entirely to the left of the Power Curve

or

• Go to Section 4 and select an external resistor from the tables

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Decel Time (Seconds)

% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

PL (Peak Percent Load) = 1521%

AL (Average Percent Load) = 285%

Decel Time = 15.0 Seconds

480V Frame C


Figure 3.2 PowerFlex 70 – 240 Volt, Frames A and B

Figure 3.3 PowerFlex 70 – 240 Volt, Frame C

PowerFlex 70 Power Curves

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

240V Frames A & B

% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


240V Frame C


Figure 3.4 PowerFlex 70 – 240 Volt, Frame D

Figure 3.5 PowerFlex 70 – 480 Volt, Frames A and B

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

240V Frame D

% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


480V Frames A & B


Figure 3.6 PowerFlex 70 – 480 Volt, Frame C

Figure 3.7 PowerFlex 70 – 480 Volt, Frame D

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

480V Frame C

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30


% P

eak

Pow

er

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

2800

3000

480V Frame D


Figure 3.8 PowerFlex 700 – 480 Volt, Frame 0


PowerFlex 700 Power Curves

00

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

480V Frame 0


% P

eak

Pow

er

00

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

480V Frame 1


% P

eak

Pow

er



00

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

480V Frame 2


% P

eak

Pow

er

Section 4

Selecting An External Resistor

In order to select the appropriate External Dynamic Brake Resistor for your application, the following data must be calculated.

Peak Regenerative Power(Expressed in watts)

This value is used to determine the maximum resistance value of the Dynamic Brake Resistor. If this value is greater than the maximum imposed by the peak regenerative power of the drive, the drive can trip off due to transient DC bus overvoltage problems.

Power Rating of the Dynamic Brake Resistor

The average power dissipation of the regenerative mode must be estimat4ed and the power rating of the Dynamic Brake Resistor chosen to be greater than the average regenerative power dissipation of the drive.

How to Select an External Dynamic Brake Resistor

4-2 Selecting An External Resistor

Protecting External Resistor Packages

Figure 4.1 External Brake Resistor Circuitry

!ATTENTION: PowerFlex drives do not offer protection for externally mounted brake resistors. A risk of fire exists if external braking resistors are not protected. External resistor packages must be self-protected from over temperature or the protective circuit show below, or equivalent, must be supplied.

Power On

R (L1)S (L2)T (L3)

Power Source DB Resistor Thermostat

Power Off

M

M

(Input Contactor) M

Three-PhaseAC Input

Selecting An External Resistor 4-3

Record the Values Calculated in Section 2

Calculate Maximum Dynamic Brake Resistance Value

When using an internal Dynamic Brake Resistor, the value is fixed. However, when choosing an external resistor, the maximum allowable Dynamic Brake resistance value (Rdb1) must be calculated.

Rdb1 = Maximum allowable value for the dynamic brake resistor (ohms)

Vd = DC bus voltage the chopper module regulates to(395V DC, 790V DC, or 987V DC)

Pb = Peak breaking power calculated in Section 2: Step 2 (watts)

Calculate Maximum Dynamic Brake Resistance:

Record Maximum Dynamic Brake Resistance:

The choice of the Dynamic Brake resistance value should be less than the value calculated in this step. If the value is greater, the drive can trip on DC bus overvoltage. Do not reduce Pb by any ratio because of estimated losses in the motor and inverter. This has been accounted for by an offsetting increase in the manufacturing tolerance of the resistance value and the increase in resistance value due to the temperature coefficient of resistor element.

Pb =

Pav =

Rdb1 =

Rdb1Vd( )2

Pb------------=

Rdb1ooooooooo( )2

ooooooooo[ ]----------------------------------=


Select Resistor

Select a resistor bank from Table 4.A or 4.B or your resistor supplier that has all of the following:

• a resistance value that is less than the value calculated (Rdb1 in ohms)

• a resistance value that is greater than the minimum resistance listed in Table A.A

• a power value that is greater than the value calculated in Step 3 (Pav in watts)

If no resistor appears in the following tables that is greater than the minimum allowable resistance and is less than the calculated maximum resistance:

• Adjust the deceleration time of the application to fit an available resistor package.

or

• Use the calculated data to purchase resistors locally.

or

• Consult the factory for other possible resistor packages.

!ATTENTION: The internal dynamic brake IGBT will be damaged if the resistance value of the resistor bank is less than the minimum resistance value of the drive. Use Table A.A to verify that the resistance value of the selected resistor bank is greater than the minimum resistance of the drive.


Table 4.A Resistor Selection for 240V AC Drives

Ohms WattsCatalog Number Ohms Watts

Catalog Number

154 182 222-1A 45 617 222-5A154 242 222-1 45 827 222-5154 408 225-1A 45 1378 225-5A154 604 225-1 45 2056 220-5A154 610 220-1A 45 2066 225-5154 913 220-1 45 3125 220-5110 255 222-2A 32 875 222-6A110 338 222-2 32 1162 222-6110 570 225-2A 32 1955 225-6A110 845 225-2 32 2906 225-6110 850 220-2A 32 2918 220-6A110 1278 220-2 32 4395 220-685 326 222-3A 20 1372 222-7A85 438 222-3 20 1860 222-785 730 225-3A 20 3063 225-7A85 1089 220-3A 20 4572 220-7A85 1094 225-3 20 4650 225-785 1954 220-3 20 7031 220-759 473 222-4A59 631 222-459 1056 225-4A59 1576 225-459 1577 220-4A59 2384 220-4


Table 4.B Resistor Selection for 480V AC Drives


Catalog Number

615 180 442-1A 128 874 442-6A615 242 442-1 128 1162 442-6615 404 445-1A 128 1951 445-6A615 602 440-1A 128 2906 445-6615 605 445-1 128 2912 440-6A615 915 440-1 128 4395 440-6439 254 442-2A 81 1389 442-7A439 339 442-2 81 1837 442-7439 568 445-2A 81 3102 445-7A439 847 445-2 81 4592 445-7439 848 440-2A 81 4629 440-7A439 1281 440-2 81 6944 440-7342 329 442-3A 56 2010 442-8A342 435 442-3 56 2657 442-8342 734 445-3A 56 4490 445-8A342 1088 445-3 56 6642 445-8342 1096 440-3A 56 6702 440-8A342 1645 440-3 56 10045 440-8237 473 442-4A 44 2561 442-9A237 628 442-4 44 3381 442-9237 1057 445-4A 44 5720 445-9A237 1570 445-4 44 8454 445-9237 1577 440-4A 44 8537 440-9A237 2373 440-4 44 12784 440-9181 620 442-5A 29 3800 442-10A181 822 442-5 29 5130 442-10181 1385 445-5A 29 8487 445-10A181 2055 445-5 29 12667 440-10A181 2068 440-5A 29 12826 445-10181 3108 440-5 29 19396 440-10


Table 4.C Resistor Selection for 600V AC Drives


Catalog Number

956 175 552-1A 196 890 552-6A956 242 552-1 196 1180 552-6956 400 555-1A 196 1987 555-6A956 597 550-1A 196 2950 555-6956 605 555-1 196 2965 550-6A956 915 550-1 196 4460 550-6695 248 552-2A 125 1386 552-7A695 333 552-2 125 1850 552-7695 553 555-2A 125 3095 555-7A695 825 550-2A 125 4620 550-7A695 832 555-2 125 4625 555-7695 1258 550-2 125 6994 550-7546 316 552-3A 85 2056 552-8A546 424 552-3 85 2720 552-8546 707 555-3A 85 4592 555-8A546 1055 550-3A 85 6801 555-8546 1059 555-3 85 6854 550-8A546 1601 550-3 85 10285 550-8364 477 552-4A 70 2527 552-9A364 635 552-4 70 3303 552-9364 1065 555-4A 70 5643 555-9A364 1588 555-4 70 8258 555-9364 1590 550-4A 70 8424 550-9A364 2402 550-4 70 12489 550-9283 614 552-5A 45 3883 552-10A283 817 552-5 45 5138 552-10283 1372 555-5A 45 8672 555-10A283 2043 555-5 45 12846 555-10283 2048 550-5A 45 12943 550-10A283 3089 550-5 45 19427 550-10


Notes:

Appendix ATable A.A Minimum Dynamic Brake Resistance

Drive NormalDuty Rating

Regen DC Bus Voltage (Vd )

Rated Continuous Power, Internal Resistors (Pdb)

Minimum Ohms (±10%),External Resistors

PowerFlex 70 PowerFlex 700 PowerFlex Product Nearest (1) Standard ResistorFrame Watts Frame Watts 4 70 700

240V, 0.5 HP

395

A 48 (2) (2) (3) 33 40 117

240V, 1 HP A 48 (2) (2) 60 33 40 60

240V, 2 HP B 28 (2) (2) 60 33 39 60

240V, 3 HP B 28 (2) (2) 48 33 39 48

240V, 5 HP C 40 (2) (2) 32 30 32 32

240V, 7.5 HP D 36 (2) (2) (3) 23 25 25

240V, 10 HP D 36 (2) (2) (3) 23 23 23

240V, 15 HP (3) (3) (2) (2) (3) (3) 15 15

240V, 20 HP (3) (3) (2) (2) (3) (3) 14 14

400V, 0.37 kW480V, 0.5 HP

658 for 400V Drive

790 for 480V Drive

A 48 0 50 (3) 68 69 117

400V, 0.75 kW480V, 1 HP A 48 0 50 121 68 71 117

400V, 1.5 kW480V, 2 HP A 48 0 50 121 68 69 117

400V, 2.2 kW480V, 3 HP B 28 0 50 97 68 69 117

400V, 4 kW480V, 5 HP B 28 0 50 97 68 69 97

400V, 5.5 kW480V, 7.5 HP C 40 0 50 (3) 74 70 77

400V, 7.5 kW480V, 10 HP C 40 1 50 (3) 74 72 77

400V, 11 kW480V, 15 HP D 36 1 50 (3) 44 45 45

400V, 15 kW480V, 20 HP D 36 2 50 (3) 31 44 45

400V, 18.5 kW480V, 25 HP – (2) 2 50 (3) (3) 31 32

400V, 22 kW480V, 30 HP – (2) 3 NA (3) (3) 31 32

400V, 30 kW480V, 40 HP – (2) 3 NA (3) (3) 26 27

400V, 37 kW480V, 50 HP – (2) 3 NA (3) (3) 27 27

400V, 45 kW480V, 60 HP – (2) 4 NA (3) (3) 20 20

(1) Chosen from Table 4.A, 4.B, or 4.C.(2) Not available at time of printing.(3) Rating not available.

A-2

400V, 55 kW480V, 75 HP

658 for 400V Drive

790 for 480V Drive

– (2) 5 NA (3) (3) 10.4 10.4

400V, 75 kW480V, 100 HP – (2) 5 NA (3) (3) 10.1 10.4

400V, 90 kW480V, 125 HP – (2) 6 NA (3) (3) 5.4 5.4

400V, 110 kW480V, 150 HP – (2) 6 NA (3) (3) 4.8 4.8

600V, 0.5 HP

987

A (2) (2) (2) (3) 117 (2) 117

600V, 1 HP A (2) (2) (2) (3) 117 (2) 117

600V, 2 HP A (2) (2) (2) (3) 117 (2) 117

600V, 3 HP B (2) (2) (2) (3) 117 (2) 117

600V, 5 HP B (2) (2) (2) (3) 80 (2) 80

600V, 7.5 HP C (2) (2) (2) (3) 80 (2) 80

600V, 10 HP C (2) (2) (2) (3) 80 (2) 80

600V, 15 HP D (2) (2) (2) (3) 48 (2) 48

600V, 20 HP D (2) (2) (2) (3) 48 (2) 48

(1) Chosen from Table 4.A, 4.B, or 4.C.(2) Not available at time of printing.(3) Rating not available.

Drive NormalDuty Rating

Regen DC Bus Voltage (Vd )

Rated Continuous Power, Internal Resistors (Pdb)

Minimum Ohms (±10%),External Resistors

PowerFlex 70 PowerFlex 700 PowerFlex Product Nearest (1) Standard ResistorFrame Watts Frame Watts 4 70 700

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U.S. Allen-Bradley Drives Technical SupportTel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Publication PFLEX-AT001C-EN-P – September 2002Supersedes June 2002 Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in USA.

Index

Numerics20-COMM-C 2-31

20-COMM-D 2-47

20-COMM-R 2-118

AAC Supply Source Considerations 2-2

Accel Time 2-1

Agency Certification 1-2

Alarms 2-3

Analog Inputs 2-4

Auto Restart 2-10

Auto/Manual 2-9

AutotuneDirection Test 2-12Feedback Configuration 2-12Inertia Test 2-14Logic Command 2-15Motor Control 2-12Motor Data 2-12Motor Tests 2-14Power Circuit Test 2-12Start-Up Menu 2-11Troubleshooting 2-15

BBus Regulation 2-16

Bus Voltage 2-45

CCable

Control 2-21Motor Lengths 2-22Power 2-24Shielded/Armored Cable 2-24Standard I/O 2-26Unshielded 2-24

Cable Trays 2-27

Carrier (PWM) Frequency 2-28

CEConformity 2-69

Circuit Breakers 2-75

Common Bus Systems 2-29

Communication 2-30

Conduit 2-27

ControlNet 2-31ControlLogix Programming 2-37Datalinks Programming 2-39Explicit Messaging 2-40Setup Information 2-31Technical Information 2-33

Copy Cat 2-41

Current Limit 2-42

DDatalinks

Configuration 2-43

DC Bus Voltage/Memory 2-45

Decel Time 2-46

Derating Guidelines 1-7

DeviceNet 2-47Technical Information 2-47

Diagnostics 2-50

Digital Inputs 2-51

Digital Outputs 2-54

Dimensions 1-10

Dimensions, Bottom View 1-13

Direction Control 2-57

Distribution Systems 2-58

DPI 2-59

Drive Overload 2-63

Drive Ratings 2-64

DriveLogix 2-62

Dynamic Braking 2-66, A-1

EEfficiency 2-67

Electronic Gearing 2-68

EMCCE Conformity 2-69Directive 2-69Instructions 2-69

EMC Directive 2-69

FFaults 2-71

Flying Start 2-72

Frame 1, 2, 3 Dimensions 1-11

Index-2

Frame 5 Dimensions 1-12

Frame Bottom View Dimensions 1-13

Friction Compensation 2-73

Function Blocks 2-74

Fuses 2-75

GGrounding, General 2-76

HHeat Dissipation 1-5

HIMMemory 2-77Operations 2-78

IInput Devices 2-79

Input Modes 2-80

Input Power Conditioning 2-81

Input/Output Ratings 1-4

JJog 2-82

LLead/Lag Filters 2-83

Limits 2-84

Links 2-85

Low Voltage Directive 2-69

MMasks 2-86

Motor Control Select 2-87

Motor Nameplate 2-88

Motor Overload 2-89

Motor Start/Stop 2-90

Mounting 2-91

Mounting Dimensions 2-91

OOutput Devices

Cable Termination 2-92Drive Output Disconnection 2-92Output Reactor 2-92

Output DisplayCurrent 2-93Frequency 2-93Power 2-93Voltage 2-93

Overspeed Limit 2-94

Owners 2-95

Index-3

PParameter Access Level 2-97

ParametersAccel Time 2-1Alarm Status 1 2-3Anlg In1 Data 2-5Anlg In1 Offset 2-5Anlg In1 Scale 2-5Anlg In1 Volts 2-5Anlg ln1 Data 2-5Anlg ln1 Filt Gain 2-5Anlg ln1 Offset 2-5Anlg ln1 Scale 2-5Anlg ln1Filt BW 2-5Anlg Out1 Integer 2-8Anlg Out1 Real 2-8Anlg Out1 Scale 2-8Aux Posit Ref 2-101Brake PulseWatts 2-18Brake TP Data 2-20Brake TP Sel 2-19Bus Reg/Brake Ref 2-17Bus/Brake Cnfg 2-17Control Options 2-6Data In A1 Int 2-43, 2-106Data In A1 Real 2-43Data In A2 Int 2-106Data In B1 Int 2-106Data Out A1 Int 2-44Decel Time 2-46Delayed Spd Ref 2-152Dig Out 1 Bit 2-55Dig Out 1 Data 2-55DigIn 1 Bit 2-52DigIn 1 Data 2-52DigIn 1 Sel 2-52DigIn 1 User Data 2-52Direction Mask 2-86Direction Owner 2-95Dlink OutDataTyp 2-122Dlink OutDataType 2-36, 2-43DPI Ref Select 2-37, 2-48Drive Logic Rslt 2-33, 2-47Encdr1 Position 2-101Encdr1 Spd Fdbk 2-102Fault Clr Owner 2-95Iq Rate Limit 2-6Jog Owner 2-95Local I/O Status 2-53Logic Cmd Word 2-5

Logic Command 2-15, 2-103, 2-106, 2-109

Logic Status 2-33, 2-55MC Diag Error 1 2-15MC Diag Error 2 2-15MC Diag Error 3 2-15MC Operate Mode 2-12, 2-15Motor NP FLA 2-88Motor NP Hz 2-88Motor NP Power 2-88Motor NP Pwr Units 2-88Motor NP RPM 2-1, 2-8, 2-46, 2-88Motor NP Volts 2-88Mtr TrqCurr Ref 2-8Output Curr Disp 2-93Output Current 2-44Posit I Gain 2-100Posit Offset 1 2-103, 2-108Posit Offset 2 2-103, 2-108Posit Ref Sel 2-101Posit Spd Output 2-106Position Command 2-107Position Control 2-43, 2-103, 2-106,

2-109Position Error 2-8Position Status 2-44PositRef EGR Div 2-102, 2-107PositRef EGR Mul 2-102, 2-107PositReg Integ 2-104PositReg P Gain 2-100, 2-104, 2-109Pt-Pt Accel Time 2-109Pt-Pt Decel Time 2-109Pt-Pt Filt BW 2-109Pt-Pt Posit Ref 2-106Pt-Pt ReRef 2-107Rated Volts 2-18Real to Int In 2-145Real to Int Out 2-145S Curve Spd Ref 2-145, 2-151SL Dir Int Rx0 2-144SL Dir Int Rx3 2-144SL Dir Int Tx0 2-144, 2-145SL Dir Int Tx3 2-144SL Dir Real Rx0 2-144, 2-155SL Dir Real Rx3 2-144SL Dir Real Tx0 2-144SL Dir Real Tx3 2-144SL Mult A In 2-145SL Mult B In 2-145SL Mult Base 2-144, 2-145SL Mult Out 2-145

Index-4

SL Mult State 2-144, 2-145SL Node Cnfg 2-143SL Rx Comm Frmt 2-143SL Rx DirectSel0 2-143, 2-145SL Rx DirectSel1 2-145SL Rx DirectSel2 2-145SL Rx DirectSel3 2-143SL Rx DirectSel4 2-145SL Tx DirectSel0 2-143SL Tx DirectSel3 2-143Spd Err Filt BW 2-5, 2-6Spd Fdbk Scale 2-35Spd Ref 1 2-5Spd Ref Bypass 2-152, 2-155Spd Ref1 Divide 2-102Spd Reg BW 2-5, 2-6Speed Ref 1 2-102Speed Ref 2 2-40, 2-49Speed Ref Sel 2-37, 2-48, 2-107Speed Trim 2 2-106Start Owner 2-95Stop Owner 2-95Strim2 Filt BW 2-104, 2-109Strim2 Filt Gain 2-104, 2-109Torque Ref 1 2-43Tx Buf Data Type 2-146Tx Dir Data Type 2-144XReg Integ HiLim 2-104XReg Integ LoLim 2-104Xreg Spd HiLim 2-104, 2-109Xreg Spd LoLim 2-104, 2-109

Permanent Magnet Motors 2-98

PET 2-99

PI Loop 2-114

Position Detect 2-110

Position Loop - FollowerInitial Tuning 2-103Logic Setup 2-103Mode Select 2-101Position Offset 2-102Position Reference Scaling 2-102Positions Loop 2-103Speed Reference Select 2-101Technical Information 2-100Tuning Tips 2-104

Position Loop - Point to PointInitial Tuning 2-109Logic Setup 2-109Mode Select and Referencing 2-106Point to Point Control 2-108

Position Offset 2-108Position Reference Scaling 2-107Setup 2-106Technical Information 2-105Tuning Tips 2-109

Position Watch 2-111

Power Loss 2-112

Preset Speeds 2-113

Process PI Loop 2-114

Process Trim 2-115

Process Trim Regulator 2-116

PWM Frequency 2-28

RReflected Wave 2-117

Remote I/O AdapterControlLogix System 2-118Datalink Programming 2-122Reference/Feedback Programming

2-120Technical Information 2-118

Reset Meters 2-127

Reset Run 2-128

RFI Filter Grounding 2-129

SScaling Blocks 2-131

S-Curve 2-130

Shear Pin Fault 2-132

Shielded Cable 2-24

Skip Frequency 2-133

SpecificationAgency Certification 1-2Control 1-2Electrical 1-2Environment 1-1Feedback 1-3Heat Dissipation 1-5Input/Output Ratings 1-4Protection 1-1

Speed Control 2-134

Speed Feedback 2-135

Speed Mode 2-134

Speed PI Regulator 2-138

Speed Reference 2-136

Speed Reference Select 2-137

Index-5

Speed Regulation 2-134

Start Inhibits 2-139

Start Permissives 2-140

Start-Up 2-141

Stop Modes 2-142

Surrounding Air Derates 1-7

SynchLinkBuffered Data 2-146Configuration 2-143Direct Data 2-144Master PowerFlex 700S Setup 2-150Slave PowerFlex 700S Setup 2-153Speed Synchronization Example 2-149Technical Information 2-143

TTest Points 2-157

Thermal Regulator 2-158

Torque Reference 2-159

Torque Select 2-160

Troubleshooting 2-161

UUnshielded Cable 2-24

User Sets 2-162

VVelocity Feedback 2-163

Velocity Feedback Control 2-165

Velocity Pl Control 2-166

Velocity Reference Control 2-164

Voltage Class 2-167

WWatts Loss 2-168

WirePower 2-24

www 1-1, 2-69, 2-76, 2-81

Index-6

www.rockwellautomation.com

Corporate HeadquartersRockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201

Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing SolutionsAmericas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444Europe: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36-BP 3A/B, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Headquarters for Dodge and Reliance Electric ProductsAmericas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433Europe: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 1774Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733

U.S. Allen-Bradley Drives Technical SupportTel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Publication PFLEX-RM002A-EN-E – October, 2002Copyright © 2002 Rockwell Automation, Inc. All rights reserved. Printed in USA.

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