Rockwell Automation 20L-LL User Manual

PowerFlex 700L Active Converter Power Module

USER MANUAL

Firmware Version 3.xxx

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at

literature) 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 Rockwell Automation, Inc. 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, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. 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 Rockwell Automation, Inc. is prohibited.

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

http://www.rockwellautomation.com/

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous

environment, which may lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and

understanding of the product.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequences.

Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.

Allen-Bradley, PowerFlex, DriveExplorer, DriveExecutive, and DPI are either registered trademarks or trademarks of Rockwell Automation, Inc.

PowerFlex 700L Active Converter Power Module User Manual

Summary of Changes

The information below summarizes the changes resulting from the firmware v3.001 upgrade to this manual since its last release (June, 2006):

Description of New or Updated Information Page(s)

To all pages, added a new footer containing:

• Publication description (1st line).

• Publication number hyperlink underlined in blue (2nd line) linking to the date of the

publication on the back cover.

The back cover publication date line hyperlinks to the newest version of the publication on Rockwell Automation’s Literature Library web site.

Added new information about the Active Converter operating as a Coupled unit (DPI SLAVE) or as a Stand Alone unit (DPI MASTER).

Changed the following for Parameter 051 - [Option Select]:

• Bit 6 changed from “Reserved” to “VC Inverter.”

• Bit 7 changed from “Reserved” to “Prechg Cntrl.”

• The default changed from “xxxx xxxx xx00 0001” to “xxxx xxxx 0000 0001.”

Added new Parameter 105 - [Regen I Lmt]. 3-9 Changed Parameter 153 - [CML Bandwidth] maximum value from “3000 Rad/sec” to

“4000 Rad/sec.” Changed the description for Parameter 157 - [PF Bandwidth] to include that it should be

used only when unbalanced voltage compensation is enabled in Parameter 051 [Option Select].

Changed Parameter 162 - [Capacitance] maximum value from “32767 µF” to “65535 µF.” 3-12 Added new Parameter 170 - [Bus Capacitance]. 3-12 Added new Bit 11 (High DC Link) to Parameter 214 - [Start Inhibit]. 3-14 Changed Parameter 238 - [Fault Config] default from “xxxx xxx1 1110 1100” to

“xxxx xxx1 0110 1100.” Added two new parameter groups which are only displayed and available in the

Communication File when the Converter is operated as a Stand Alone unit:

• Masks and Owners Group

– Parameter 340 - [Logic Mask] – Parameter 341 - [Start Mask] – Parameter 342 - [Fault Clr Mask] – Parameter 343 - [Stop Owner] – Parameter 344 - [Start Owner] – Parameter 345 - [Fault Clr Owner]

• Security Group

– Parameter 346 - [Port Mask Act] – Parameter 347 - [Write Mask Cfg] – Parameter 348 - [Write Mask Act] – Parameter 349 - [Logic Mask Act]

Added the following new fault codes:

• 70 – FiltCap Contactr

• 71 – Port 1 Adapter

• 72 – Port 2 Adapter

• 73 – Port 3 Adapter

• 74 – Port 4 Adapter

• 75 – Port 5 Adapter

• 76 – Port 6 Adapter

• 81 – Port 1 DPI Loss

• 82 – Port 2 DPI Loss

• 83 – Port 3 DPI Loss

• 84 – Port 4 DPI Loss

• 85 – Port 5 DPI Loss

• 86 – Port 6 DPI Loss

Throughout Manual

1-6

3-6

3-11

3-15

3-18

4-3

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soc-ii Summary of Changes

PowerFlex 700L Active Converter Power Module User Manual

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Preface Overview

Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

What Is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

LPM20 Liquid-Cooled AC Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

PowerFlex 700L Liquid-Cooled AC Drive Information . . . . . . . . . . . . . . . . . . . . . . . P-1

PowerFlex 700 Vector Control Information (standard) . . . . . . . . . . . . . . . . . . . . . . . . P-1

PowerFlex 700S Phase II Control Information (optional) . . . . . . . . . . . . . . . . . . . . . . P-2

Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Allen-Bradley Drives Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Chapter 1 Installation/Wiring

Removing the Active Converter Power Module Covers . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Removing the Active Converter Control Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Frame 2 and 3A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Frame 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Wiring the Active Converter Control Cassette I/O Terminals . . . . . . . . . . . . . . . . . . . . . 1-4

I/O Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Using the Active Converter as a Coupled Unit vs. Standalone Unit. . . . . . . . . . . . . . . 1-6

Setting the DPI MASTER/SLAVE Switch (SW1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Connecting an Active Converter Power Module to an Inverter Power Module . . . . . . . . 1-8

Frame 2 and 3A Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Frame 3B Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2 Start Up

Establishing Communication as a Coupled Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Accessing Active Converter Power Module Parameters. . . . . . . . . . . . . . . . . . . . . . . . 2-1

Verifying Feedback Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Exchanging Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

CIP Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Establishing Communication as a Stand Alone Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Accessing Active Converter Power Module Parameters. . . . . . . . . . . . . . . . . . . . . . . . 2-8

Verifying Feedback Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Converter Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Run On Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Run On PwrUp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Manual Cntrl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Start Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Sequencing Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Current Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Line Voltage Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Frequency Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Voltage Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

PWM Carrier Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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ii Table of Contents

Converter Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Converter Faults as a Coupled Unit (DPI SLAVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Displaying the Fault Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Resetting Converter Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Chapter 3 Programming and Parameters

About Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

How Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

File-Group-Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Numbered List View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Command File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Limit Config File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Inputs & Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Parameter Cross Reference – by Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Chapter 4 Troubleshooting

Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Manually Clearing Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fault Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Clearing Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Index

PowerFlex 700L Active Converter Power Module User Manual

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Preface

Overview

The purpose of this manual is to provide you with the basic information needed to wire and operate the PowerFlex 700 Active Converter Power Module.

For information on ... See page ...

Who Should Use this Manual? What Is Not in this Manual P-1 Reference Materials P-2 Manual Conventions P-2 General Precautions P-3

P-1

Who Should Use this Manual?

What Is Not in this Manual

This manual is intended for qualified personnel. You must be able to wire and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.

This manual is designed to provide only basic active converter I/O wiring, start-up, programming, and other related information.

LPM20 Liquid-Cooled AC Drive Installation

For information on installing LPM20 Liquid-Cooled AC drives, please refer to LPM20 Liquid-Cooled Adjustable Frequency AC Drive Installation Manual — (Publication No. 20N-IN001…).

PowerFlex 700L Liquid-Cooled AC Drive Information

For information on installing PowerFlex 700L Liquid-Cooled AC drives, please refer to PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual — (Publication No. 20L-UM001…).

PowerFlex 700 Vector Control Information (standard)

For PowerFlex Liquid-Cooled AC drives equipped with standard PowerFlex 700 Vector Control, please refer to the PowerFlex 700 Adjustable Frequency AC Drive User Manual — Series B (Publication No. 20B-UM002…) which provides I/O wiring, start-up, programming, and vector control encoder information.

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P-2 Overview

PowerFlex 700S Phase II Control Information (optional)

For PowerFlex Liquid-Cooled AC drives equipped with optional PowerFlex 700S Phase II Control, please refer to the PowerFlex 700S High Performance AC Drive — Phase II Control User Manual (Publication No. 20D-UM006…) which provides I/O wiring, start-up, programming, and other related information.

Reference Materials

Manual Conventions

Publications

Publications can be obtained online at

http://www.rockwellautomation.com/literature

The following manuals are recommended for general drive information:

Title Publication

Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001… Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001… Safety Guidelines for the Application, Installation, and Maintenance of Solid State

Control A Global Reference Guide for Reading Schematic Diagrams 0100-2.10 Guarding Against Electrostatic Damage 8000-4.5.2

Allen-Bradley Drives Technical Support

Online: www.ab.com/support/abdrives

• In this manual we refer also to the PowerFlex 700 Active Converter

Power Module as Active Converter, converter or PowerFlex 700AC.

• To help differentiate parameter names and LCD display text from other

text, the following conventions will be used:

SGI-1.1

PowerFlex 700L Active Converter Power Module User Manual

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– Parameter Names will appear in [brackets].

For example: [DC Bus Voltage].

– Display Text will appear in “quotes.” For example: “Enabled.”

• The following words are used throughout the manual to describe an action:

Word Me aning

Can Possible, able to do something Cannot Not possible, not able to do something May Permitted, allowed Must Unavoidable, you must do this Shall Required and necessary Should Recommended Should Not Not recommended

Overview P-3

General Precautions

ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are

required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, refer to Allen-Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring

or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.

ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or

implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/ or equipment damage.

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing

any work on the drive. After removing power to the drive, wait 5 minutes for the bus capacitors to discharge. Refer to the:

• LPM20 Liquid-Cooled Adjustable Frequency AC Drive

Installation Manual (Publication No. 20N-IN001…),

Figure 4.2, and measure the DC bus voltage at the locations shown. The voltage must be zero.

• PowerFlex 700L Liquid-Cooled Adjustable Frequency AC

Drive User Manual (Publication No. 20L-UM001…), and

measure the DC bus voltage at the DC POSITIVE and DC NEGATIVE test point sockets located on the front of the power module. The voltage must be zero.

ATTENTION: Risk of injury or equipment damage exists. DPI host products must not be directly connected together via 1202

cables. Unpredictable behavior can result if two or more devices are connected in this manner.

PowerFlex 700L Active Converter Power Module User Manual

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P-4 Overview

Notes:

PowerFlex 700L Active Converter Power Module User Manual

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Chapter 1

Installation/Wiring

This chapter provides information on installing and wiring the PowerFlex 700 Active Converter Power Module.

For information on… See page…

Removing the Active Converter Power Module Covers Removing the Active Converter Control Cassette 1-2 Wiring the Active Converter Control Cassette I/O Terminals 1-4

Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed. All items must be read and understood before the actual installation begins.

1-2

ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume

responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

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1-2 Installation/Wiring

Removing the Active Converter Power Module Covers

All converter covers, regardless of drive frame size, are similarly removed by unfastening the screws. A Frame 3B converter is shown as an example.

PORT MOD NET A NET B

(4 Screws)

PowerFlex 700L

Liquid-Cooled AC Drive

Frame 3B Converter shown

Removing the Active Converter Control Cassette

Regenerative PowerFlex 700L Liquid-Cooled AC drives use an Active Converter Power Module equipped with a converter control cassette.

Frame 2 and 3A Drives

PowerFlex 700L Liquid-Cooled Frame 2 and 3A drives combine the Active Converter and Inverter into a single Power Module. Figure 1.1 location and removal of the Active Converter control cassette to access its terminal blocks for control wiring. (The Inverter control cassette is located just above the Active Converter control cassette.)

shows the

PowerFlex 700L Active Converter Power Module User Manual

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Installation/Wiring 1-3

Figure 1.1 Removing the Frame 2 and 3A Active Converter Control Cassette

Synchronization Cable

(For use with 700S Phase II Control only)

Internal DPI Cable

Synchronization Cable

(For use with 700 Vector Control only)

Frame 3B Drives

Pin 1

40-Pin Ribbon Cable

SHLD

Communications Adapter Option

Detail

Figure 1.2 shows the location and removal of the Active Converter control

cassette to access its terminal blocks for control wiring. Frame 3B drives have separate Converter Power Modules and Inverter Power Modules.

Figure 1.2 Removing the Frame 3B Active Converter Control Cassette

Synchronization Cable

(For use with coupled Inverter Power

Modules with 700S Phase II Control only)

Internal DPI Cable

Synchronization Cable

(For use with coupled Inverter Power

Modules with 700 Vector Control only)

40-Pin Ribbon Cable

Pin 1

Detail

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1-4 Installation/Wiring

Wiring the Active Converter Control Cassette I/O Terminals

All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with drive operation. Use grommets, when hubs are not provided, to guard against wire chafing.

ATTENTION: Do not route signal and control wiring with

Important points to remember about I/O wiring:

• Use Copper wire only. Wire gauge requirements and recommendations

are based on 75 degrees C. Do not reduce wire gauge when using higher temperature wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Control and signal wires should be separated from power wires by at

least 0.3 meters (1 foot).

Important:I/O terminals labeled “(–)” or “Common” are

power wiring in the same conduit. This can cause interference with drive operation. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

not referenced to earth ground and are designed to greatly reduce common mode interference. Grounding these terminals can cause signal noise.

Terminal blocks P1 and P2, shown in Figure 1.1 connection points for all inputs, outputs, and power connections to the Active Converter control cassette.

1. Remove the terminal block plug from the socket, and make connections.

2. Reinstall the terminal block plug when wiring is complete. The terminal

blocks have keys, which make it difficult to insert a terminal block plug into the wrong socket.

and Figure 1.3, contain

PowerFlex 700L Active Converter Power Module User Manual

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J1 40-Pin

Ribbon Cable

Header

Installation/Wiring 1-5

Figure 1.3 Active Converter Control Cassette I/O Terminal, Cable Connection, and

DPI SLAVE/MASTER Switch SW1 Locations

Active Converter Control PCB Assembly

J2 30-Pin

Ribbon Cable

Header

J9 Synchronization

Cable Header

(700S Ph. II Control only)

J4 Internal DPI

Cable Header

P1 I/O Terminals

(see Table 1.B for

terminal descriptions)

P1-7 and P1-8

Synchronization

Cable Connection

(700 Vector Control only)

P1-13 and P1-14

Factory-Installed Gate Kill Jumper

SW1

DPI SLAVE = OFF

DPI MASTER = ON

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

7 6 5 4 3 2 1

SW1

P2 I/O Terminals

(see Table 1.C for

terminal descriptions)

I/O Terminal Blocks

Table 1.A Active Converter Control Board I/O Terminal Block Specifications

Name Description

I/O Blocks Signal and power

(1)

Voltage Feedback Resistor PCB Assembly

Wire Size Range

Maximum Minimum Maximum Recommended

connections

Maximum/minimum that the terminal block will accept - these are not recommendations.

1.5 mm (16 AWG)

(1)

0.14 mm (28 AWG)

PowerFlex 700L Active Converter Power Module User Manual

0.25 N-m (2.2 lb.-in.)

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Torque

0.22 N-m (1.9 lb.-in.)

1-6 Installation/Wiring

Table 1.B Active Converter Control PCB Assembly P1 Terminal Descriptions

Pin Description

1Comm Out + 2Comm Out 3 SOC Out + 4 SOC Out 5 Comm In + 6 Comm In 7 SOC In + 8 SOC In 9Aux Out N.O. 10 Aux Out Common 11 Analog In Signal 12 Analog In Common 13 Gate Enable 14 24 Vdc 15 Aux Input

Table 1.C Voltage Feedback Resistor PCB Assembly P2 Terminal Descriptions

Pin Description

7L3 4L2 1L1

Specific pins on P1 and P2 terminals require control wiring connections to the Input Filter Bay. For wiring information, please refer to the PowerF lex

700L Liquid-Cooled Adjustable Frequency AC Drive User Manual

(Publication No. 20L-UM001…).

Using the Active Converter as a Coupled Unit vs. Standalone Unit

Frame 3B converter power structures may be ordered as a unit Coupled to an inverter (DPI SLAVE), or as a Stand Alone unit (DPI MASTER). Frame 2 and Frame 3A power structures are always wired for the converter to be a Coupled unit.

Coupled

Figure 1.4

(DPI SLAVE). In this configuration, the Converter is connected to a PowerFlex 700L Inverter through DPI Port 6. When configured for "Run On Start," the Converter is able to start and stop automatically as the Inverter is started and stopped.

shows the Active Converter wired to operate as a Coupled unit

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Installation/Wiring 1-7

Figure 1.4 Active Converter Operating as a Coupled Unit (DPI SLAVE)

Frame 3A with Converter as a

Coupled Unit (DPI SLAVE)

I n

HIM HIM v e r t e r

o n v e r t e r

1203-USB or 1203-SSS

Serial Converter

Personal

Computer

Stand Alone

Figure 1.5

unit (DPI MASTER). In this configuration, the Converter may have a HIM or any PowerFlex 7-Class network communication adapter (20-COMM-x) connected. This may be preferred when the converter is to supply the DC bus for a set of common bus inverters. When configured for "Run On Start," the precharge bypass contactor may be configured to close when the power is turned on and the DC Bus voltage is stable (see Parameter 51 - [Option Select]). The Converter starts and stops with commands from the HIM, the 1203-USB or 1203-SSS serial converter, or a 20-COMM-x network communication adapter.

Frame 3B with Converter as a

Coupled Unit (DPI SLAVE)

C o n v e

r t

I n v e r t e r

1203-USB or 1203-SSS

Serial Converter

Personal

Computer

shows the Active Converter wired to operate as a Stand Alone

Figure 1.5 Active Converter Operating as a Stand Alone Unit (DPI MASTER)

Frame 3B with Converter as a

Stand Alone Unit (DPI MASTER)

C o

HIM

n v e

r t

196755-C01

193136

20-COMM-x

181046-C01

HIM

r t

1203-USB or 1203-SSS

Serial Converter

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Computer

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1-8 Installation/Wiring

The Frame 3B Active Converter power module is ordered as a Stand Alone unit (DPI SLAVE) by specifying equipment type P in the catalog number (refer to the catalog number explanation in the PowerFlex 700L User Manual).

The Stand Alone (DPI SLAVE) Active Converter is supported with Active Converter firmware revision 3.001 (or higher).

To operate the Frame 3B Active Converter as a Stand Alone unit (DPI SLAVE) the DPI MASTER/SLAVE switch (SW1) on the Active Converter control board must be properly set. Refer to Setting the DPI MASTER/

SLAVE Switch (SW1) below for details.

Setting the DPI MASTER/SLAVE Switch (SW1)

Active Converters with version 2.006 (or lower) firmware are always operated as a peripheral on DPI port 6. In this case, switch SW1 on the Active Converter control PCB assembly (Figure 1.3 SLAVE). Do not use the ON setting. For Active Converters with version

3.001 (or higher) firmware, switch SW1 is used to select between converter operation as a Coupled unit (DPI SLAVE position) or as a Stand Alone unit (DPI MASTER position).

) is set to OFF (DPI

Connecting an Active Converter Power Module to an Inverter Power Module

Frame 2 and 3A Drives

Coupling a Frame 2 or 3A Power Module is achieved by using two cables: a DPI cable and a control synchronization cable. These cables are factory installed.

Frame 3B Drives

Coupling a Frame 3B Active Converter Power Module to a Frame 3B Inverter Power Module is achieved by using two cables: a DPI cable and a control synchronization cable. For the Complete Drive equipment type, these cables are factory installed. When Power Modules are purchased separately, these cables are user installed. For information regarding these cables and their installation, please refer to the PowerFlex 700L Liquid-Cooled Adjustable Frequency AC Drive User Manual (Publication No. 20L-UM001…), Chapter 3 in the “Synchronization Connections for Frame B” section.

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Chapter 2

Start Up

The start-up procedure built into the HIM addresses only the start up of the inverter. This chapter describes how to start up the PowerFlex 700 Active Converter Power Module.

For information on… See page…

Establishing Communication as a Coupled Unit Establishing Communication as a Stand Alone Unit 2-8 Converter Sequencing 2-12 Control Setup 2-14 Converter Faults 2-17

2-1

Establishing Communication as a Coupled Unit

When the Converter is set to operate as a Coupled unit (DPI SLAVE), the first step after turning on power is to verify that you are able to communicate with the unit and that it properly displays selected data.

Data is exchanged between the Inverter Power Module and Active Converter Power Module to pass control and status information.

An example is given for how to communicate with the Active Converter Power Module using a CIP message from a ControlLogix controller.

Accessing Active Converter Power Module Parameters

The Active Converter operates as a DPI peripheral on port 6. This section describes how to access parameters in the Active Converter.

Using the HIM

1. On power up, the HIM displays the main menu and communicates with

the Inverter.

F-> Stopped Auto

0.0 RPM

Main Menu:

Diagnostics

Parameter

Device Select

2. As you scroll down to “Device Select,” the HIM shows the following

indication. With “Device Select” highlighted, press the Enter key.

F-> Stopped Auto

0.0 RPM

Main Menu:

Parameter

Device Select

Memory Storage

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2-2 Start Up

3. The HIM displays that it is currently communicating with the Inverter on

DPI Port 0.

F-> Stopped Auto

0.0 RPM

Device: Port 0

PowerFlex 700S 2

PowerFlex 700 AC

4. Press the Down arrow to scroll to “PowerFlex 700 AC.”

F-> Stopped Auto

0.0 RPM

Device: Port 6 PowerFlex 700S 2

PowerFlex 700 AC

5. With “PowerFlex 700 AC” highlighted as shown in Step 4, press the

Enter key to start communicating with the Active Converter on DPI Port

Port 6 Device PowerFlex 700AC Main Menu:

Diagnostics

Parameter

Device Select

– To examine the fault queue in the Active Converter, press the Up

Arrow to scroll to “Diagnostics” and press the Enter key.

– To begin examining parameters (with “Parameters” highlighted),

press the Enter key.

– To resume communication with the Inverter, press the Down Arrow to

scroll to “Device Select” and press the Enter key.

6. After accessing the Parameter menu, the display shows the File menu.

Press the Up or Down Arrow to select the desired file and press the Enter key.

Port 6 Device PowerFlex 700AC

FGP: File

Monitor

Command Limit Config

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Start Up 2-3

7. The display then shows the groups of parameters in the selected file.

Press the Up or Down Arrow to select the desired group and press the Enter key.

Port 6 Device PowerFlex 700AC FGP: Group

Current

Vol ta ge Power & Ti me

8. The display then shows the parameters in the selected group. Press the

Up or Down Arrow to select the desired parameter and press the Enter key.

Port 6 Device PowerFlex 700AC FGP: Parameter

Rated Amps

Input Current R Input Current S

9. The display then shows the value of the selected parameter and allows

for entry of a new value for parameters that are read/write.

Port 6 Device PowerFlex 700AC FGP: Par 1

Rated Amps

705.0 Amps

[Alt] [View] - > Limits

Using DriveExplorer

When using DriveExplorer, the window shows the files and groups for the Active Converter (left pane) and the parameters for the selected group (right pane). Double-click a parameter in the right pane to edit it

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2-4 Start Up

Using DriveExecutive

When using DriveExecutive, the Active Converter parameters are displayed in a linear list. Uploading reads parameter values from all DPI peripherals but downloading parameters only write to the Inverter. To download parameter values to the Active Converter, you must first select the Converter.

Verifying Feedback Parameters

Using the HIM, DriveExplorer or DriveExecutive, verify that reasonable values are displayed for the following parameters in the Active Converter Power Module:

• Line to Line Voltage – Verify converter parameters 11 - [Input Voltage

RS], 12 - [Input Voltage ST], and 13 - [Input Voltage TR] display a reasonable Line to Line RMS Voltage. Verify the voltage imbalance displayed in parameter 16 - [V Imbalance] does not exceed 5.0%.

• DC Link Voltage – Verify converter parameter 14 - [DcLink Voltage]

displays a reasonable DC Link Voltage.

• AC Line Frequency – Verify converter parameter 40 - [Line Frequency]

displays a reasonable AC Line Frequency.

• Ambient Temperatures – Verify converter parameter 30 - [Ambient

Temp] displays a reasonable ambient temperature. Verify parameter 32 [IGBT Junction Temp] displays the temperature of the liquid being pumped through the coldplate.

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