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1. EMC EN 61800 3 EN 50081 1 EN 50082 2 Digital Control Inputs Input Current 6mA Analog Control Inputs SRC Source Mode SNK Sink Mode 4 20mA Analog 250 ohm input impedance 18 24V ON 0 6V ON 0 10V DC Analog 100k ohm input impedance 0 6V OFF 18 24V OFF External Pot 1 10k ohms 2 Watt minimum Control Output Programmable Output form C relay Resistive Rating 3 0A at 30V DC 3 0A at 125V AC 3 0A at 240V AC Inductive Rating 0 5A at 30V DC 0 5A at 125V AC 0 5A at 240V AC Fuses and Circuit Breakers Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Other Protective Devices 140M xxx A B Bulletin 140 Manual Motor Starter or HMCP circuit breaker or equivalent Protective Features Motor Protection Ft overload protection 150 for 60 Secs 200 for 3 Secs Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fau Over Voltage 100 120V AC Input Trip occurs at 405V DC bus voltage equivalent to 150V AC incoming line 200 240V AC Input Trip occurs at 405V DC bus voltage equivalent to 290V AC incoming line 380 480V AC Input Trip occurs at 810V DC bus voltage equivalent to 575V AC incoming line Under Voltage 100 120V AC Input Trip occurs at 210V DC bus voltage equivalent to 75V AC incoming line 200 240V AC Input Trip occurs at 210V DC bus voltage equivalent to 150V AC incoming line 380 480V
2. Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation BrihlstraBe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication 22A UM001C EN E June 2002 Supersedes February 2002 Copyright 2002 Rockwell Automation Inc All rights reserved
3. CD Allen Bradley Power Adjustable Frequency AC Drive FRN 2 xx User Manual Automation 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 Awww 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 i
4. equals 30 0 Hz Returns the same data as Reading 03 Parameter d001 Output Freq 8451 RS485 DSI Protocol C 5 Reading 03 Drive Error Codes The PowerFlex 4 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 Drive Error Codes Logic Status Address Decimal Value Decimal Description 0 No Fault 2 Auxiliary Input 3 Power Loss 4 Undervoltage 5 Overvoltage 6 Motor Stalled 7 Motor Overload 8 Heatsink Overtemperature 12 HW Overcurrent 300 13 Ground Fault 29 Analog Input Loss 33 Auto Restart Tries 8449 38 Phase U to Ground Short 39 Phase V to Ground Short 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 80 AutoTune Fail 81 Communication Loss 100 Parameter Checksum Error 122 I O Board Fail Reading 03 and Writing 06 Drive Parameters To access drive parameters the Modbus register address equals the parameter number For example a decimal 1 is used to address Parameter d001 Output Freq and decimal 39 is used to address Parameter P039 Accel Time 1 Additional Information Refer to http Awww ab com drives for additional information C 6 RS485 DSI Protocol Notes A AC Supply Ground 1 4 Source 1 3 Ungrounded 1 3 Advanced Program Group Paramete
5. 0 1 600 0 Secs Display 0 1 Secs Maximum Freq 2 Xe 6 Speed G 6 lt a 0 B Accel Time Time I Decel Time 0 3 16 Programming and Parameters Advanced Program Group continued A069 Internal Freq Related Parameter s P038 Provides the frequency command to the drive when P038 Speed Reference is set to 1 Internal Freq When enabled this parameter will change the frequency command in real time using the integral keypad Up Arrow or Down Arrow when in program mode Important Once the desired command frequency is reached the Enter key must be pressed to store this value to EEPROM memory If the ESC key is used before the Enter key the frequency will return to the original value following the normal accel decel curve Values Default 60 0 Hz Min Max 0 0 240 0 Hz Display 0 1 Hz A070 Preset Freq ol Related Parameter s P038 A051 A052 A071 Preset Freq 1 A072 Preset Freq 2 A073 Preset Freq 3 Provides a fixed frequency command value when A051 A052 Digital Inx Sel is set to 4 Preset Frequencies 1 To activate A070 Preset Freq 0 set P038 Speed Reference to option 4 Preset Freq 0 3 Values A070 Default 0 0 Hz A071 Default 5 0 Hz A072 Default 10 0 Hz A073 Default 20 0 Hz Min Max 0 0 240 0 Hz Display 0 1 Hz Input State of Digital In 1 Input State of Digital In 2 I O Terminal 05 I O Terminal 06 Frequency
6. 3150 MCM SLC Modbus scanner and 8193 for others e g Panel Views RS485 DSI Protocol C 3 Writing 06 Logic Command Data The PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8192 Logic Command P036 Start Source must be set to 5 RS485 DSI Port in order to accept the commands Logic Command Address Decimal Bit s Description 0 1 Stop 0 Not Stop 1 1 Start 0 Not Start 2 1 Jog 0 No Jog 3 1 Clear Faults 0 Not Clear Faults 00 No Command 01 Forward Command 5 4 10 Reverse Command 11 Change Direction Toggle 6 Not Used 7 Not Used 00 No Command 98 01 Accel Rate 1 Enable 10 Accel Rate 2 Enable 8192 11 Hold Accel Rate Selected 00 No Command 01 Decel Rate 1 Enable 10 Decel Rate 2 Enable 11 Hold Decel Rate Selected 000 No Command 001 Freq Source P036 Start Source 010 Freq Source A069 Internal Freq 011 Freq Source Comms Addr 8193 11 10 14 13 12 100 A070 Preset Freq 0 101 A071 Preset Freq 1 110 A072 Preset Freq 2 111 A073 Preset Freq 3 15 Not Used Writing 06 Reference The Speed Reference to a PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8193 Reference P038 Speed Reference must be set to 5 RS485 DSI
7. 89 336 EEC e EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes e If the plastic top panel is removed or the optional conduit box is not installed 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 e The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents e Use of line filters in ungrounded systems is not recommended e Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements Many factors can influence total machine installation compliance 1 20 Installation Wiring Essential Requirements for CE Compliance Conditions 1 3 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800 3 1 Grounding as described in Figure 1 6 Refer to page 1 5 for additional grounding recommendations 2 Output power control I O and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation 3 Allowable cable length in Table 1 I is not exceeded Table 1 1 Allowable Cable Length Filter Type EN61800 3 First Environment EN61800 3 First Environment Restricted Distribution or Unrestricted Dist
8. Port in order to accept the Speed Reference Reference Address Decimal Description A decimal value entered as xxx x where the decimal point is fixed For example a decimal 100 equals 10 0 Hz and 543 equals 54 3 Hz 8193 RS485 DSI Protocol Reading 03 Logic Status Data The PowerFlex 4 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 Logic Status Logic Status Address Decimal Bit s Description 1 Ready 0 Not Ready 1 Active Running 0 Not Active 1 Cmd Forward 0 Cmd Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating 1 Alarm 0 No Alarm 1 Faulted 0 Not Faulted 1 At Reference 0 Not At Reference 1 Reference Controlled by Comm 10 1 Operation Cmd Controlled by Comm 1 Parameters have been locked 12 Digital Input 1 Status 13 Digital Input 2 Status 14 Not Used 15 Not Used 8448 oj o ni alaj amp ovl rm o Reading 03 Feedback The Feedback Output Frequency from the PowerFlex 4 drive can be read via the network by sending Function Code 03 reads to register address 8451 Feedback Feedback Address Decimal Description A xxx x decimal value where the decimal point is fixed For example a decimal 423 equals 12 3 Hz and 300
9. amp W Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01 Amps d004 Output Voltage Related Parameter s P031 A084 A088 Output voltage present at terminals T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 Drive Rated Volts Display 1 VAC d005 DC Bus Voltage Present DC bus voltage level Values Default Read Only Min Max Based on Drive Rating Display 1 VDC 3 4 Programming and Parameters Display Group continued d006 Drive Status Related Parameter s A095 Present operating condition of the drive Jodo l 1 Condition True 0 Condition False Running Bit 0 Forward Bit 1 Accelerating Bit 2 Decelerating Bit 3 Values Default Read Only Min Max 0 1 Display 1 d007 Fault 1 Code d008 Fault 2 Code d009 Fault 3 Code A code that represents a drive fault The codes will appear in these parameters in the order they occur d007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max F2 F122 Display F1 7 32 bit parameter d010 Process Display Related Parameter s d001 A099 The output frequency scaled by A099 Process Factor Output Process _ Process Freq X Factor Display Values Default Read Only Min Max 0 00 9999 Display 0 01 1
10. 2 2 3 0 22 RF012 BS 22 RF012 BL 3 7 5 0 22 RF012 BS 22 RF012 BL 1 This filter is suitable for use with a cable length of at least 10 meters 33 feet for Class A and 1 meter for Class B environments These ratings can be ordered with internal S Type filters Refer to the Catalog Number explanation on page P 4 and Table B B for details 3 This filter is suitable for use with a cable length of at least 100 meters for Class A and 5 meters for Class B environments B 4 Accessories and Dimensions Table B F Communication Option Kits Item Description Catalog Number Serial Converter Module Provides serial communication via DF1 protocol for 22 SCM 232 RS485 to RS232 use with DriveExplorer and DriveExecutive software Includes DSI to RS232 serial converter 1 1203 SFC serial cable 1 22 RJ45CBL C20 cable 1 DriveExplorer Lite CD 1 DSI Cable 2 0 meter RJ45 to RU45 cable male to male 22 RJ45CBL C20 connectors Serial Cable 2 0 meter serial cable with a locking low profile 1203 SFC connector to connect to the serial converter and a 9 pin sub miniature D female connector to connect to a computer Null Cable Converter For use when connecting the serial converter to 1203 SNM DriveExplorer on a handheld PC DriveExplorer Software Windows based software package that provides an 9306 4EXP01ENE CD ROM Version 3 01 intuitive means for monitoring or configuring or later Allen Bradley drives
11. 25 1 5 180 265 0 75 5 0 10 140M C2E B63 100 C09 25 22A A2P3N104 0 37 0 5 2 3 180 265 1 15 6 0 10 140M C2E B63 100 C09 30 22A A4P5N104 0 75 1 0 4 5 180 265 2 25 10 0 15 140M C2E C16 100 C12 150 22A A8PON104 1 5 2 0 8 0 180 265 4 0 18 0 30 140M D8E C20 100 C23 180 200 240V AC 3 Phase Input 0 230V 3 Phase Output 22A B1P5N104 0 2 0 25 1 5 180 265 0 75 1 8 3 140M C2E B25 100 C09 25 22A B2P3N104 0 37 0 5 2 3 180 265 1 15 2 5 6 140M C2E B40 100 C09 30 22A B4P5N104 0 75 1 0 4 5 180 265 2 25 5 2 10 140M C2E C10 100 C09 50 22A B8PON104 1 5 2 0 8 0 180 265 14 0 9 5 15 140M C2E C16 100 C12 80 22A B012N104 2 2 3 0 12 0 180 265 5 5 15 5 25 140M C2E C16 100 C16 115 22A B017N104 3 7 5 0 17 5 180 265 86 21 0 35 140M F8E C25 100 C23 165 380 480V AC 3 Phase Input 0 460V 3 Phase Output 22A D1P4N104 0 37 0 5 1 4 340 528 11 4 1 8 3 140M C2E B25 100 C09 30 22A D2P3N104 0 75 1 0 2 3 340 528 2 3 3 2 6 140M C2E B40 100 C09 40 22A D4P0N104 1 5 2 0 4 0 340 528 4 0 5 7 10 140M C2E B63 100 C09 60 22A D6PON104 2 2 3 0 6 0 340 528 5 9 7 5 15 140M C2E C10 100 C09 190 22A D8P7N104 3 7 5 0 8 7 340 528 18 6 9 0 15 140M C2E C16 100 C16 145 Input Output Ratings Output Frequency 0 240 Hz Programmable Efficiency 97 5 Typical uso UL csa 22 2 Ci EMC Directive 89 336 LV EN 50178 EN 60204
12. 3 meters 1 foot Important I O terminals labeled Common are not referenced to the safety ground PE terminal and are designed to greatly reduce common mode interference source could cause component damage Verify proper configuration ATTENTION Driving the 4 20mA analog input from a voltage A prior to applying input signals 1 12 Installation Wiring Control Wire Types Table 1 G Recommended Control and Signal Wirel Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 8 mm2 18AWG twisted pair 100 300V or equiv shield with drain 60 degrees C Belden 8770 0 8 mm2 18AWG 3 conductor shielded for 140 degrees F or equiv remote pot only 1 Ifthe wires are short and contained within a cabinet which has no sensitive Circuits the use of shielded wire may not be necessary but is always recommended I O Terminal Block Table 1 H 1 0 Terminal Block Specifications Maximum Wire Size Minimum Wire Size Torque 1 3 mm 16 AWG 0 13 mm 26 AWG 0 5 0 8 N m 4 4 7 lb in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Maximum Control Wire Recommendations Do not exceed control wiring length of 30 meters 100 feet Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the I O terminal block Common must be connected to ground terminal protective
13. Control Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Analog Input Within 0 05 of set output frequency Within 0 5 of maximum output frequency Speed Regulation Open Loop with Slip Compensation 2 of base speed across a 40 1 speed range Stop Modes Multiple programmable stop modes including Ramp Coast DC Brake Ramp to Hold and S Curve Accel Decel Two independently programmable accel and decel times Each time may be programmed from 0 600 seconds in 0 1 second increments Intermittent Overload 150 Overload capability for up to 1 minute 200 Overload capability for up to 3 seconds Electronic Motor Overload Class 10 protection with speed sensitive Protection response A 4 Supplemental Drive Information Notes Appendix B Accessories and Dimensions For information on See page Product Selection B 1 Product Dimensions B 5 Product Selection Table B A Catalog Number Description 22A A 1P5 N 1 1 4 Drive Voltage Rating Rating Enclosure HIM Emission Class Comm Slot Table B B PowerFlex 4 Drives Drive Ratings Frame Input Voltage kW HP Output Current Catalog Number Size 120V 50 60 Hz 0 2 0 25 15A 22A V1P5N104 A 1 Phase 0o37 o5 23A 22A V2P3N104 A No Filter 0 75 1 0 45A 22A V4P5N104 B 240V 50 60 Hz 02 0 25 15A 22A A1P5N114 A 1 Phas
14. Level A081 Drive Type d017 DB Resistor Sel A082 Elapsed Run Time d018 S Curve A083 Testpoint Data d019 Start Boost A084 0 10V Analog Input d020 Maximum Voltage A088 4 20mA Analog Input d021 Current Limit A089 Motor OL Select A090 PWM Frequency A091 Auto Rstrt Tries A092 Auto Rstrt Delay A093 Start At PowerUp A094 Reverse Disable A095 Flying Start En A096 Compensation A097 SW Current Trip A098 Process Factor A099 Fault Clear A100 Program Lock A101 Testpoint Sel A102 Comm Data Rate A103 Comm Node Addr A104 Comm Loss Action A105 Comm Loss Time A106 Comm Format A107 0 10V Analog Input Low A110 0 10V Analog Input High A111 4 20mA Analog Input Low A112 4 20mA Analog Input High A113 Slip Compensation A114 Programming and Parameters 3 3 Display Group d001 Output Freq Related Parameter s d002 d010 P034 P035 Output frequency present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 0 P035 Maximum Freq Display 0 1 Hz d002 Commanded Freq Related Parameter s d001 P034 P035 P038 Value of the active frequency command Displays the commanded frequency even if the drive is not running Important The frequency command can come from a number of sources Refer to Start and Speed Reference Control on page 1 17 for details Values Default Read Only Min Max 0 0 P035 Maximum Freq Display 0 1 Hz d003 Output Current The output current present at T1 T2 amp T3 U V
15. Page 3 9 the network P038 Speed Reference Set to 5 RS485 DSI Port if the Speed Reference is Page 3 11 controlled from the network A103 Comm Data Rate Sets the data rate for the RS485 DSI Port All nodes Page 3 23 on the network must be set to the same data rate A104 Comm Node Addr Sets the node address for the drive on the network Page 3 23 Each device on the network requires a unique node address A105 Comm Loss Action Selects the drive s response to communication Page 3 24 problems A106 Comm Loss Time Sets the time that the drive will remain in Page 3 24 communication loss before the drive implements A105 Comm Loss Action A107 Comm Format Sets the transmission mode data bits parity and stop Page 3 24 bits for the RS485 DSI Port All nodes on the network must be set to the same setting Supported Modbus Function Codes The peripheral interface DSI used on PowerFlex 4 drives supports some of the Modbus function codes Modbus Function Code Command 03 Read Holding Registers 06 Preset Write Single Register Important Modbus devices can be 0 based registers are numbered starting at 0 or 1 based registers are numbered starting at 1 Depending on the Modbus Master used the register addresses listed on the following pages may need to be offset by 1 For example Logic Command may be register address 8192 for some master devices e g ProSoft
16. Read Only Min Max 0 1 Display 1 3 6 Programming and Parameters Display Group continued d014 Dig In Status Related Parameter s A051 A052 Status of the control terminal block digital inputs ANAT LIL LL l 1 Input Present 0 Input Not Present Digital In1 Sel I O Terminal 05 Bit 0 Digital In2 Sel I O Terminal 06 Bit 1 Reserved Bit 2 Reserved Bit 3 Values Default Read Only Min Max 0 1 Display 1 d015 Comm Status Related Parameter s A103 thru A107 Status of the communications device AAAI aa l 1 Condition True 0 Condition False Receiving Data Bit 0 Transmitting Data Bit 1 RS485 DSI Based Option Connected Bit 2 Allen Bradley devices only Communication Error Occurred Bit 3 Values Default Read Only Min Max 0 1 Display 1 d016 Control SW Ver Main Control Board software version Values Default Read Only Min Max 1 00 99 99 Display 0 01 d017 Drive Type Used by Rockwell Automation field service personnel Values Default Read Only Min Max 1001 9999 Display 1 Programming and Parameters 3 7 Display Group continued d018 Elapsed Run Time Accumulated time drive is outputting power Time is displayed in 10 hour increments Values Default Read Only Min Max 0 9999 Hrs Display 1 10Hrs d019 Testpoint Data Relat
17. active A051 or A052 will override the speed reference commanded by this parameter Refer to Start and Speed Reference Control on page 1 17 for details about how other drive settings can override the setting of this parameter Options 0 Drive Potentiometer Internal frequency command from the potentiometer on the Default integral keypad Internal Freq Internal frequency command from A069 Internal Freq 2 0 10V Input Remote External frequency command from the 0 10V analog input or Potentiometer remote potentiometer 3 4 20mA Input External frequency command from the 4 20mA analog input Preset Freq 0 3 External frequency command as defined by A070 A073 Preset Freq x when A051 and A052 Digital Inx Sel are programmed as Preset Frequencies and the digital inputs are active 5 RS485 DSI Port External frequency command from the communications port P039 Accel Time 1 Related Parameter s P038 P040 A051 A052 A067 Sets the rate of acceleration for all speed increases Maximum Freq _ KecelTime Accel Rate Values Default 10 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs Maximum Freq Speed 0 B Accel Time Time I Decel Time 0 3 12 Programming and Parameters Basic Program Group continued P040 Decel Time 1 Related Parameter s P038 P039 A051 A052 A068 Sets the rate of deceleration for all speed decreases Ma
18. 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 e IEC BS88 British Standard Parts 1 amp 2 EN60269 1 Parts 1 amp 2 type gG or equivalent should be used e UL UL Class CC T or J must be used Circuit Breakers Refer to listings in the following tables for recommended circuit breakers inverse time or instantaneous trip and 140M Self Protecting Motor Starters 1 Typical designations include but may not be limited to the following Parts 1 amp 2 AC AD BC BD CD DD ED EFS EF FF FG GF GG GH Typical designations include Type CC KTK R FNQ R Type J JKS LPJ Type T JJS JJN A 2 Supplemental Drive Information Specifications Output Ratings Input Ratings Branch Circuit Protection Power Catalog Dissipation Number Voltage 140M Motor IP20 Open kW HP Amps Range kVA Amps Fuses Protectors Contactors Watts 100 115V AC 1 Phase Input 0 230V 3 Phase Output 22A V1P5N104 0 2 0 25 1 5 90 126 0 75 6 0 10 140M C2E C10 100 C09 25 22A V2P3N104 0 37 0 5 2 3 90 126 1 15 9 0 15 140M C2E C16 100 C12 30 22A V4P5N104 0 75 1 0 4 5 90 126 2 25 18 0 130 140M D8E C20 100 C23 150 200 240V AC 1 Phase Input 0 230V 3 Phase Output 22A A1P5N104 0 2 0
19. the Run inputs do not need to be toggled after a Stop input for the drive to run again A Stop function is provided only when the Stop input is active open 4 2 Wire High Speed Important There is greater potential voltage on the output terminals when using this option e Outputs are kept in a ready to run state The drive will respond to a Start command within 10 ms e O Terminal 1 Stop coast to stop 5 RS485 DSI Port e Remote communications e O Terminal 1 Stop coast to stop Important When commanding Jog via the RS485 communications port on drives with firmware version 1 02 or earlier the Jog command will follow the commanded direction from I O Terminal 03 On firmware versions 1 03 and later the commanded direction will be provided via the RS485 communications port Important When sending a continuous start command via the RS485 communications port on drives with firmware version 1 02 or earlier a maintained stop input is required to stop the drive Once the stop input is inactive the drive will restart On firmware versions 1 03 and later once a stop input is received the start command must transition from high to low to high for the drive to start 3 10 Programming and Parameters Basic Program Group continued P037 Stop Mode Related Parameter s P036 A080 A081 A082 Active stop mode for all stop sources e g keypad run forward I O Terminal 02 run reverse I O T
20. to avoid an overcurrent or overvoltage fault from occurring 6 Above Frequency Drive exceeds the frequency Hz value set in A056 Relay Qut Level 7 Above Current Drive exceeds the current Amps value set in A056 Relay Out Level Important Value for A056 Relay Out Level must be entered in percent of drive rated output current 8 Above DC Bus Volts Drive exceeds the DC bus voltage value set in A056 Relay Out Level 9 Retries Exhausted Value set in A092 Auto Rstrt Tries is exceeded Programming and Parameters 3 15 Advanced Program Group continued 7 32 bit parameter A056 Relay Out Level Related Parameter s A055 Sets the trip point for the digital output relay if the value of A055 Relay Out Sel is 6 7 or 8 Min Max 0 240 Hz 0 180 A055 Setting 0 815 Volts Values Default 0 0 Min Max 0 0 9999 Display 0 1 1 A067 Accel Time 2 Related Parameter s P039 Sets the rate of acceleration for all speed increases except jog Maximum Freq _ KecelTime Accel Rate Values Default 20 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs Maximum Freq Q 3 6 Speed De O 0 B Accel Time le Time Decel Time 0 A068 Decel Time 2 Related Parameter s P040 Sets the rate of deceleration for all speed decreases except jog Maximum Freq _ DecelTime Decel Rate Values Default 20 0 Secs Min Max
21. undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system P 4 Overview Catalog Number Explanation 22A A 15 N 1 1 4 Die Conn Sii Code Code Version 22A PowerFlex 4 4 RS485 Code Rating 0 No Filter Code Voltage Ph 1 Integral EMI Filter V 120VAC 1 A 240V AC 1 Code Interface Module B 240V AC 3 1 Fixed Keypad D 480V AC 3 Code Enclosure N Panel Mount IP 20 NEMA Type Open Output Current 380 480V Input Output Current 100 120 Input or 200 240V Input HP Code Amps kW HP Code Amps kW HP 1P4 1 4 0 37 0 5 1P5 1 5 0 2 0 25 2P3 23 0 75 1 0 2P3 23 0 37 0 5 4PO 40 1 5 2 0 4P5 45 0 75 1 0 6PO 6 0 2 2 3 0 8PO 8 0 1 5 2 0 8P7 87 3 7 5 0 012 12 2 2 3 0 017 17 5 3 7 5 0 Chapter 1 Installation Wiring This chapter provides information on mounting and wiring the PowerFlex 4 Drive For information on See page For information on See page Opening the Cover 1 1 Fuses and Circuit Breakers 1 6 Mounting Considerations 1 2 Power Wiring 1 8 AC Supply Source Considerations 1 3 VO Wiring 1 11 Recommendations General Grounding Requirements 1 4 EMC Instructions 1 19 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 b
22. 00 Min Max 0 FFFF Display 1 Hex A103 Comm Data Rate Sets the serial port rate for the RS485 DSI port Important Power to drive must be cycled before any changes will affect drive operation Options 0 1200 1 2400 2 4800 3 9600 Default 4 19 2K 5 38 4K A104 Comm Node Addr Sets the drive node address for the RS485 DSI port if using a network connection Important Power to drive must be cycled before any changes will affect drive operation Values Default 100 Min Max 1 247 Display 1 3 24 Programming and Parameters Advanced Program Group continued A105 Comm Loss Action Related Parameter s P037 A106 Selects the drive s response to a loss of the communication connection or excessive communication errors Options 0 Fault Default Drive will fault on an F81 Comm Loss and coast to stop 1 Coast to Stop Stops drive via coast to stop 2 Stop Stops drive via P037 Stop Mode setting 3 Continue Last Speed Drive continues operating at communication commanded speed saved in RAM A106 CommLossTime Related Parameter s A105 Sets the time that the drive will remain in communication loss before implementing the option selected in A105 Comm Loss Action Values Default 5 0 Secs Min Max 0 1 60 0 Secs Display 0 1 Secs A107 Comm Format Selects the protocol RTU only data bits 8 data bits on
23. 02 Display Compensation A097 Advanced Program Contrl In Status d013 Display Control Source d012 Display Control SW Ver d016 Display Current Limit A089 Advanced Program DB Resistor Sel A082 Advanced Program DC Brake Level A081 Advanced Program DC Brake Time A080 Advanced Program DC Bus Voltage d005 Display Decel Time 1 P040 Basic Program Decel Time 2 A068 Advanced Program Dig In Status d014 Display Digital Inx Sel A051 A052 Advanced Program Drive Status d006 Display Drive Type d017 Display Elapsed Run Time d018 Display Parameter Name No Group Fault x Code d007 d009 Display Fault Clear A100 Advanced Program Flying Start En A096 Advanced Program Internal Freq A069 Advanced Program Jog Accel Decel A079 Advanced Program Jog Frequency A078 Advanced Program Maximum Freq P035 Basic Program Maximum Voltage A088 Advanced Program Minimum Freq P034 Basic Program Motor NP Hertz P032 Basic Program Motor NP Volts P031 Basic Program Motor OL Current P033 Basic Program Motor OL Select A090 Advanced Program Output Current d003 Display Output Freq d001 Display Output Voltage d004 Display Preset Freq x A070 A073 Advanced Program Process Display d010 Display Process Factor A099 Advanced Program Program Lock A101 Advanced Program PWM Frequency A091 Advanced Program Relay Out Level A056 Advanced Program Relay Out Sel A055 Advanced Program Reset To Defaults P041 Basic Program Reverse Disable A095 Advanced Program S Curve A083 Advanced
24. 113 4 20mA Analog Input High Values Default 0 0 Min Max 0 0 100 0 Display 0 1 A113 4 20mA Analog Input High Related Parameter s d021 P035 P038 Sets the analog input level that corresponds to P035 Maximum Freq if a 4 20mA input is used by P038 Speed Reference Analog inversion can be accomplished by setting this value smaller than A112 4 20mA Analog Input Low Values Default 100 0 Min Max 0 0 100 0 Display 0 1 A114 Slip Compensation Related Parameter s P033 Compensates for the inherent slip in an induction motor This frequency is added to the commanded output frequency based on motor current Values Default 2 0 Hz Min Max 0 0 10 0 Hz Display 0 1 Hz 3 26 Programming and Parameters Parameter Cross Reference by Name Parameter Name No Group 0 10V Analog Input d020 Display 0 10V Analog Input High A111 Advanced Program 0 10V Analog Input Low A110 Advanced Program 4 20mA Analog Input 021 Display 4 20mA Analog Input A113 Advanced Program High 4 20mA Analog Input A112 Advanced Program Low Accel Time 1 P039 Basic Program Accel Time 2 A067 Advanced Program Auto Rstrt Delay A093 Advanced Program Auto Rstrt Tries A092 Advanced Program Comm Data Rate A103 Advanced Program Comm Format A107 Advanced Program Comm Loss Action A105 Advanced Program Comm Loss Time A106 Advanced Program Comm Node Addr A104 Advanced Program Comm Status d015 Display Commanded Freq d0
25. 168 6 61 2 2 4 9 2 Overall height of drive with IP 30 NEMA 1 UL Type 1 option kit installed Overall height of standard IP 20 Open Type drive Table B H PowerFlex 4 Frames Ratings are in kW and HP 120V AC 1 Phase 0 2 0 25 0 2 0 25 0 37 0 5 0 37 0 5 0 37 0 5 0 75 1 0 0 75 1 0 1 5 2 0 B 0 75 1 0 1 5 2 0 2 2 3 0 3 7 5 0 Figure B 2 Optional Conduit Box Dimensions are in millimeters and inches 79 1 59 2 64 ae E se i a seer 22 2 22 2 1 57 7 068 1 60 0 88 20 7 g 0 81 25 6 pms 1 01 O ig O O f So oot ig Ty i f T d D A 75 3 o zJ G2 Ca 74 3 OEN 2 96 De i 2 93 Wad TS n E 5 a I f aA Frame A Frame B B 6 Accessories and Dimensions Figure B 3 Dynamic Brake Modules Dimensions are in millimeters and inches 72 86 4 2 84 g 340 SO 50 _ 0 31 0 55 75 y le asn 0 30 o KEE g B A A DANGER 6 86 0 27 lao BR BR D Mm 1 i Mounting
26. 25 150 175 200 of Motor NP Hertz Min Derate Max Derate a of Motor OL Curent 888 of Motor OL Curent sg 9 Tag i 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 of Motor NP Hertz of Motor NP Hertz A091 PWM Frequency Sets the carrier frequency for the PWM output waveform The chart below provides derating guidelines based on the PWM frequency setting Important Ignoring derating guidelines can cause reduced drive performance Values Default 4 0 kHz Min Max 2 0 16 0 kHz Display 0 1 kHz 100 o 96 92 _ 88 g4 80 S 7 En z 68 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Carrier Frequency kHz Programming and Parameters 3 21 Advanced Program Group continued A092 Auto Rstrt Tries Sets the maximum number of times the drive attempts to reset a fault and restart Clear a Type 1 fault and restart the drive 1 Set A092 Auto Rstrt Tries to a value other than 0 2 Set A093 Auto Rstrt Delay to a value other than 0 Clear an OverVoltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A092 Auto Rstrt Tries to a value other than 0 2 Set A093 Auto Rstrt Delay to 0 ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regula
27. 49 feet 1200 Vp p 40 meters 131 feet 1600 Vp p 170 meters 558 feet 1 Longer cable lengths can be achieved by installing devices on the output of the drive Consult factory for recommendations Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive control run commands 1 10 Installation Wiring Power Terminal Block The drive utilizes a finger guard over the power wiring terminals To remove 1 Press in and hold the locking tab 2 Slide finger guard down and out Replace the finger guard when wiring is complete Figure 1 4 Power Terminal Block A Frame Shown R L1 S L2 T L3 UTi V T2 WITS EIEN ERBO BR BR O Terminal Description R L1 S L2 1 Phase Input R L1 S L2 T L3 3 Phase Input U T1 To Motor U T1 Switch any two motor V T2 To Motor V T2 Sr D leads to change a Motor Wit A SG forward direction W T3 To Motor W T3 L BR BR Dynamic Brake Resistor Connection 0 75 kW 1 HP ratings and higher Sa
28. AC Input Trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line Control Ride Through Minimum ride through is 0 5 Secs typical value 2 Secs Faultless Power Ride Through 100 milliseconds Dynamic Braking Internal brake IGBT included with all ratings 0 75 kW 1 HP and larger Refer to page B 2 for external dynamic brake module options 1 200 240V AC 1 Phase drives are also available with an integral EMC filter Catalog suffix changes from N104 to N114 Supplemental Drive Information A 3 Specification Category Environment Altitude 1000 m 3300 ft max without derating Ambient Operating Temperature IP20 10 to 50 degrees C 14 to 122 degrees F NEMA 1 10 to 40 degrees C 14 to 104 degrees F Cooling Method Convection 0 2 kW 0 25 HP drive ratings Catalog Numbers 22A V1P5N104 22A A1P5N114 22A A1P5104 and 22A B1P5N104 Fan All other drive ratings Storage Temperature 40 to 85 degrees C 40 to 185 degrees F Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity 0 to 95 non condensing Shock operating 15G peak for 11ms duration 1 0ms Vibration operating 1G peak 5 to 2000 Hz
29. Ambient Temperature Enclosure Rating Minimum Mounting Minimum Maximum Clearances IP 20 Open Type Use Mounting Option A 40 C 104 F 1 cll 10 C 14 F IP 30 NEMA 1 UL Type 1 Use Mounting Option B 50 C 122 F IP 20 Open Type Use Mounting Option B 1 Rating requires installation of the PowerFlex 4 IP 30 NEMA 1 UL Type 1 option kit Debris Protection A plastic top panel is included with the drive Install the panel to prevent debris from falling through the vents of the drive housing during installation Remove the panel for IP 20 Open Type applications Storage Store within an ambient temperature range of 40 to 85 C Store within a relative humidity range of 0 to 95 non condensing Do not expose to a corrosive atmosphere Installation Wiring 1 3 AC Supply Source Considerations Ungrounded Distribution Systems referenced to ground These devices should be disconnected if the drive ATTENTION PowerFlex 4 drives contain protective MOVs that are AN is installed on an ungrounded distribution system Disconnecting MOVs To prevent drive damage the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage To disconnect these devices remove the jumper shown in the Figures 1 1 and 1 2 1 Turn the screw counterclockwise to loosen 2 Pull t
30. Drive Start Up 2 1 Integral Keypad 0 2 3 Viewing and Editing Parameters 2 4 About Parameters 3 1 Parameter Organization 3 2 Display Group 000 3 3 Basic Program Group 3 8 Advanced Program Group 3 13 Parameter Cross Reference by Name 3 26 Drive Statusy ce cit e ss ait 4 1 Fauli ties hanes the wages aes 4 1 Fault Descriptions 4 3 Common Symptoms and Corrective Actions 4 5 Supplemental Drive Information Drive Fuse amp Circuit Breaker Ratings A 1 Specifications 0000 A 2 Accessories and Dimensions Product Selection B 1 Product Dimensions B 5 RS485 DSI Protocol Preface Overview The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex 4 Adjustable Frequency AC Drive For information on See page Who Should Use this Manual P 1 Reference Materials P 1 Manual Conventions P 2 Drive Frame Sizes P 2 General Precautions P 3 Catalog Number Explanation P 4 Who Should Use this Manual This manual is intended for qualified personnel You must be able to program and operate Adjustable Frequency AC Drive devices In addition you must have an understanding of the parameter settings and functions Referenc
31. Holes 29 vw PI TE aces Mo 86988 o 144 x Catalog Number B 160 BMA1 BMB1 245 9 64 225 8 86 160 BMA2 BMB2 334 13 15 314 12 36 Figure B 4 Bulletin 1321 3R Series Line Reactors Dimensions are in millimeters and inches Weights are in kilograms and pounds Catalog Number A B c D E Weight 1321 3R2 A 112 4 40 104 4 10 70 2 75 50 1 98 37 1 44 11 8 4 1321 3R2 B 112 4 40 104 4 10 70 2 75 50 1 98 37 1 44 1 8 4 1321 3R4 A 112 4 40 104 4 10 76 3 00 50 1 98 37 1 44 1 8 4 1321 3R4 B 112 4 40 104 4 10 76 3 00 50 1 98 37 1 44 1 8 4 1321 3R8 A 152 6 00 127 5 00 76 3 00 53 2 10 51 2 00 3 1 7 1321 3R8 B 152 6 00 127 5 00 76 3 00 53 2 10 51 2 00 3 6 8 1321 3R12 A 152 6 00 127 5 00 76 3 00 53 2 10 51 2 00 4 1 9 1321 3R18 A 152 6 00 133 5 25 79 3 10 54 2 13 51 2 00 4 1 9 1321 3R18 B 152 6 00 133 5 25 86 3 40 63 2 48 51 2 00 5 4 12 Accessories and Dimensions B 7 Figure B 5 Frame A EMC Line Filters Dimensions are in millimeters and inches Catalog Numbers 22 RF5P7 AS AL 22 RF9P5 AS AL 22 RF010 AL 1 94 lt Br 5 29 60 Wily KERN 2 36 K h J leleleleo O O 220 8 66 208 8 19 A X
32. Program Slip Compensation A114 Advanced Program Speed Reference P038 Basic Program Start At PowerUp A094 Advanced Program Start Boost A084 Advanced Program Start Source P036 Basic Program Stop Mode P037 Basic Program SW Current Trip A098 Advanced Program Testpoint Data d019 Display Testpoint Sel A102 Advanced Program Chapter 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 4 drive Included is a listing and description of drive faults with possible solutions when applicable For information on For information on See page Drive Status Fault Descriptions 4 3 Faults 7 Common Symptoms and 4 5 Corrective Actions Drive Status The condition or state of your drive is constantly monitored Any changes will be indicated through the integral keypad LED Indications See page 2 3 for information on drive status indicators and controls Faults A fault is a condition that stops the drive There are two fault types Type Fault Description Auto Reset Run When this type of fault occurs and A092 Auto Rstrt Tries is set to a value greater than 0 a user configurable timer A093 Auto Rstrt Delay begins When the timer reaches zero the drive attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault will be reset and the drive will be restarted Non Resetable This type of fault may require
33. Programming and Parameters 3 5 Display Group continued d012 Control Source Related Parameter s P036 P038 A051 A052 Displays the active source of the Start Command and Speed Command which are normally defined by the settings of P036 Start Source and P038 Speed Reference but may be overridden by digital inputs Refer to the flowcharts on pages 1 17 and 1 18 for details JOIO Start Command Bit 0 0 Keypad 1 3 Wire 2 2 Wire 3 2 Wire Level Sensitive 4 2 Wire High Speed 5 RS485 DSI Port 9 Jog Speed Command Bit 1 0 Drive Potentiometer 1 A069 Internal Freq 2 0 10V Input Remote Potentiometer 3 4 20mA Input 4 A070 A073 Preset Freq x A051 A052 Digital Inx Sel must be set to 4 5 RS485 DSI Port 9 Jog Freq Reserved Bit 2 Reserved Bit 3 Values Default Read Only Min Max 0 9 Display 1 Status of the control terminal block control inputs Important Actual control commands may come from a source other than the control terminal block JOG l 1 Input Present 0 Input Not Present Start Run FWD Input I O Terminal 02 Bit 0 Direction Run REV Input I O Terminal 03 Bit 1 Stop Input 1 0 Terminal 01 Bit 2 Reserved Bit 3 The stop input must be present in order to start the drive When this bit is a 1 the drive can be started When this bit is a 0 the drive will stop Values Default
34. RAM FAULT duu l PROGRAM FAULT O duu I PROGRAM FAULT O Dre Dr PROGRAM O FAULT O mnt mnt Pudi ae edu PROGRAM FAULT O a YH Sr 2 FF AoW PROGRAM FAUI 5 ecu PROGRAM O FAULT O PROGRAM FAULT The Basic Program Group page 3 8 contains the most commonly changed parameters Pudi rust This example provides basic o VOLTS o AMPS e HERTZ o VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ e VOLTS o AMPS o HERTZ o VOLTS o AMPS o HERTZ Chapter 3 Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 4 parameters Parameters are programmed viewed edited using the integral keypad As an alternative programming can also be performed using DriveExplorer or DriveExecutive software a personal computer and a serial converter module Refer to Appendix B for catalog numbers For information on See page About Parameters 3 1 Parameter Organization 3 2 Basic Program Group 3 8 Advanced Program Group 3 13 Parameter Cross Reference by Name 3 26 About Parameters To configure a drive to operate in a specific way drive parameters may have to be set Three types of parameters exist e ENUM ENUM parameters allow a selection from 2 or more item
35. Source Accel Decel Parameter Used 0 0 A070 Preset Freq 0 Accel Time 1 Decel Time 1 1 0 A071 Preset Freq 1 Accel Time 1 Decel Time 1 0 1 A072 Preset Freq 2 Accel Time 2 Decel Time 2 1 1 A073 Preset Freq 3 Accel Time 2 Decel Time 2 When a Digital Input is set to Accel 2 amp Decel 2 and the input is active that input overrides the settings in this table A078 Jog Frequency Related Parameter s P035 A051 A052 Sets the output frequency when a jog command is issued Values Default 10 0 Hz Min Max 0 0 P035 Maximum Freq Display 0 1 Hz Programming and Parameters 3 17 Advanced Program Group continued A079 Jog Accel Decel Sets the acceleration and deceleration time when a jog command is issued Values Default 10 0 Secs Min Max 0 1 600 0 Secs Display 0 1 Secs Sets the length of time that DC brake current is injected into the motor Refer to parameter A081 DC Brake Level Values Default 0 0 Secs Min Max 0 0 90 0 Secs Display 0 1 Secs A081 DC Brake Level Related Parameter s P037 A080 Defines the maximum DC brake current in amps applied to the motor when P037 Stop Mode is set to either Ramp or DC Brake Values Default Drive Rated Amps x 0 05 Min Max 0 0 Drive Rated Amps x 1 8 Display 0 1 Amps Ramp to Stop Mode DC Injection Braking Mode Voltage peed Speed DC Brake Time _ Vol
36. V DC power source can be used Refer to the External Supply SRC example 2 Wire SNK Control Internal Supply SNK Non Reversing 02 Stop Ri lop Aun u Installation Wiring 1 15 Input Connection Example 2 Wire SRC Control Internal Supply SRC External Supply SRC Run FWD Run REV 11 P036 Start Source 2 3 02 02 or4 03 Stop Run Stop Run Forward 08 Input must be active for Forward 04 the drive to run When Stop Run P i Reverse input is opened the drive Stop Run will stop as specified by Reverse P037 Stop Model 24V Common If both Run Forward and Each digital input draws 6 mA Run Reverse inputs are closed at the same time an undetermined state could occur 2 Wire SNK Control Internal Supply SNK Run FWD Run REV S Stop Run i Forward a 8 04 ews 3 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing P036 Start Source 1 A momentary input will 01 01 start the drive A stop 02 02 input to I O Terminal 01 will stop the drive as 04 specified by P037 Stop Mode 24V Common Each digital input draws 6 mA 3 Wire SNK Control Non Reversing 01 02 03 04 1 16 Installation Wiring Input Connection Example 3 Wire SRC Control Inte
37. Voltage UnderVoltage or Heatsink OvrTmp fault without restarting the drive 1 Set A092 Auto Rstrt Tries to a value other than 0 2 Set A093 Auto Rstrt Delay to 0 Auto Restart Reset Run The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention This allows remote or unattended operation Only certain faults are allowed to be reset Certain faults Type 2 that indicate possible drive component malfunction are not resettable Caution should be used when enabling this feature since the drive will attempt to issue its own start command based on user selected programming No F2 F3 F4 F5 F6 F7 F8 F12 F13 Fault Descriptions Table 4 A Fault Types Descriptions and Actions Qa Fault a Auxiliary Input Power Loss UnderVoltage OverVoltage Motor Stalled Motor Overload Heatsink OvrTmp HW OverCurrent Ground Fault Description Auxiliary input interlock is open DC bus voltage remained below 85 of nominal DC bus voltage fell below the minimum value DC bus voltage exceeded maximum value Drive is unable to accelerate motor Internal electronic overload trip Heatsink temperature exceeds a predefined value The drive output current has exceeded the hardware current limit A current path to earth ground has be
38. Y m gt k 5 5 0 22 Le 0 94 Ill Figure B 6 Frame B EMC Line Filters Dimensions are in millimeters and inches Catalog Numbers 22 RF012 BS BL 22 RF018 BS 22 RF021 BS BL a ek 34 29 8 i 784 dini ee 8 07 i f e 3 XT eee 217 229 8 54 9 02 oOo 216 8 50 Nett Dey allt 1 048 a HET k 5 5 0 22 B 8 Accessories and Dimensions Notes Appendix C RS485 DSI Protocol PowerFlex 4 drives support the RS485 DSI protocol to allow efficient operation with Rockwell Automation peripherals In addition some Modbus functions are supported to allow simple networking PowerFlex 4 drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode BB ets Controllers LH OL OLE Oe Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node Figure C 1 Network Wiring Diagram PowerFlex 4 PowerFlex 4 PowerFlex 4 Master Node 1 Node 2 Node n TxRxD 4 DRD 4 PRD 4 120 ohm resistor zi 120 ohm resistor a FRONT TxRxD _t 5 TxRxD 5 T
39. ance one step in programming menu Select a digit when viewing parameter value Up Arrow Scroll through groups and parameters CA WY Down Arrow Increase decrease the value of a flashing digit Enter Advance one step in programming menu lt Save a change to a parameter value ES Potentiometer Used to control speed of drive Default is active Controlled by parameter P038 Speed Reference R Zl Start Used to start the drive Default is active C1 Controlled by parameter P036 Start Source Reverse Used to reverse direction of the drive Default is active EN Controlled by parameters P036 Start Source and A095 Reverse Disable Stop Used to stop the drive or clear a fault This key is always active Controlled by parameter P037 Stop Mode 2 4 Start Up Viewing and Editing Parameters The last user selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied The following is an example of basic integral keypad and display functions navigation instructions and illustrates how to program the first Program Group parameter Step 1 When power is applied the last user selected Display Group parameter number is briefly displayed with flashing characters The display then defaults to that parameter s current value Example shows the value of d001 Output Freq with the drive stopped 2 Press Esc once to display the Display Group parameter number shown on p
40. and communication adapters online Compatibility Windows 95 98 ME NT 4 0 Service Pack 3 or later 2000 XP and CE DriveExecutive software Windows based software package that provides an 9303 4DTEOQ1ENE CD ROM Version 1 01 or later intuitive means for monitoring or configuring Allen Bradley drives and communication adapters online and offline Compatibility Windows 98 ME NT 4 0 Service Pack 3 or later 2000 and XP 1 See www ab com drives driveexplorer htm for supported devices Q For pricing information refer to the PowerFlex 4 Price List Publication 22A PLO01A EN P Table B G IP30 NEMA 1 UL Type 1 Kit Item IP30 NEMA 1 UL Type 1 Kit Drive Description Frame Field installed kit Converts drive to IP30 NEMA 1 UL Type 1 enclosure Includes Catalog Number 22 JBAA conduit box with mounting screws and plastic top panel 22 JBAB 1 For pricing information refer to the PowerFlex 4 Price List Publication 22A PL001A EN P Accessories and Dimensions B 5 Product Dimensions Figure B 1 PowerFlex 4 Drives Dimensions are in millimeters and inches Weights are in kilograms and pounds A 1 al 80 3 15 185 7 28 136 5 35 67 2 64 _ 152 5 98 100 3 94 213 8 39 136 5 35 87 3 43 180 7 09 87 4 3 44
41. ating Type Description Standard 600V 75 C or 90 C 167 F e Four tinned copper conductors with XLPE insulation Option 1 or 194 F RHH RHW 2 e Foil shield and tinned copper drain wire with 85 braid Belden 29501 29507 or coverage equivalent e PVC jacket Standard Tray rated 600V 75 C or e Three tinned copper conductors with XLPE insulation Option 2 90 C 167 F or 194 F e 5 mil single helical copper tape 25 overlap min RHH RHW 2 with three bare copper grounds in contact with shield Shawflex 2ACD 3ACD or PVC jacket equivalent Class I amp Il Tray rated 600V 75 C or e Three bare copper conductors with XLPE insulation Division amp Il 90 C 167 F or 194 F with impervious corrugated continuously welded RHH RHW 2 aluminum armor e Black sunlight resistant PVC jacket overall e Three copper grounds on 10 AWG and smaller Installation Wiring 1 9 Reflected Wave Protection The drive should be installed as close to the motor as possible Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor reflected wave phenomena See Table 1 E for recommendations The reflected wave data applies to all frequencies 2 to 16 kHz For 240V ratings reflected wave effects do not need to be considered Table 1 E Maximum Cable Length Recommendations Reflected Wave 380 480V Ratings Motor Insulation Rating Motor Cable Only 1000 Vp p 15 meters
42. ations without additional short circuit protection Refer to the technical support literature for the 140M for more details Installation Wiring 1 7 Table 1 D Minimum Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Rating kW HP Amps Protectors MCS Contactors Catalog No Catalog No 120V AC 0 2 0 25 10 140M C2E C10 100 C09 1 Phase 0 37 0 5 15 140M C2E C16 100 C12 0 75 1 0 30 140M D8E C20 100 C23 240V AC 0 2 0 25 10 140M C2E B63 100 C09 1 Phase 0 37 0 5 10 140M C2E B63 100 C09 0 75 1 0 15 140M C2E C16 100 C12 1 5 2 0 30 140M D8E C20 100 C23 240V AC 0 2 0 25 3 140M C2E B25 100 C09 3 Phase 0 37 0 5 6 140M C2E B40 100 C09 0 75 1 0 10 140M C2E C10 100 C09 1 5 2 0 15 140M C2E C16 100 C12 2 2 3 0 25 140M C2E C16 100 C16 3 7 5 0 35 140M F8E C25 100 C23 480V AC 0 37 0 5 3 140M C2E B25 100 C09 3 Phase 0 75 1 0 6 140M C2E B40 100 C09 1 5 2 0 10 140M C2E B63 100 C09 2 2 3 0 15 140M C2E C10 100 C09 3 7 5 0 15 140M C2E C16 100 C16 1 Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent 1 8 A Installation Wiring Power Wiring 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 protectio
43. command The drive Run indicator is lit and output is 0 Hz Check d012 Control Source for correct source e fthe source is an analog input check wiring and use a meter to check for presence of signal e Check d002 Commanded Freq to verify correct command Incorrect reference source is being selected via remote device or digital inputs None e Check d012 Control Source for correct source e Check d014 Dig In Status to see if inputs are selecting an alternate source Verify settings for A051 A052 Digital Inx Sel e Check P038 Speed Reference for the source of the speed reference Reprogram as necessary e Review the Speed Reference Control chart on page 1 17 Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive None Reprogram P039 Accel Time 1 or A067 Accel Time 2 Excess load or short None Compare d003 Output Current with acceleration times force the A089 Current Limit drive into current limit slowing Remove excess load or reprogram or stopping acceleration P039 Accel Time 1 or A067 Accel Time 2 Check for improper A084 Start Boost setting Speed command source or _ None Verify d002 Commanded Freq value is not as expected Check d012 Control Source for the proper Speed Command Programming is preventing the None Check P035 Maximum Freq to drive output from
44. ded specifications information A 2 Section on RS485 DSI Protocol added C 1 C 5 The following parameter descriptions or values have changed P037 Stop Mode Description changed 3 10 A084 Start Boost New default value for 5 HP drives 3 19 A107 Comm Format Description changed 3 24 The following parameters have been added d020 0 10V Analog Input 3 7 d021 4 20mA Analog Input 3 7 A110 0 10V Analog Input Low 3 24 A111 0 10V Analog Input High 3 25 A112 4 20mA Analog Input Low 3 25 A113 4 20mA Analog Input High 3 25 A114 Slip Compensation 3 25 soc 2 Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Appendix A Appendix B Appendix C Index Overview Installation Wiring Start Up Table of Contents Programming and Parameters Troubleshooting Who Should Use this Manual P 1 Reference Materials P 1 Manual Conventions P 2 Drive Frame Sizes P 2 General Precautions P 3 Catalog Number Explanation P 4 Opening the Cover 1 1 Mounting Considerations 1 2 AC Supply Source Considerations 1 3 General Grounding Requirements 1 4 Fuses and Circuit Breakers 1 6 Power Wiring 0 00000 1 8 I O Wiring Recommendations 1 11 Start and Speed Reference Control 1 17 EMC Instructions 1 19 Prepare For
45. drive or motor repair or is caused by wiring or programing errors The cause of the fault must be corrected before the fault can be cleared 4 2 Troubleshooting Fault Indication Condition Display Drive is indicating a fault viata taal The integral keypad provides visual notification of a mo E n g 5 i urs fault condition by displaying the following Hi EN ALS I are lt lt O SADS IAD e Flashing fault number e Flashing fault indicator Press the Escape key to regain control of the integral keypad Manually Clearing Faults Step Key s 1 Press Esc to acknowledge the fault The fault information will be removed so that you can use the integral keypad Ese Access d007 Fault 1 Code to view the most recent fault information 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared See Table 4 A 3 After corrective action has been taken clear the fault by one of these methods e Press Stop if P037 Stop Mode is set to a value between 0 and 3 e Cycle drive power e Set A100 Fault Clear to 1 or 2 e Cycle digital input if A051 A052 Digital Inx Sel is set to option 7 Clear Fault Automatically Clearing Faults Clear a Type 1 fault and restart the drive 1 Set A092 Auto Rstrt Tries to a value other than 0 2 Set A093 Auto Rstrt Delay to a value other than 0 Clear an Over
46. e Win Integral S Typer O87 108 23A 22A A2P3N114 A EMC Filter 0 75 10 45A 22A A4P5N114 A 15 20 8 0A 22A A8PON114 B 240V 50 60 Hz 0 2 0 25 1 5A 22A A1P5N104 A 1 Phase 0o37 o5 23A 22A A2P3N104 A No Filter 0 75 10 45A 22A A4P5N104 A 15 20 8 0A 22A A8PON104 B 240V 50 60 Hz 0 2 0 25 1 5A 22A B1P5N104 A 3 Phase 037 105 23A 22A B2P3N104 A No Filter 0 75 10 45A 22A B4P5N104 A 15 2 0 8 0A 22A B8PON104 A 22 3 0 12 00 22A B012N104 B 37 5 0 175 22A B017N104 B 480V 50 60 Hz 0o37 105 14A 22A D1P4N104 A 3 Phase 0 75 1 0 23A 22A D2P3N104 A No Filter 15 20 40A 22A D4PON104 A 22 3 0 6 0A 22A D6PON104 B 37 5 0 8 7A 22A D8P7N104 B Accessories and Dimensions Table B C Dynamic Brake Modules Drive Ratings Input Voltage kw HP Catalog Number 120V 50 60 Hz 0 2 0 25 1 1 Phase 0 37 05 1 0 75 1 0 160 BMA1 240V 50 60 Hz 0 2 0 25 1 1 Phase 0 37 05 0 0 75 1 0 160 BMA1 15 2 0 160 BMA2 240V 50 60 Hz 0 2 0 25 o 3 Phase 0 37 05 1 0 75 1 0 160 BMA1 1 5 2 0 160 BMA2 2 2 3 0 160 BMA2 3 7 5 0 160 BMA2 480V 50 60 Hz 0 37 0 5 1 3 Phase 0 75 1 0 160 BMB1 1 5 2 0 160 BMB2 2 2 3 0 160 BMB2 3 7 5 0 160 BMB2 2 Drive does not support dynamic braking Two in parallel required Table B D Bulletin 1321 3R Series Line Reactors Maximum Fundamental Continuous Watts Catalog Input Voltage kW HP Am
47. e Materials The following manuals are recommended for general drive information Title Publication Available Online at Industrial Automation Wiring 1770 4 1 www ab com manuals gi and Grounding Guidelines Preventive Maintenance of DRIVES SB001A EN E www ab com manuals dr Industrial Control and Drive System Equipment Safety Guidelines for the SGI 1 1 www ab com manuals gi Application Installation and Maintenance of Solid State Control A Global Reference Guide for 0100 2 10 www ab com manuals ms Reading Schematic Diagrams Guarding Against Electrostatic 8000 4 5 2 www ab com manuals dr Damage P 2 Overview Manual Conventions e In this manual we refer to the PowerFlex 4 Adjustable Frequency AC Drive as drive PowerFlex 4 or PowerFlex 4 Drive e Parameter numbers and names are shown in this format P031 Motor NP Volts Name Number Group d Display Group P Basic Program Group A Advanced Program Group e The following words are used throughout the manual to describe an action Word Can Meaning Possible able to do something Cannot Not possible not able to do something May Permitted allowed Shall Required and necessary Should Recommended Should Not Not Recommended Drive Frame Sizes Similar PowerFlex 4 drive sizes are grouped into frame sizes to simplify spare parts ordering dimensioning etc A cross reference o
48. e voltage e or Install Isolation Transformer with grounded secondary if necessary Ungrounded distribution system 1 Refer to Appendix B for accessory ordering information General Grounding Requirements The drive Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity of all ground connections should be periodically checked Figure 1 3 Typical Grounding Installation Wiring 1 5 Ground Fault Monitoring If a system ground fault monitor RCD is to be used only Type B adjustable devices should be used to avoid nuisance tripping Safety Ground PE This is the safety ground for the drive that is required by code One of these points must be connected to adjacent building steel girder joist a floor ground rod or bus bar Grounding points must comply with national and local industrial safety regulations and or electrical codes Motor Ground The motor ground must be connected to one of the ground terminals on the drive Shield Termination SHLD Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield The motor cable shield connected to one of these terminals drive end should also be connected to the mo
49. earth If using the RS485 DSI port I O Terminal 16 should also be connected to ground terminal protective earth Installation Wiring 1 13 Figure 1 5 Control Wiring Block Diagram g g g o Important I O Terminal 01 is P036 VO Terminal 01 always a coast to stop input except _ StartSource Stop Stop when P036 Start Source is set to Keypad Per P037 Coast 3 Wire control In three wire Sire Per P037 Per P037 control I O Terminal 01 is controlled 2 Wire Per P037 Coast by P037 Stop Mode All other stop __RS485Port_ Per P037 Coast sources are controlled by P037 Stop Mode Typical Typical Stop 1 SRC Wiring SNK Wiring Important The drive is shipped with T gt 10 o lo a jumper installed between I O Stat Run FWD om oH Terminals 01 and 11 Remove this Direction Run REV 5 oo jumper when using I O Terminal 01 Digital Common as a stop input Digital Input 4 a HEN Q2 Two wire control shown For three Digital Input 2 on ao wire control use a momentary input a on I O Terminal 02 to 2AVDC command a start Use a maintained 10V DC c input oo for I O Terminal 03 to 0 10V In I T change direction Relay N O Analog Common I J Relay Common 4 20mA In 7 Potentio
50. ed Flashing red status light Clear fault e Press Stop e Cycle power e Set A100 Fault Clear to option 1 Clear Faults e Cycle digital input if A051 A052 Digital Inx Sel is set to option 7 Clear Fault Incorrect programming None Check parameter settings e P036 Start Source is set to option 0 Keypad or option 5 RS485 DSI Port e A051 A052 Digital Inx Sel is set to option 5 Local and the input is active Incorrect input wiring None Wire inputs correctly and or install See 1 14 for wiring examples e 2 wire control requires Run Forward Run Reverse or Jog input e 3 wire control requires Start and Stop inputs e Stop input is always required jumper Incorrect Sink Source DIP switch setting None Set switch to match wiring scheme 4 6 Troubleshooting Drive does not Start from Integral Keypad Cause s Indication Corrective Action Integral keypad is not enabled Green LED above Start key is not illuminated e Set parameter P036 Start Source to option 0 Keypad e Set parameter A051 A052 Digital Inx Sel to option 5 Local and activate the input 1 0 Terminal 01 Stop input is not present None Wire inputs correctly and or install jumper Drive does not respond to changes in spee d command Cause s Indication Corrective Action No value is coming from the source of the
51. ed Parameter s A102 The present value of the function selected in A102 Testpoint Sel Values Default Read Only Min Max O FFFF Display 1 Hex d020 0 10V Analog Input Related Parameter s A110 A111 The present value of the voltage at I O Terminal 13 100 0 10 volts Values Default Read Only Min Max 0 0 100 0 Display 0 1 d021 4 20mA Analog Input Related Parameter s A112 A113 The present value of the current at I O Terminal 15 0 0 4mA 100 0 20mA Values Default Read Only Min Max 0 0 100 0 Display 0 1 3 8 Programming and Parameters Basic Program Group Stop drive before changing this parameter P031 Motor NP Volts Related Parameter s A084 Set to the motor nameplate rated volts Values Default Based on Drive Rating Min Max 20 Drive Rated Volts Display 1 VAC Stop drive before changing this parameter P032 Motor NP Hertz Related Parameter s A084 Set to the motor nameplate rated frequency Values Default 60 Hz Min Max 10 240 Hz Display 1 Hz Set to the maximum allowable motor current The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150 for 60 seconds or 200 for 3 seconds Values Default Based on Drive Rating Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps P034 Minimum Freq Related Parameter s P035 Sets the lowest frequency the drive will output continuously Values Defau
52. egins ATTENTION The following information is merely a guide for proper installation The Allen Bradley Company 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 Opening the Cover 1 Press and hold in the tabs on each side of the cover 2 Pull the cover out and up to release 1 2 Installation Wiring Mounting Considerations Mount the drive upright on a flat vertical and level surface Install on 35 mm DIN Rail or Install with screws Table 1 4 Screw Mounting Recommendations Minimum Panel Thickness Mounting Torque 1 9 mm 0 0747 in m4 x 0 7 8 32 1 56 1 96 Nm 14 17 Ib in Protect the cooling fan by avoiding dust or metallic particles Do not expose to a corrosive atmosphere Protect from moisture and direct sunlight Minimum Mounting Clearances Refer to Appendix B for mounting dimensions L R icin i yon 205 Mounting Option A SOR No clearance required gt between drives Powerflex Powerflex Mounting Option B N Powerflex Powerflex nm a i E D 4 7 in vv vv 4 7 in AN LV S Ambient Operating Temperatures Table 1 B Enclosure and Clearance Requirements
53. en detected at one or more of the drive output terminals ption of fault types Troubleshooting 4 3 Action 1 Check remote wiring 2 Verify communications programming for intentional fault 1 Monitor the incoming AC line for low voltage or line power interruption 2 Check input fuses Monitor the incoming AC line for low voltage or line power interruption Monitor the AC line for high line voltage or transient conditions Bus overvoltage can also be caused by motor regeneration Extend the decel time or install dynamic brake option Increase P039 A067 Accel Time x or reduce load so drive output current does not exceed the current set by parameter A089 Current 1 An excessive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current 2 Verify A084 Start Boost setting Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 40 C 104 F for IP 30 NEMA 1 UL Type 1 installations or 50 C 122 F for IP20 Open type installations 2 Check fan Check programming Check for excess load improper A084 Start Boost setting DC brake volts set too high or other causes of excess current Check the motor and external wiring to the drive output terminals for a grounded condition 1 See page 4 1 for a descri Action manually clear Check the wiring between the drive and m
54. er should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly Installation Wiring 1 17 Start and Speed Reference Control The drive speed command can be obtained from a number of different sources The source is normally determined by P038 Speed Reference However when A051 or A052 Digital Inx Sel is set to option 2 4 5 or 6 and the digital input is active A051 or A052 will override the speed reference commanded by P038 Speed Reference See the chart below for the override priority Drive will Start and Run at Jog Speed Jog Input Enabled and Active A051 or A052 2 Yes Direction comes from Terminal 03 Dir Run REV Local Remote Input Enabled and Active A051 or A052 5 Start Speed and Direction commands come from Integral Keypad Comm Select Input Enabled and Active A051 or A052 6 Start Speed and Direction commands come from RS485 DSI port Run as specified by P038 Speed Reference P038 Speed Reference 4or5 Start and Direction commands come from P036 Start Source Run as specified by A071 A073 Preset Freq 1 3 A051 A052 Preset Inputs Active oo Be Start and Direction commands come from P036 Start Source Run as specified by P038 Speed Reference Start and Direction commands come from P036 Start Source 1 18 Installati
55. erminal 03 RS485 port except as noted below Important O Terminal 01 is always a coast to stop input except when P036 Start Source is set for 3 Wire control When in three wire control I O Terminal 01 is controlled by P037 Stop Mode Options 0 Ramp Clear Fault Ramp to Stop Stop command clears active fault Default 1 Coast Clear Fault Coast to Stop Stop command clears active fault 2 DC Brake Clear DC Injection Braking Stop Stop command clears active Fault fault 3 DC Brake WShutoff DC Injection Braking Stop with Auto Shutoff Clear Fault e Standard DC Injection Braking for value set in A080 DC Brake Time OR e Drive shuts off if the drive detects that the motor is stopped Stop command clears active fault 4 Ramp Ramp to Stop 5 Coast Coast to Stop 6 DC Brake DC Injection Braking Stop 7 DC Brake w Shutoff DC Injection Braking Stop with Auto Shutoff e Standard DC Injection Braking for value set in A080 DC Brake Time OR e Drive shuts off if current limit is exceeded Stop input also clears active fault Programming and Parameters 3 11 Basic Program Group continued P038 Speed Reference Related Parameter s d012 A069 A070 A071 A072 A073 Sets the source of the speed reference to the drive Important When A051 or A052 Digital Inx Sel is set to option 2 4 5 or 6 and the digital input is
56. everse disabled Options 0 Reverse Enabled Default 1 Reverse Disabled A096 Flying Start En Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM Options 0 Disabled Default 1 Enabled A097 Compensation Enables disables correction options that may improve problems with motor instability Options 0 Disabled 1 Electrical Default 2 Mechanical 3 Both A098 SW Current Trip Enables disables a software instantaneous within 100 ms current trip Values Default 0 0 Disabled Min Max 0 0 Drive Rated Amps x 2 Display 0 1 Amps A099 Process Factor Related Parameter s d010 Scales the value displayed by d010 Process Display Output Process _ Process Freq X Factor Display Values Default 30 0 Min Max 0 1 999 9 Display 0 1 Programming and Parameters 3 23 Advanced Program Group continued Stop drive before changing this parameter A100 Fault Clear Resets a fault and clears the fault queue Options 0 Ready Default 1 Reset Active Fault 2 Clear Fault Queue Parameters d007 d009 Fault x Code A101 Program Lock Protects parameters against change by unauthorized personnel Options 0 Unlocked Default 1 Locked A102 Testpoint Sel Used by Rockwell Automation field service personnel Values Default 4
57. exceeding limiting values insure that speed is not limited by programming Motor operation is unstable Troubleshooting 4 7 Cause s Indication Corrective Action Motor data was incorrectly entered None 1 Correctly enter motor nameplate data into P031 P032 and P033 2 Enable A097 Compensation 3 Use A084 Start Boost to reduce boost level Drive will not reverse motor direction Cause s Indication Corrective Action Digital input is not selected for None Check Digital Inx Sel See reversing control page 3 13 Choose correct input and program for reversing mode Digital input is incorrectly None Check input wiring See page 1 13 wired Motor wiring is improperly None Switch two motor leads phased for reverse Reverse is disabled None Check A095 Reverse Disable 4 8 Troubleshooting Notes Appendix A Supplemental Drive Information For information on Drive Fuse amp Circuit Breaker Ratings A 1 Specifications A 2 Drive Fuse amp Circuit Breaker Ratings The tables on the following pages provide drive ratings and recommended AC line input fuse and circuit breaker information Both types of short circuit protection are acceptable for UL and IEC requirements Sizes listed are the recommended sizes based on 40 degree C and the U S N E C Other country state or local codes may require different ratings Fusing If
58. f drive catalog numbers and their respective frame sizes is provided in Appendix B gt D Overview P 3 General Precautions ATTENTION The drive contains high voltage capacitors which take time to discharge after removal of mains supply Before working on drive ensure isolation of mains supply from line inputs R S T L1 L2 L3 Wait three minutes for capacitors to discharge to safe voltage levels Failure to do so may result in personal injury or death Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels 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 This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B 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
59. fety Ground PE Table 1 F Power Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Torque A 3 3 mm 12 AWG 0 8 mm 18 AWG 5 1 7 2 2 N m 16 19 Ib in B 5 3 mm 10 AWG 1 3 mm2 16 AWG 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Installation Wiring 1 11 1 0 Wiring Recommendations Motor Start Stop Precautions and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage The drive is designed to use control input signals that will start and stop the motor If used the input device must not exceed one operation per minute or drive damage can occur ATTENTION A contactor or other device that routinely disconnects solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC line to the drive When the AC line is removed there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop An auxiliary braking method may be required ATTENTION The drive start stop control circuitry includes Important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires should be separated from power wires by at least 0
60. he jumper completely out of the drive chassis 3 Tighten the screw to keep it in place Figure 1 1 Jumper Location A Frame Shown Important Tighten screw after jumper removal Figure 1 2 Phase to Ground MOV Removal Three Phase BALI AC Input S L2 T L 3 be Jumper 1 p p 4 1 4 Installation Wiring Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive see Appendix A Listed in Table 1 C are certain input power conditions which may cause component damage or reduction in product life If any of the conditions exist as described in Table 1 C install one of the devices listed under the heading Corrective Action on the line side of the drive Important Only one device per branch circuit is required It should be mounted closest to the branch and sized to handle the total current of the branch circuit Table 1 C Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactance e Install Line Reactor e or Isolation Transformer Greater than 120 kVA supply transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of normal Remove MOV jumper to ground line to lin
61. ilter RFI 1 5 Frame Designations P 2 A 1 B 5 Fuses Input 1 6 Ratings A 1 Index 2 G General Precautions P 3 Ground Fault 4 3 Grounding Filter 1 5 General 1 4 H Heatsink OvrTmp Fault 4 3 HW OverCurrent Fault 4 3 1 0 Wiring 1 11 Wiring Examples 1 14 1 15 I O Board Fail Fault 4 4 Input Contactor 1 11 Input Fusing 1 6 Input Potentiometer 1 14 Input Power Conditioning 1 4 Installation 1 1 Integral Keypad 2 3 Interference EMC RFI 1 18 K Keypad 2 3 L LEDs 2 3 M Minimum Clearances 1 2 Motor Cable Length 1 9 Motor Overload Fault 4 3 Motor Stalled Fault 4 3 motor starter 1 6 oe Options and Clearances MOVs 1 3 0 Opening the Cover 1 1 Operating Temperatures 1 2 Operator Interface 2 3 OverVoltage Fault 4 3 P Parameter Descriptions 3 1 Types 3 1 Viewing and Editing 2 4 Parameter Checksum Fault 4 4 Parameter Cross Reference by Name 3 25 Parameters Advanced Program Group 3 13 Display Group 3 3 Program Group 3 8 PE Ground 1 5 Phase Short Fault 4 4 Phase to Ground Fault 4 4 Potentiometer Wiring 1 14 Power Cables Wiring 1 8 Power Conditioning Input 1 4 Power Loss Fault 4 3 Power Unit Fault 4 4 Powering Up the Drive 2 1 2 2 Precautions General P 3 Product Selection B 1 Program Group Parameters 3 8 Programming 3 1 R Ratings A 1 Reflective Wave Protection 1 9 Removing Cover 1 1 Repeated Start Stop 1 11 Repeated Start Stop P
62. lated with 14 Analog Common E analog inputs from digital I O i For external 4 20mA input supply 15 14 20mA In Not Active input impedance 250 ohm P038 g _ Terminal should be connected to safety ground PE 16 RS485 DSI Shield when using the RS485 DS communications port 3 Only one analog frequency source may be connected at a time If more than one reference is connected at the same time an undetermined frequency reference will result 1 14 Installation Wiring I O Wiring Examples Input Connection Example Potentiometer P038 Speed Reference 2 0 10V Input 1 10k Ohm Pot Recommended 2 Watt minimum z2 Li 13 i 14 Analog Input Voltage Current 0 to 10V 100k ohm P038 Speed Reference 2 0 10V P038 Speed Reference 2 impedance Input 4 20mA Input 4 20 mA 100 ohm impedance O p i 8 O Comman 14 Q Common O 15 Y Is 2 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing P036 Start Source 2 3 il S i or 4 Stop Run Input must be active for Stop Run f r the drive to run When input is opened the drive will stop as specified by ee Gommon P037 Stop Mode Each digital input draws 6 mA If desired a User Supplied 24
63. lt 0 0 Hz Min Max 0 0 240 0 Hz Display 0 1 Hz Stop drive before changing this parameter P035 Maximum Freq Related Parameter s P034 Sets the highest frequency the drive will output Values Default 60 Hz Min Max 0 240 Hz Display 1 Hz Programming and Parameters 3 9 Basic Program Group continued Stop drive before changing this parameter P036 Start Source Related Parameter s d012 Sets the control scheme used to start the drive Refer to Start and Speed Reference Control on page 1 17 for details about how other drive settings can override the setting of this parameter Important For all settings except option 3 the drive must receive a leading edge from the start input for the drive to start after a stop input loss of power or fault condition Options 0 Keypad Default e Integral keypad controls drive operation e O Terminal 1 Stop coast to stop e When active the Reverse key is also active unless disabled by A095 Reverse Disable 1 3 Wire 1 0 Terminal 1 Stop stop according to the value set in P037 Stop Mode 2 2 Wire 1 0 Terminal 1 Stop coast to stop 3 2 Wire Level Drive will restart after a Stop command when Sensitive e Stop is removed and e Start is held active ATTENTION Hazard of injury exists due to unintended operation When P036 Start Source is set to option 3 and the Run input is maintained
64. ly parity None Even Odd and stop bits 1 stop bit only used by the RS485 port on the drive Refer to Appendix C for details on using the drive communication features Important Power to drive must be cycled before any changes will affect drive operation Options 0 RTU 8 N 1 Default 1 RTU 8 E 1 2 RTU 8 0 1 A110 0 10V Analog Input Low Related Parameter s d020 P034 P038 Sets the analog input level that corresponds to P034 Minimum Freq if a 0 10V input is used by P038 Speed Reference Analog inversion can be accomplished by setting this value larger than A111 0 10V Analog Input High Values Default 0 0 Min Max 0 0 100 0 Display 0 1 Maximum Freq Minimum Freq 0 0 10V Analog Input Low 0 10V Analog Input High Programming and Parameters 3 25 A111 0 10V Analog Input High Related Parameter s d020 P035 P038 Sets the analog input level that corresponds to P035 Maximum Freq if a 0 10V input is used by P038 Speed Reference Analog inversion can be accomplished by setting this value smaller than A110 0 10V Analog Input Low Values Default 100 0 Min Max 0 0 100 0 Display 0 1 A112 4 20mA Analog Input Low Related Parameter s d021 P034 P038 Sets the analog input level that corresponds to P034 Minimum Freq if a 4 20mA input is used by P038 Speed Reference Analog inversion can be accomplished by setting this value larger than A
65. meter Relay N C RS485 Shield mete a 2 Watt Min 01 02 03 04 05 06 VY Ri R2 RS g awe E ong Resistive 3 0A 3 0A 3 0A D D D ER Inductive 0 5A 0 5A 0 5A SRC No Signal Default Description R1 Relay N O Fault Normally open contact for output relay R2 Relay Common Common for output relay R3 Relay N C Fault Normally closed contact for output relay A055 i Inputs can be wired as Sink SNK or Source SRC via DIP Switch Sink Source DIP Switch Source SRC setting 1 The factory installed jumper or a normally closed input 1 01 Stop Coast must be present for the drive to start Bose 02 Start Run FWD Not Active 036 P037 wines l Command comes from the integral keypad by default To 03 Direction Run REV Not Active disable reverse operation see A095 Reverse Disable a P037 ig B For digital inputs Electronically isolated with digital inputs 04 Digital Common from analog I O 05 Digital Input 1 Preset Frequencies Program with A051 Digital In1 Sel A051 06 Digital Input 2 Preset Frequencies Program with A052 Digital In2 Sel A052 B Drive supplied power for digital inputs 11 24 DC Maximum output current is 100mA Drive supplied power for 0 10V external potentiometer 12 10vDC Maximum output current is 15mA P038 q 3 For external 0 10V input supply 13 0 10V In Not Active input impedance 100k ohm or potentiometer wiper E088 For 0 10V In or 4 20mA In Electronically iso
66. meters 3 19 Advanced Program Group continued A084 StartBoost Related Parameter s P031 Sets the boost voltage of P031 Motor NP Volts and redefines the Volts per Hz curve 1 1 Drive may add additional voltage unless Option 5 is selected Options 1 30 0 2 35 0 40 0 45 0 0 0 no IR Comp 00 ay g Default for 3 7kW 5HP Drives 8 5 0 Default 9 75 Constant Torque 10 10 0 11 12 5 12 15 0 13 17 5 14 20 0 Variable Torque NIOJ 1 2 Motor NP Volts rat C POES 1 2 Motor NP Hertz 50 100 Motor NP Hertz A088 Maximum Voltage Sets the highest voltage the drive will output Values Default Drive Rated Volts Min Max 20 Drive Rated Volts Display 1 VAC 3 20 Programming and Parameters Advanced Program Group continued A089 Current Limit Maximum output current allowed before current limiting occurs Values Default Drive Rated Amps x 1 5 Min Max 0 1 Drive Rated Amps x 1 8 Display 0 1 Amps A090 Motor OL Select Related Parameter s P032 Drive provides Class 10 motor overload protection Settings 0 2 select the derating factor for the It overload function Options 0 No Derate Default 1 Minimum Derate 2 Maximum Derate No Derate of Motor OL Curent pkoas S883888 ir 25 50 75 100 1
67. n and disconnect devices Failure to do so may result in personal injury and or equipment damage 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 power leads Motor Cable Types Acceptable for 200 600 Volt Installations General A variety of cable types are acceptable for drive installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide allow a spacing of 0 3 meters 1 foot for every 10 meters 32 8 feet of length In all cases long parallel runs must be avoided Do not use cable with an insulation thickness less than 15 mils 0 4 mm 0 015 in UL installations in 50 C ambient must use 600V 75 C or 90 C wire UL installations in 40 C ambient should use 600V 75 C or 90 C wire Unshielded THHN THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Do not use THHN or similarly coated wire in wet areas Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity Shielded Location R
68. n whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product Shock Hazard labels may be located on or inside the drive to alert h 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 ANA 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 Summary of Changes The information below summarizes the changes to the PowerFlex 4 User Manual since the last release Description of New or Updated Information See Page s Minimum mounting clearances between drive reduced to 25 mm 1 0 in 1 2 Expanded information on branch circuit protective devices 1 7 New information on I O wiring including additional wiring examples 1 13 1 16 Expan
69. nal injury and or equipment damage caused by improper fusing or circuit breaker selection use only the recommended line fuses circuit breakers specified in this section Fusing The PowerFlex 4 has been UL tested and approved for use with input fuses The ratings in the table that follows are the minimum recommended values for use with each drive rating The devices listed in this table are provided to serve as a guide Other devices which meet the requirements of UL508C and UL489 with similar trip characteristics may be used in order to meet local or national electrical codes Bulletin 140 Manual Motor Starters UL489 Circuit Breakers When using Bulletin 140 manual motor starters or UL489 rated circuit breakers the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection e Bulletin 140 manual motor starters can be used in single and group motor applications e In single motor applications a fuse or UL489 rated circuit breaker is required ahead of the Bulletin 140 manual motor starter e In group motor installations the Bulletin 140 can be used for protection of an individual motor within the group and one set of fuses or a UL489 rated circuit breaker serves as the Branch Circuit Protective Device for the entire Group Installation e Ifthe installation is not required to meet NEC requirements Bulletin 140M manual motor starters can be used in single and group motor applic
70. network may require additional external harmonic mitigation e Other drive ratings meet the current harmonic requirements of EN61000 3 2 without additional external mitigation 1 22 Installation Wiring Notes Chapter 2 Start Up This chapter describes how to start up the PowerFlex 4 Drive To simplify drive setup the most commonly programmed parameters are organized in a single Basic Program Group Important Read the General Precautions section before proceeding ATTENTION Power must be applied to the drive to perform the following start up procedures Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure Do Not Proceed Remove All Power including user supplied control voltages User supplied voltages may exist even when main AC power is not applied to the drive Correct the malfunction before continuing Prepare For Drive Start Up Before Applying Power to the Drive 1 Confirm that all inputs are connected to the correct terminals and are secure 2 Verify that AC line power at the disconnect device is within the rated value of the drive 3 Verify that any digital control power is 24 volts 4 Verify that the Sink SNK Source SRC Setup DIP Switch is set to match
71. on Wiring Accel Decel Selection The selection of Accel Decel rates can be made through digital inputs RS485 DSI communications and or parameters Jog Input Enabled and Active A051 or A052 2 A079 Jog Accel Decel used RS485 DSI Port Controls Speed Active when A067 Accel Time 2 A068 Decel Time 2 is selected by RS485 DSI port Input is programmed as Accel 2 amp Decel 2 A051 or A052 1 A067 Accel Time 2 A068 Decel Time 2 is active when input is active Speed is controlled by Preset Freq x A051 or A052 4 P039 Accel Time 1 P040 Decel Time 1 A067 Accel Time 2 A068 Decel Time 2 determined by the active Preset Frequency See A070 A073 Preset Freq 0 3 on page 3 16 P039 Accel Time 1 P040 Decel Time 1 are used Installation Wiring 1 19 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 Manual CE Declarations of Conformity are available online at http Awww ab com certification ce docs Low Voltage Directive 73 23 EEC e EN50178 Electronic equipment for use in power installations EMC Directive
72. otor 2 Check motor for grounded phase 3 Replace drive if fault cannot be cleared 1 Check the motor and drive output terminal wiring for a shorted condition 2 Replace drive if fault cannot be cleared 1 Clear the fault or cycle power to the drive 2 Program the drive parameters as needed Check load requirements and A098 SW Current Trip setting Reduce load or extend Accel Time a Cycle power 2 Replace drive if fault cannot be cleared 1 If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters or complete drive as required 2 Check connection 3 An adapter was intentionally disconnected 4 Turn off using A105 Comm Loss Action Set P041 Reset To Defaults to option 1 Reset Defaults 1 Cycle power 2 Replace drive if fault cannot be cleared 4 4 Troubleshooting B No Fault Description F33 Auto Rstrt Tries Drive unsuccessfully attempted Correct the cause of the fault and to reset a fault and resume running for the programmed number of A092 Auto Rstrt Tries F38 Phase U to Gnd A phase to ground fault has been F39 Phase V to Gnd detected between the drive and F40 Phase W to Gnd motor in this phase F41 Phase UV Short Excessive current has been F42 Phase UW Short detected between these two F43 Phase VW Short Utput terminals F48 Params The drive was commanded to Defaulted
73. ower up The parameter number will flash 3 Press Esc again to enter the group menu The group menu letter will flash 4 Press the Up Arrow or Down Arrow to scroll through the group menu d P and A 5 Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash 6 Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group 7 Press Enter or Sel to view the value of a parameter If you do not want to edit the value press Esc to return to the parameter number 8 Press Enter or Sel to enter program mode to edit the parameter value The right digit will flash and the Program LED will illuminate if the parameter can be edited 9 Press the Up Arrow or Down Arrow to change the parameter value If desired press Sel to move from digit to digit or bit to bit The digit or bit that you can change will flash 10 Press Esc to cancel a change The digit will stop flashing the previous value is restored and the Program LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off Press Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then d001 Output Frequency is displayed Press Enter or Sel to enter the group menu Key s War Example Displays I nn PROG
74. ps Amps Inductance Loss _ Number 240V 50 60 Hz 0 2 0 25 2 3 12 0 mh 7 5W 1321 3R2 A S Ehase 0 37 05 4 6 120mh 21W 1321 3R4 D 0 75 1 0 4 6 3 0 mh 14 5W 1321 3R4 A 15 12 0 8 12 1 5 mh 19 5W 1321 3R8 A 2 2 3 0 12 18 1 25 mh 26W 1321 3R12 A 3 7 5 0 118 27 0 8 mh 36W 11321 3R18 A 480V 50 60 Hz 0 37 10 5 2 3 20 0 mh 11 3W 1321 3R2 B amp Phase 075 10 2 3 120mh 7 5W 1921 3R2 A 15 20 4 6 6 5 mh 20W 1321 3R4 B 2 2 3 0 8 12 12 0 mh 25 3W 1321 3R8 C 3 7 5 0 18 27 3 0 mh 29W 1321 3R8 B 1 Catalog numbers listed are for 3 impedance open style units NEMA Type 1 and 5 impedance reactor types are also available Refer to publication 1321 TD001x Table B E EMC Line Filters Drive Ratings Accessories and Dimensions B 3 S Type Filter LType Filter Input Voltage kW HP Catalog Number 1 Catalog Number 8 120V 50 60 Hz 0 2 0 25 22 RF010 AL 1 Phase 037 0 5 R 22 RF010 AL 0 75 1 0 22 RF018 BL 240V 50 60 Hz 0 2 0 25 22 RF010 AL ae 037 0 5 g 22 RF010 AL 0 75 1 0 22 RF010 AL 15 2 0 2 22 RF018 BL 240V 50 60 Hz 0 2 0 25 22 RF9P5 AS 22 RF9P5 AL S phase 0o37 0 5 22 RF9P5 AS 22 RF9P5 AL 0 75 1 0 22 RF9P5 AS 22 RF9P5 AL 1 5 2 0 22 RF9P5 AS 22 RF9P5 AL 2 2 3 0 22 RF021 BS 22 RF021 BL 3 7 5 0 22 RF021 BS 22 RF021 BL 480V 50 60 Hz 0 37 0 5 22 RF5P7 AS 22 RF5P7 AL 3 Phase 0 75 1 0 22 RF5P7 AS 22 RF5P7 AL 1 5 2 0 22 RF5P7 AS 22 RF5P7 AL
75. recautions 1 11 RFI see EMC RFI RWR Reflective Wave Reducer 1 9 S Safety Ground 1 5 Shielded Power Cables 1 8 Short Circuit Protection 1 6 Software 3 1 Start and Speed Reference Selection and Control 1 16 1 17 Start Stop Repeated 1 11 Index 3 Start Up Checklist 2 1 2 2 Static Discharge ESD P 3 Status LEDs 2 3 Supply Source AC 1 3 SW OverCurrent Fault 4 4 System Grounding 1 4 T Terminal Block I O 1 12 Power 1 10 Three Wire Control 1 14 1 15 Two Wire Control 1 14 1 15 U UnderVoltage Fault 4 3 Ungrounded Supply 1 3 Unshielded Power Cables 1 8 W Wiring 1 1 Block Diagram 1 13 I O 1 11 I O Examples 1 14 1 15 Potentiometer 1 14 Power 1 8 Index 4 Notes o www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846
76. ribution amp Second Environment 2 Integral 10 meters 33 feet 1 meter 3 feet External S Type 10 meters 33 feet 1 meter 3 feet External L Type 100 meters 328 feet 5 meters 16 feet 1 Refer to Appendix B for details on optional external filters iD 2 Equivalent to EN55011 Class A 3 Equivalent to EN55011 Class B Figure 1 6 Connections and Grounding Shielded Enclosurel IP 30 NEMA 1 UL Type 1 Fittings and Metal Conduit Enclosure Ground Connection Shielded Motor Cable Option Kit PowerFie E verte i TEO eII D o 2 g EM DE EMI Filter l Ly p Bild U T1 L2 ta _ S L2 3 p Lila T ata EMER Building Structure Steel 1 First Environment Unrestricted Distribution installations require a shielded enclosure Keep wire length as short as possible between the enclosure entry point and the EMI filter 2 Integral EMI filters are available on 240V 1 Phase drives Installation Wiring 1 21 EN61000 3 2 e 0 75 kW 1 HP 240V 1 Phase and 3 Phase drives and 0 37 kW 0 5 HP 240V 1 Phase drives are suitable for installation on a private low voltage power network Installations on a public low voltage power
77. rnal Supply SRC External Supply SRC Reversing P036 Start Source 1 A momentary input will start the drive A stop input to I O Terminal 01 will stop the drive as specified by P037 Stop Mode I O Terminal 03 determines direction Direction 24V Common Each digital input draws 6 mA 3 Wire SNK Control Reversing O Direction Typical Multiple Drive Connection Examples Input Connection Example Multiple Digital Input Connections Customer Inputs can be wired per External Supply SRC or Internal Supply SNK examples on page 1 15 Customer Inputs 7 7 7 Optional Ground Connection When connecting a single input such as Run Stop Reverse or Preset Speeds to multiple drives it is important to connect I O Terminal 04 common together for all drives If they are to be tied into another common such as earth ground or separate apparatus ground only one point of the daisy chain of I O Terminal 04 should be connected Multiple Analog Connections S2O OOOO OCOOOOD OVOOOODO OOGOOOE Remote Potentiometer 7 7 7 Optional Ground Connection When connecting a single potentiometer to multiple drives it is important to connect I O Terminal 14 common together for all drives I O Terminal 14 common and I O Terminal 13 potentiometer wip
78. roup Consists of most commonly used Ese Sell A W W I programmable functions Go Oo m Advanced Program Group onsists of remaining programmable functions I Consi ini ble functi Fault Designator E Consists of list of codes for specific fault conditions Displayed only when fault is present No LED LED State Description Run Direction Steady Red Indicates drive is running and commanded motor direction Status Flashing Red Drive has been commanded to change direction Indicates actual motor direction while decelerating to zero Alphanumeric Steady Red Indicates parameter number parameter value or fault code Display Flashing Red Single digit flashing indicates that digit can be edited All digits flashing indicates a fault condition Displayed Units Steady Red Indicates the units of the parameter value being displayed Program Status Steady Red Indicates parameter value can be changed Fault Status Flashing Red Indicates drive is faulted Pot Status Steady Green Indicates potentiometer on Integral Keypad is active Start Key Status Steady Green Indicates Start key on Integral Keypad is active The Reverse key is also active unless disabled by A095 Reverse Disable No Key Name Description 8 Escape Back one step in programming menu Ese Cancel a change to a parameter value and exit Program Mode Select Adv
79. rs 3 13 Ambient Temperatures 1 2 Armored Cable 1 8 Auto Rstrt Tries Fault 4 4 Auxiliary Input Fault 4 3 B Before Applying Power 2 1 2 2 Bus Capacitors Discharging P 3 C Cable Length 1 12 Cable Power 1 8 Capacitors Discharging P 3 Catalog Number Explanation P 4 CE Conformity 1 18 Checklist Start Up 2 1 2 2 Circuit Breakers Input 1 6 Comm Loss Fault 4 4 Command Sources for Start and Speed 1 16 Common Symptoms and Corrective Action 4 5 Contactors Input 1 11 Control 2 and 3 Wire 1 14 1 15 Conventions Manual P 2 Cover Opening 1 1 Cross Reference Parameter by Name 3 25 D Dimensions Drive B 5 Minimum Clearances 1 2 Discharging Bus Capacitors P 3 Display 2 3 Index Display Group Parameters 3 3 Distribution Systems Ungrounded Drive Frame Size P 2 B 5 Drive Grounding 1 4 Drive Overload Fault 4 4 Drive Ratings P 4 A 1 DriveExecutive 3 1 DriveExplorer 3 1 E Earthing see Grounding EMC RFI Grounding Filter 1 5 Interference 1 18 Enclosure Rating Changing 1 2 ESD Static Discharge P 3 F Faults Auto Rstrt Tries 4 4 Auxiliary Input 4 3 Comm Loss 4 4 Drive Overload 4 4 Ground Fault 4 3 Heatsink OvrTmp 4 3 HW OverCurrent 4 3 I O Board Fail 4 4 Motor Overload 4 3 Motor Stalled 4 3 OverVoltage 4 3 Parameter Checksum 4 4 Phase Short 4 4 Phase to Ground Short 4 4 Power Loss 4 3 Power Unit 4 4 SW OverCurrent 4 4 UnderVoltage 4 3 F
80. s Each item is represented by a number e Numeric Parameters These parameters have a single numerical value i e 0 1 Volts e Bit Parameters Bit parameters have four individual bits associated with features or conditions If the bit is 0 the feature is off or the condition is false If the bit is 1 the feature is on or the condition is true Some parameters are marked as follows Stop drive before changing this parameter yy 32 bit parameter Parameters marked 32 bit will have two parameter numbers when using RS485 communications and programming software 3 2 Programming and Parameters Parameter Organization See page 3 3 See page 3 8 See page 3 13 Output Freq d001 Motor NP Volts P031 Digital In1 Sel A051 Commanded Freq d002 Motor NP Hertz P032 Digital In2 Sel A052 Output Current d003 Motor OL Current P033 Relay Out Sel A055 Output Voltage d004 Minimum Freq P034 Relay Out Level A056 DC Bus Voltage d005 Maximum Freq P035 Accel Time 2 A067 Drive Status d006 Start Source P036 Decel Time 2 A068 Fault 1 Code d007 Stop Mode P037 Internal Freq A069 Fault 2 Code d008 Speed Reference P038 Preset Freq 0 A070 Fault 3 Code d009 Accel Time 1 P039 Preset Freq 1 A071 Process Display d010 Decel Time 1 P040 Preset Freq 2 A072 Control Source d012 Reset To Defaults P041 Preset Freq 3 A073 Contrl In Status d013 Jog Frequency A078 Dig In Status d014 Jog Accel Decel A079 Comm Status d015 DC Brake Time A080 Control SW Ver d016 DC Brake
81. set in A079 Jog Accel Decel e A valid Start command will override this input Auxiliary Fault When enabled an F2 Auxiliary Input fault will occur when the input is removed Preset Frequencies Default Refer to A070 A073 Preset Freq x Important Digital Input 1 or 2 has priority for frequency control when it is programmed as a Preset Speed and is active Local When active sets integral keypad as start source and potentiometer on the integral keypad as speed source RS485 DSI Port e Can only be tied to one input e When active sets communications device as default start speed command source Clear Fault When active clears an active fault 3 14 Programming and Parameters A055 Relay Out Sel Related Parameter s P033 A056 A092 Sets the condition that changes the state of the output relay contacts Options 0 Ready Not Faulted Relay changes state when power is applied This indicates Default that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 Motor Running Motor is receiving power from the drive 3 Reverse Drive is commanded to run in reverse direction 4 Motor Overload Motor overload condition exists 5 Ramp Regulated Ramp regulator is modifying the programmed accel decel times
82. tions or industry guidelines Values Default 0 Min Max 0 9 Display 1 A093 Auto Rstrt Delay Related Parameter s A092 Sets the time between restart attempts when A092 Auto Rstrt Tries is set to a value other than zero Values Default 1 0 Secs Min Max 0 0 120 0 Secs Display 0 1 Secs Stop drive before changing this parameter A094 Start At PowerUp Enables disables a feature that allows a Start or Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored Requires a digital input configured for Run or Start and a valid start contact This parameter will not function if parameter P036 Start Source is set to 4 2 Wire High Speed ATTENTION Equipment damage and or personal injury may result if this parameter is used in an inappropriate application Do not use this function without considering applicable local national and international codes standards regulations or industry guidelines Options 0 Disabled Default 1 Enabled 3 22 Programming and Parameters Advanced Program Group continued Stop drive before changing this parameter A095 Reverse Disable Enables disables the function that allows the direction of motor rotation to be changed The reverse command may come from a digital command the keypad or a serial command All reverse inputs including two wire Run Reverse will be ignored with r
83. tor frame motor end Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal The conduit box option may be used with a cable clamp for a grounding point for the cable shield When shielded cable is used for control and signal wiring the shield should be grounded at the source end only not at the drive end RFI Filter Grounding Using single phase drives with integral filter or an external filter with any drive rating may result in relatively high ground leakage currents Therefore the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded bonded to the building power distribution ground Ensure that the incoming supply neutral is solidly connected bonded to the same building power distribution ground Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection Some local codes may require redundant ground connections The integrity of all connections should be periodically checked 1 6 Installation Wiring Fuses and Circuit Breakers The PowerFlex 4 does not provide branch short circuit protection This product should be installed with either input fuses or an input circuit breaker National and local industrial safety regulations and or electrical codes may determine additional requirements for these installations ATTENTION To guard against perso
84. ts Speed Volts S DC Brake Level Time t Stop Command Stop Command ATTENTION Ifa hazard of injury due to movement of equipment or material exists an auxiliary mechanical braking device must be used ATTENTION This feature should not be used with synchronous or permanent magnet motors Motors may be demagnetized during braking gt gt 3 18 Programming and Parameters Advanced Program Group continued Stop drive before changing this parameter A082 DB Resistor Sel Enables disables external dynamic braking Setting Min Max 0 Disabled 1 AB Resistor 5 Duty Cycle 2 No Protection 100 Duty Cycle 3 99 Duty Cycle Limited 3 99 of Duty Cycle Values Default 0 Min Max 0 99 Display 1 A083 S Curve Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve Time is added 1 2 at the beginning and 1 2 at the end of the ramp Values Default 0 Disabled Min Max 0 100 Display 1 Example Accel Time 10 Seconds S Curve Setting 30 S Curve Time 10 x 0 3 3 Seconds 100 S Curve Target L J I S Curve Time Accel Time l l I Total Time to Accelerate Accel Time S Curve Time gt 50 S Curve Targeti2 H I l l i i l l l r SCure Time l Total Time to Accelerate Accel Time S Curve Time il Programming and Para
85. write default values to EEPROM F63 SW OverCurrent Programmed A098 SW Current Trip has been exceeded F64 Drive Overload Drive rating of 150 for 1 minute or 200 for 3 seconds has been exceeded F70 Power Unit Failure has been detected in the drive power section F81 Comm Loss RS485 DSI port stopped communicating F100 Parameter The checksum read from the Checksum board does not match the checksum calculated F122 1 O Board Fail Failure has been detected in the drive control and I O section See page 4 1 for a description of fault types Troubleshooting 4 5 Common Symptoms and Corrective Actions Motor does not Start Cause s Indication Corrective Action No output voltage to the motor None Check the power circuit e Check the supply voltage e Check all fuses and disconnects Check the motor e Verify that the motor is connected properly Check the control input signals e Verify that a Start signal is present If 2 Wire control is used verify that either the Run Forward or Run Reverse signal is active but not both e Verify that I O Terminal 01 is active e Verify that P036 Start Source matches your configuration e Verify that A095 Reverse Disable is not prohibiting movement is Drive does not Start from Start or Run Inputs wired to the terminal block Cause s Indication Corrective Action Drive is Fault
86. xRxD 5 ad i Shield Shield Shield x X e X NOTE The shield is connected at ONLY ONE end of each cable segment Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 4 RJ45 socket contain power etc for other Rockwell Automation peripheral devices and must not be connected Wiring terminations on the master controller will vary depending on the master controller used and TxRxD and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations Note that there is no standard for the and wires and consequently Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wires at the master controller Standard RS485 wiring practices apply Termination resistors need to be applied at each end of the network cable RS485 repeaters may need to be used for long cable runs or if greater than 32 nodes are needed on the network RS485 DSI Protocol Control Terminal 16 on the PowerFlex 4 must also be connected to PE ground there are two PE terminals on the drive See Figure 1 5 for more information Parameter Configuration The following PowerFlex 4 parameters are used to configure the drive to operate on a network Parameter Details Reference P036 Start Source Set to 5 RS485 DSI Port if Start is controlled from
87. ximum Freq Decel Time Decel Rate Values Default 10 0 Secs Min Max 0 1 600 0 Secs Display 0 1 Secs Maximum Freq NE NG Speed CO gt 0 W Accel Time Time I Decel Time 0 Stop drive before changing this parameter P041 Reset To Defaults Resets all parameter values to factory defaults Options 0 Idle State Default 1 Reset Defaults e After the reset function is complete this parameter will set itself back to 0 e Causes an F48 Params Defaulted fault Programming and Parameters 3 13 Advanced Program Group Stop drive before changing this parameter A051 Digital In1 Sel I O Terminal 5 A052 Digital In2 Sel I O Terminal 6 Selects the function for the digital inputs Refer to the flowchart on page 1 17 for more information on speed reference control priority Related Parameter s A067 A068 A070 A073 A078 A079 Options 0 Not Used 1 Accel 2 amp Decel 2 e Can only be tied to one input e When active A067 Accel Time 2 and A068 Decel Time 2 are used for all ramp rates except Jog Refer to the flowchart on page 1 18 for more information on Accel Decel selection Jog e When input is present drive accelerates according to the value set in A079 Jog Accel Decel and ramps to the value set in A078 Jog Frequency e When input is removed drive ramps to a stop according to the value
88. your control wiring scheme See Figure 1 5 on page 1 13 for location Important The default control scheme is Source SRC The Stop terminal is jumpered I O Terminals 01 and 11 to allow starting from the keypad If the control scheme is changed to Sink SNK the jumper must be removed from I O Terminals 01 and 11 and installed between I O Terminals 01 and 04 5 Verify that the Stop input is present or the drive will not start Important If I O Terminal 01 is used as a stop input the jumper between I O Terminals 01 and 11 must be removed 2 2 Start Up Applying Power to the Drive 6 Apply AC power and control voltages to the drive 7 Familiarize yourself with the integral keypad features see page 2 3 before setting any Program Group parameters Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from the integral keypad No programming is required to start stop change direction and control speed directly from the integral keypad Important To disable reverse operation see A095 Reverse Disable If a fault appears on power up refer to Fault Descriptions on page 4 3 for an explanation of the fault code Start Up 2 3 Integral Keypad eo Menu Description br p m f V anes Display Group View Only mn u verre TT gd Consists of commonly viewed drive operating PROGRAM FAULT pa conditions o 00O Basic Program G

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