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Allen Bradley PowerFlex 40 Users Manual

1. Specifications Output Ratings Input Ratings Branch Circuit Protection Catalog Number Voltage 140M Motos kW HP Amps Range kVA Amps Fuses Protectors Contactors 100 120V AC 10 1 Phase Input 0 230V 3 Phase Output 22B V2P3x104 0 4 0 5 2 3 90 132 1 15 9 0 15 140M C2E C16 100 C12 22B V5P0x104 0 75 1 0 5 0 90 132 2 45 20 3 35 140M D8E C20 100 C23 22B V6P0x104 1 1 1 5 6 0 90 132 3 0 24 0 40 140M F8E C32 100 C37 200 240V AC 10 1 Phase Input 0 230V 3 Phase Output 22B A2P3x104 0 4 0 5 2 3 180 264 1 15 16 0 10 140M C2E B63 100 C09 22B A5P0x104 0 75 1 0 5 0 180 264 2 45 12 0 20 140M C2E C16 100 C12 22B A8P0x104 1 5 2 0 8 0 180 264 4 0 18 0 30 140M D8E C20 100 C23 22B A012x104 2 2 3 0 12 0 180 264 5 5 25 0 40 140M F8E C32 100 C37 200 240V AC 10 3 Phase Input 0 230V 3 Phase Output 22B B2P3x104 0 4 0 5 2 3 180 264 1 15 2 5 6 140M C2E B40 100 C07 22B B5P0x104 0 75 1 0 5 0 180 264 2 45 5 7 10 140M C2E C10 100 C09 22B B8P0x104 1 5 2 8 0 180 264 4 0 9 5 15 140M C2E C16 100 C12 22B B012x104 2 3 0 12 0 180 264 55 155 25 140M C2E C16 100 C23 22B B017x104 3 7 5 0 17 5 180 264 8 6 21 0 30 140M F8E C25 100 C23 22B B024x104 5 7 5 24 0 180 264 11 8 26 1 40 140M F8E C32 100 C37 22B B033x104 7 5 10 0 33 0 180 264 16 3 34 6 60 140M G8E C45 100 C60 380 480V AC 10 3 Phase Input 0 460
2. o 297 309 11 69 12 17 297 11 69 i d 5 5 0 22 gt k Accessories and Dimensions B 17 Figure B 13 Remote Panel Mount Small HIM Dimensions are in millimeters and inches Catalog Number 22 HIM C2S oy jy BS E 93 0 98 3 66 t A B 180 ia 7 09 B 18 Accessories and Dimensions Figure B 14 NEMA Type 1 Bezel Dimensions are in millimeters and inches Catalog Number 22 HIM B1 25 2 f 0 99 lt 2m gt Stee _ he 7 2 64 114 93 0 44 3 66 Ss F E K CO00O0 COO0O0O 180 CQOO0O0 7 09 OOOmM QUOC ao Appendix C RS485 DSI Protocol PowerFlex 40 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 40 drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode oT er anioe E te a e a For information regarding DeviceNet or other communication protocols refer to the appropriate user manual Network Wiring Ne
3. 1 1 Mounting Considerations 1 3 AC Supply Source Considerations 1 5 General Grounding Requirements 1 7 Fuses and Circuit Breakers 1 8 Power Wiring 00 000 1 10 IP66 NEMA UL Type 4X Installations 1 14 T O Wiring Recommendations 1 14 Start and Speed Reference Control 1 23 EMC Instructions 1 25 Prepare For Drive Start Up 2 1 Integral Keypad teorier snese 2 3 Viewing and Editing Parameters 2 4 Remote HIM Menu Structure 2 5 About Parameters 00 3 1 Parameter Organization 3 2 Display Group 05 3 3 Basic Program Group 3 9 Advanced Program Group 3 14 Parameter Cross Reference by Name 3 44 Drive Status 0000200005 4 1 PAU te sipeye esate tee le EEE EE ape Bo 4 1 Fault Descriptions 4 3 Common Symptoms and Corrective Actions 4 5 Supplemental Drive Information Drive Fuse amp Circuit Breaker Ratings A 1 SPeciicatiOns 22 6 4 74 kee Lesa Lk A 2 Accessories and Dimensions Product Selection 00 B 1 Product Dimensions B 7 RS485 DSI Protocol RJ45 DSI Splitter Cable StepLogic Basic Logic and Timer Counter Functions PID Set Up 2 Table of Contents Preface Overview The purpose of this manual is to provide you with the basic in
4. 0 10V Trim 4 20mA Trim Comm Trim NI o o A O N A133 PID Feedback Sel Select the source of the PID feedback Refer to Appendix F for details Options 0 0 10V Input Default The PID will not function with a bipolar input Negative voltages are treated as 0 volts 1 4 20mA Input 2 Comm Port A134 PID Prop Gain Sets the value for the PID proportional component when the PID mode is enabled by A132 PID Ref Sel Values Default 0 01 Min Max 0 00 99 99 Display 0 01 3 38 Programming and Parameters Advanced Program Group continued A135 PID Integ Time Sets the value for the PID integral component when the PID mode is enabled by A132 PID Ref Sel Values Default 0 1 Secs Min Max 0 0 999 9 Secs Display 0 1 Secs A136 PID Diff Rate Sets the value for the PID differential component when the PID mode is enabled by A132 PID Ref Sel Values Default 0 01 1 Secs Min Max 0 00 99 99 1 Secs Display 0 01 1 Secs A137 PID Setpoint Provides an internal fixed value for process setpoint when the PID mode is enabled by A132 PID Ref Sel Values Default 0 0 Min Max 0 0 100 0 Display 0 1 A138 PID Deadband Sets the lower limit of the PID output Values Default 0 0 Min Max 0 0 10 0 Display 0 1 A139 PID Preload Sets the value used to preload the integral component
5. Digital In1 gt Counter In Digital In2 gt Reset Counter l m Limit Switch gt i Note that a Reset Timer input is not required for this example since the Timer Start input both clears and starts the timer StepLogic Basic Logic and Timer Counter Functions Counter Function Digital inputs and outputs control the counter function and are configured with parameters A051 A054 Digital Inx Sel set to 19 Counter In and 21 Reset Counter Digital outputs relay and opto type define a preset level and indicate when the level is reached Level parameters A056 Relay Out Level A059 Opto Out1 Level and A062 Opto Out2 Level are used to set the desired count value Parameters A055 Relay Out Sel A058 Opto Out Sel and A061 Opto Out2 Sel are set to 17 Counter Out which causes the output to change state when the level is reached Example e A photo eye is used to count packages on a conveyor line e An accumulator holds the packages until 5 are collected e A diverter arm redirects the group of 5 packages to a bundling area e The diverter arm returns to its original position and triggers a limit switch that resets the counter e Parameters are set to the following options A051 Digital In1 Sel set to 19 to select Counter In A052 Digital In2 Sel set to 21 to select Reset Counter A055 Relay Out Sel set to 17 to select Counter Out
6. Comm Select Input Enabled and Active Digital Inx Sel 6 Start Speed and Direction commands come from RS485 DSI port Speed commands come from 0 10V 0 10V Override Enabled and Active Digital Inx Sel 13 Start and Direction follows P036 Start Source or Bi Polar input when enabled Speed commands come from 4 20mA 4 20mA Override Enabled and Active Digital Inx Sel 14 Start and Direction follows P036 Start Source Run as specified by P038 Speed Refernece P038 Speed Reference 40r5 Start and Direction commands come from P036 Start Source Run as specified by A071 A077 Preset Freq 1 7 A051 A052 A053 Preset Inputs Active Start and Direction commands come from P036 Start Source Run as specified by A132 PID Ref Select PID Enabled A132 PID Ref Select 0 Yes 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 24 Installation Wiring Accel Decel Selection The Accel Decel rate can be obtained by a variety of methods The default rate is determined by P039 Accel Time 1 and P040 Decel Time 1 Alternative Accel Decel rates can be made through digital inputs RS485 DSI communications and or parameters See the chart below for the override priority Ze 100
7. gt 92 2 3 63 l lt 69 2 2 72 gt 28 5 145 7 1 80 Ca 1 12 122 2 0 87 22 2 ES a 087 g u F QOO 2 O V 7 Yes Y IS R O V Accessories and Dimensions B 9 Figure B 4 PowerFlex 40 Flange Mount Drives Dimensions are in millimeters and inches 244 R ie 94 3 sig Uly 9 61 44 3 71 2 48 i 8 43 a Ny Frame B 130 3 F 0 613 105 8 138 2 11 81 4 17 5 44 q TT 325 al 12 8 d S Q if q z a 22B CCC Ww Frame C Accessories and Dimensions Figure B 5 PowerFlex 40 Flange Mount Cutout Dimensions Dimensions are in millimeters and inches mc 2 a R Za 5 71 0 26 23 5 g 0 93 T ena 197 7 76 o 8 27 225 Aeaee a 2 8 86 7 7 ro 98 5 3 88 53 0 21 Y Ve s 14 31 49 _ 75 0 55 41 22 1 93 gg 0 30 P 9 96 160 6 30 Frame B 8 a i 164
8. 01 02 01 02 input to I O Terminal 01 ce 04 will stop the drive as specified by P037 LN Commn Stop Mode be Each digital input draws 6 mA 3 Wire SNK Control Internal Supply SNK Non Reversing 0080 01 02 03 04 0 3 Wire SRC Control 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 1 O Terminal 03 determines direction Internal Supply SRC External Supply SRC 08 01 02 03 Direction 24V Common 8 01 02 03 04 Each digital input draws 6 mA 1 21 Installation Wiring Input Output Connection Example 3 Wire SNK Control Internal Supply SNK Reversing Stop les 01 L is e 03 04 gt Direction E o S Opto Output 1 amp 2 Opto Output 1 A058 Opto Out1 Sel determines Ss Opto Output 1 I O Terminal 17 operation A061 Opto Out2 Sel determines Opto Output 2 I O 17 Terminal 8 operation K When using 09 Opto Output with an inductive load such as a relay install a recovery diode parall
9. 4 20mA Trim Selects Trim Control Selects the 4 20mA Input 8 Comm Trim Selects Trim Control The reference word from a communication network see Appendix C for details on the reference word such as Modbus RTU or DeviceNet becomes the PID Reference The value sent over the network is scaled so that P035 Maximum Freq x 10 100 reference For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 reference A133 PID Feedback Sel is used to select the source of the PID feedback Table F B A133 PID Feedback Sel Options Option 0 0 10V Input Description Selects the 0 10V Input default setting Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 1 4 20mA Input Selects the 4 20mA Input 2 Comm Port The reference word from a communication network see Appendix C of the PowerFlex 40 User Manual for details on the reference word such as Modbus RTU or DeviceNet becomes the PID Feedback The value sent over the network is scaled so that P035 Maximum Freq x 10 100 Feedback For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 Feedback PID Set Up F 5 Analog PID Reference Signals Parameters A110 Anlg In 0 10V Lo and A111 Anlg In 0 10V Hi are used to scale or invert an analog PID Reference Impor
10. A056 Relay Out Level set to 5 0 counts StepLogic Parameters StepLogic Basic Logic and Timer Counter Functions E 7 Table E A Code Descriptions for Parameters A140 A147 Digit 3 Digit 2 Digit 1 Digit 0 0 0 F 1 Table E B Digit 3 Defines the action during the step currently executing Accel Decel StepLogic Output Setting Parameters Used State Commanded Direction 0 1 Off FWD 1 1 Off REV 2 1 Off No Output 3 1 On FWD 4 1 On REV 5 1 On No Output 6 2 Off FWD 7 2 Off REV 8 2 Off No Output 9 2 On FWD A 2 On REV b 2 On No Output Table E C Digit 2 Defines what step to jump to or how to end program when the logic conditions specified in Digit 1 are met Setting Logic Jump to Step 0 Jump to Step 1 Jump to Step 2 Jump to Step 3 Jump to Step 4 Jump to Step 5 Jump to Step 6 Jump to Step 7 End Program Normal Stop End Program Coast to Stop oO CO NN DD om A w wp o End Program and Fault F2 E 8 StepLogic Basic Logic and Timer Counter Functions Table E D Digit 1 Defines what logic must be met to jump to a step other than the very next step Setting Description Logic 0 Skip Step jump immediately SKIP 1 Step based on the time programmed in the respective Stp Logic Time x TIME
11. Stop Uses P037 Stop Mode 3 Zero Ref Drive runs at zero speed reference 4 Min Freq Ref Drive runs at minimum frequency 5 Max Freq Ref Drive runs at maximum frequency 6 Int Freq Ref Drive runs at internal frequency A123 10V Bipolar Enbl Related Parameter s P038 A111 Enables disables bipolar control In bipolar mode direction is commanded by the sign of the reference Options 0 Uni Polar In Default 0 to 10V only 1 Bi Polar In 10V A124 Var PWM Disable Related Parameter s A091 Stop drive before changing this parameter Enables disables a feature that varies the carrier frequency for the PWM output waveform defined by A091 PWM Frequency Disabling this feature when low frequency conditions exist may result in IGBT stress and nuisance tripping Options 0 Enabled Default 1 Disabled A125 Torque Perf Mode Related Parameter s A084 A085 A086 A087 A127 Stop drive before changing this parameter Enables disables sensorless vector control operation Options 0 V Hz 1 Sensrls Vect Default A126 Motor NP FLA Related Parameter s A127 Set to the motor nameplate rated full load amps Values Default Drive Rated Amps Min Max 0 1 Drive Rated Amps x 2 Display 0 1 Amps 3 36 Programming and Parameters Advanced Program Group continued A127 Autotune Related Parameter s A125 A126 A128 A129 S
12. e Runat Step 0 e Transition to Step 1 when Logic In1 is true Logic senses the edge of Logic In1 when it transitions from off to on Logic In1 is not required to remain on e Transition to Step 2 when both Logic In1 and Logic In2 are true The drive senses the level of both Logic In1 and Logic In2 and transitions to Step 2 when both are on e Transition to Step 3 when Logic In2 returns to a false or off state Inputs are not required to remain in the on condition except under the logic conditions used for the transition from Step 2 to Step 3 Start Step 0 Stepi Step2 Step 3 Frequency Logic Int gt a Logic In2 gt Time The step time value and the basic logic may be used together to satisfy machine conditions For instance the step may need to run for a minimum time period and then use the basic logic to trigger a transition to the next step Start Step 0 Step 1 Frequency Logic Int gt Logic In2 gt Time StepLogic Basic Logic and Timer Counter Functions Timer Function Digital inputs and outputs control the timer function and are configured with parameters A051 A054 Digital Inx Sel set to 18 Timer Start and 20 Reset Timer Digital outputs relay and opto type define a preset level and indicate when the level is reached Level parameters A056 Relay Out Level A059 Opto Out1 Level and A062 Opto Out2 Leve
13. 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 Typical B Frame C Frame RILI S L2 T L3 U T1 VT2 W T3 ALI S l2 T L3 UMi V2 WMT3 P2 Pt PERO SSSR appease EERRER DC DC BR BR O O DC DC BR BR Terminal Description R L1 S L2 1 Phase Input R L1 S L2 T L3 3 Phase Input U T1 To Motor U T1 5 Switch any two motor V T2 To Motor V T2 16 leads to change WT3 To Motor W T3 forward direction DC Bus Inductor Connection C Frame drives only The C Frame drive is shipped with a jumper between P2 P1 Terminals P2 and P1 Remove this jumper only when a DC U U Bus Inductor will be connected Drive will not power up without a jumper or inductor connected DC DC DC Bus Connection BR BR Dynamic Brake Resistor Connection Safety Ground PE 1 Important Terminal screws may become loose during shipment Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive Table 1 E Power Terminal Block Specifications B 5 3 mm 10 AWG 1 3 mmf 16 AWG 1 7 2 2 N m 16 19 lb in 0 8 4 mm 8 AWG 1 3 mm 16 AWG 2 9 3 7 N m 26 33 Ib
14. Allen Bradley Adjustable Frequency AC Drive FRN 1 xx 4 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 Rockwell Automation sales office or online at http www rockwellautomation comlliterature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of
15. OverVoltage Motor Stalled Motor Overload Heatsink OvrTmp HW OverCurrent Ground Fault Analog Input Loss 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 been detected at one or more of the drive output terminals An analog input is configured to fault on signal loss A signal loss has occurred Configure with A122 Analog In Loss 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 Limit 1 An excessive motor load exists Reduce
16. Table 1 B Input Power Conditions Input Power Condition Corrective Action Install Line Reactor e or Isolation Transformer e or Bus Inductor 5 5 amp 11 kW 7 5 amp 15 HP drives only Low Line Impedance less than 1 line reactance Greater than 120 kVA supply transformer Install Line Reactor e or Isolation 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 line voltage e or Install Isolation Transformer Ungrounded distribution system with grounded secondary if necessary 240V open delta configuration stinger leg e Install Line Reactor 1 For drives applied on an open delta with a middle phase grounded neutral system the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the stinger leg high leg red leg etc This leg should be identified throughout the system with red or orange tape on the wire at each connection point The stinger leg should be connected to the center Phase B on the reactor Refer to Table B D for specific line reactor part numbers Refer to Appendix B for accessory ordering information Installation Wiring 1 7 General Grounding Requirements The drive Safety Ground PE must be connected to system
17. 22 RF018 BL 240V 50 60 Hz 0 4 0 5 2 22 RF018 BL 1 Phase 0 75 10 g 22 RF018 BL 15 2 0 2 22 RF018 BL 2 2 3 0 2 22 RF025 CL 240V 50 60 Hz 0 4 0 5 22 RF021 BS 22 RF021 BL 3 Phase 0o75 hio 22 RF021 BS 22 RF021 BL 15 2 0 22 RF021 BS 22 RF021 BL 2 2 3 0 22 RF021 BS 22 RF021 BL 3 7 5 0 22 RF021 BS 22 RF021 BL 5 5 75 22 RF034 CS 22 RF034 CL 75 10 0 22 RF034 CS 22 RF034 CL 480V 50 60 Hz 0 4 0 5 22 RF012 BS 22 RF012 BL 3 Phase 0 75 1 0 22 RF012 BS 22 RF012 BL 15 2 0 22 RF012 BS 22 RF012 BL 2 2 3 0 22 RF012 BS 22 RF012 BL 4 0 5 0 22 RF012 BS 22 RF012 BL 5 5 7 5 22 RF018 CS 22 RF018 CL 75 10 0 22 RF018 CS 22 RF018 CL 11 0 15 0 22 RF026 CS 22 RF026 CL 600V 50 60 Hz 0 75 1 0 22 RF8P0 BL 3 Phase 15 2 0 5 22 RF8P0 BL 2 2 3 0 22 RF8P0 BL 4 0 5 0 22 RF8P0 BL 55 75 22 RF015 CL 75 10 0 22 RF015 CL 11 0 15 0 22 RF024 CL 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 Filter must be Series B or later 4 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 Accessories and Dimensions B 5 Table B G Human Interface Module HIM Option Kits and Accessories Item Descript
18. 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 A054 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 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 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 F29 Fault Descriptions Table 4 A Fault Types Descriptions and Actions Fault Auxiliary Input Power Loss UnderVoltage
19. Display 0 1 Hz A115 Process Time Lo Related Parameter s d010 P034 Scales the time value when the drive is running at P034 Minimum Freq When set to a value other than zero d010 Process Display indicates the duration of the process Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A116 Process Time Hi Related Parameter s d010 P035 Scales the time value when the drive is running at P035 Maximum Freq When set to a value other than zero d010 Process Display indicates the duration of the process Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A117 Bus Reg Mode Controls the operation of the drive voltage regulation which is normally operational at decel or when the bus voltage rises Refer to the Attention statement on page P 3 for important information on bus regulation Options 0 Disabled 1 Enabled Default A118 Current Limit 2 Related Parameter s P033 A051 A054 A089 Maximum output current allowed before current limiting occurs This parameter is only active if A051 A054 Digital Inx Sel is set to 25 Current Lmt2 and is active Values Default Drive Rated Amps x 1 5 Min Max 0 1 Drive Rated Amps x 1 8 Display 0 1 Amps 3 34 Programming and Parameters Advanced Program Group continued A119 Skip Frequency Related Parameter s A120 Sets the frequency at which the drive will not operate A setting of 0 disables this param
20. Logic In2 is Active 4 Jump to Step 4 4 Step if Logic In1 is Not Active 5 Jump to Step 5 5 Step if Logic In2 is Not Active 6 Jump to Step 6 6 Step if either Logic In1 or Logic In2 is Active 7 Jump to Step 7 7 Step if both Logic In1 and Logic In2 is Active 8 End Program Normal Stop 8 Step if neither Logic In1 or Logic In2 is Active 9 End Program Coast to Stop 9 Step if Logic In1 is Active and Logic In2 is Not Active A End Program and Fault F2 A Step if Logic In2 is Active and Logic In1 is Not Active b Step after Stp Logic Time x and Logic In1 is Active C Step after Stp Logic Time x and Logic In2 is Active d Step after Stp Logic Time x and Logic In1 is Not Active E Step after Stp Logic Time x and Logic In2 is Not Active F Do Not Step Ignore Digit 2 Settings Programming and Parameters 3 41 Advanced Program Group continued A150 Stp Logic Time 0 Related Parameter s P038 A055 A058 A061 A151 Stp Logic Time 1 A070 A077 A140 A147 A152 Stp Logic Time 2 A153 Stp Logic Time 3 A154 Stp Logic Time 4 A155 Stp Logic Time 5 A156 Stp Logic Time 6 A157 Stp Logic Time 7 Sets the time to remain in each step if the corresponding StpLogic command word is set to Step after Time Values Default 30 0 Secs Min Max 0 0 999 9 Secs Display 0 1 Secs A160 EM Brk Off Dela
21. and connected to Master port M on RJ45 Splitter Cable Connecting One Temporary Peripheral and One Permanent Peripheral NEMA 1 Bezel NEMA 4 with DSI MDI Hand Held Panel Mount U 2 DSI MDI Drive Parameter 9 Device Type set to Master and connected to Master port M on RJ45 Splitter Cable Parameter 1 Adapter Cfg set to Auto default or Slave and connected to Slave port S on RJ45 Splitter Cable Serial Converter D 4 RJ45 DSI Splitter Cable Connecting Two Permanent Peripherals NEMA 1 Bezel with DSI MDI Hand Held NEMA 4 Panel Mount Unit DSI MDI Drive Parameter 9 Device Type set to Master and connected to Master port M on RJ45 Splitter Cable Parameter 9 Device Type set to Slave and connected to Slave port S on RJ45 Splitter Cable Connecting an RS 485 Network DSI MDI Drives AK U0 RJ45 TB2P Two position _ Terminal Block AK U0 RJ45 TR1 Terminating Resistor end of network L or i or Customer supplied RJ45 male to RJ45 male cables with wires connected at pins 4 and 5 only 1o00000 Both the Master M and Slave S ports on the RJ45 Splitter Cable operate as standard RS 485 ports in this configuration Appendix E StepLogic Basic Logic and Timer Counter Functions Four PowerFlex 40 logic functions provide the capability to program simpl
22. ee Time 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 24 Programming and Parameters Advanced Program Group continued A082 DB Resistor Sel Related Parameter s P037 Stop drive before changing this parameter Enables disables external dynamic braking Setting Min Max 0 Disabled 1 Normal RA Res 5 Duty Cycle Refer to Table B C on page B 2 2 NoProtection 100 Duty Cycle 3 99 x Duty Cycle Limited 3 99 of Duty Cycle The drive is able to provide full braking indefinitely Braking power is limited by the external DB resistor When this parameter is set to 1 Normal RA Res and an appropriate resistor is used see selection Table B C the drive provides calculated resistor overload protection However the drive cannot protect against a brake IGBT failure external resistor package must be self protected from over temperature or the protective ATTENTION A risk of fire exists if external braking resistors are not protected The A circuit shown in Figure B 9 on page B 13 or equivalent must be supplied Values Default 0 Min Max 0 99 Display 1 A083 S Curve Sets the percentage of acceleration or de
23. 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 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 motor 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
24. in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations 1 14 Installation Wiring A IP66 NEMA UL Type 4X Installations Use the plugs supplied with IP66 NEMA UL Type 4X rated drives to seal unused holes in the conduit entry plate Important Completely seat the plug inner rim for the best seal N 1 0 Wiring Recommendations Motor Start Stop Precautions ATTENTION A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage The drive is designed to use control input signals that will start and stop the motor If used the input device must not exceed one operation per minute or drive damage can occur ATTENTION The drive start stop control circuitry includes solid state components If hazards due to accidental contact with moving machinery or unintentional flow of liquid gas or solids exist an additional hardwired stop circuit may be required to remove the AC line to the drive 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 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 p
25. 1 only Ordered Separately BACnet ControlNet DeviceNet EtherNet IP LonWorks PROFIBUS DP Catalog Number 22 COMM B 22 COMM C 22 COMM D 22 COMM E 22 COMM L 22 COMM P External DSI Communications Kit External mounting kit for 22 COMM communication options 22 XCOMM DC BASE External Comms Power Supply Optional 100 240V AC Power Supply for External DSI Communications Kit 20 XCOMM AC PS1 Compact I O Module Three channel 1769 SM2 Communication Adapter Cover that houses the DeviceNet Communication Cover Adapter IP20 NEMA UL Type 1 only B Frame Drive 22B CCB C Frame Drive 22B CCC Serial Converter Module Provides serial communication via DF1 protocol 22 SCM 232 RS485 to RS232 for 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 RJ45 cable male to male connectors 22 RJ45CBL C20 Serial Cable 2 0 meter serial cable with a locking low profile connector to connect to the serial converter and a 9 pin sub miniature D female connector to connect to a computer 1203 SFC Null Cable Converter For use when connecting the serial converter to DriveExplorer on a handheld PC 1203 SNM Splitter Cable RJ45 one to two port splitter cable AK U0 RJ45 SC1 Terminating Resistors RJ45 1
26. 10 Auto Rstrt Tries Fault F33 4 4 Auxiliary Input Fault F2 4 3 B Before Applying Power 2 1 Bus Capacitors Discharging P 3 1 2 C Cable Length 1 15 Cable Power 1 10 Capacitors Discharging P 3 1 2 Catalog Number Explanation P 4 CE Conformity 1 25 Checklist Start Up 2 1 Circuit Breakers 1 8 Comm Loss Fault F81 4 4 Command Sources for Start and Speed 1 23 Common Symptoms and Corrective Action 4 5 Contactors 1 14 Control Wiring 1 16 Control 2 and 3 Wire 1 18 Conventions Manual P 2 Cover Opening 1 1 Cross Reference Parameter by Name 3 44 D Data Diagnostic 2 6 Data Saving 2 6 Deceleration Rate 1 24 Index Dimensions Drive B 7 Minimum Clearances 1 3 Direction of Drive 2 2 of Motor 1 13 Discharging Bus Capacitors P 3 1 2 Disconnecting Output Power 1 12 Display 2 3 Display Group Parameters 3 3 ee Systems Ungrounded Drive Frame Size P 2 B 7 Drive Grounding 1 7 Drive Overload Fault F64 4 4 Drive Ratings P 4 A 1 DriveExecutive 3 1 DriveExplorer 3 1 E Earthing see Grounding Edit Parameters 2 4 EMC RFI Grounding Filter 1 8 Interference 1 25 Enclosure Rating Changing 1 3 ESD Static Discharge P 3 F Faults Analog Input Loss F29 4 3 Auto Rstrt Tries F33 4 4 Auxiliary Input F2 4 3 Comm Loss F81 4 4 Drive Overload F64 4 4 Ground Fault F13 4 3 Heatsink OvrTmp F8 4 3 HW OverCurrent F12 4 3 I O Board Fail F122 4 5 Motor Overload F
27. 17 18 19 DSI SRC D A 1 AVAC gt Resistive 3 0A 3 0A 3 0A Inductive 0 5A 0 5A 0 5A 1 Important O Terminal 01 is always a coast to stop P036 Start Source Stop VO Terminal 01 Stop input except when P036 Start Source is set to Keypad Per P037 Coast 3 Wire or Momt FWD REV control In three wire 3 Wire Per P037 Per P037 control I O Terminal 01 is controlled by P037 Stop 2 Wire Pathos Coast a Momt FWD REV Per P037 Per P037 Mode All other stop sources are controlled by P037 ASIBS Pon Per POG7 Coast Stop Mode Important The drive is shipped with a jumper installed between I O Terminals 01 and 11 Remove this jumper when using I O Terminal 01 as a stop or enable input Two wire control shown For three wire control use a momentary input on I O Terminal 02 to command a start Use a maintained input o for I O Terminal 03 to change direction When using an opto output with an inductive load such as a relay install a recovery diode parallel to the relay as shown to prevent damage to the output When the ENBL enable jumper is removed I O Terminal 01 will always act as a hardware enable causing a coast to stop without software interpretation Installation Wiring 1 17 Table 1 H Control I O Terminal Designations No Signal Default Description Param R1 Relay N O Fault Normally open
28. 3 5 1321 3R4 D 112 4 40 104 4 10 92 3 62 66 2 60 37 1 44 2 7 6 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 3R8 C 152 6 00 127 5 00 85 3 35 63 2 48 51 2 00 4 9 11 1321 3R12 A 152 6 00 127 5 00 76 3 00 53 2 10 51 2 00 4 1 9 1321 3R12 B 152 6 00 127 5 00 76 3 00 53 2 10 51 2 00 4 5 10 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 1321 3R25 A 183 7 20 146 5 76 85 3 35 60 2 35 76 3 00 4 9 11 1321 3R35 A 193 7 60 146 5 76 91 3 60 66 2 60 76 3 00 6 3 14 Accessories and Dimensions B 15 Figure B 11 Frame B EMC Line Filters Dimensions are in millimeters and inches Catalog Numbers 22 RF8P0 BL 22 RF012 BS BL Series B 22 RF018 BS 22 RF021 BS BL oy 4 z6 B 3 07 l QQ olelstelaloX e 217 8 54 9 02 216 8 50 e A P A 17 EN 76 Ric 2 7 k 5 5 0 22 Iil B 16 Accessories and Dimensions Figure B 12 Frame C EMC Line Filters Dimensions are in millimeters and inches Catalog Numbers 22 RF018 CS CL 22 RF025 CL 22 RF026 CS CL 22 RF034 CS CL 60 130 5 2 36 90 612 1 26 3 54 er oeeie
29. 7 253 0 31 6 46 Pa 0 21 S PS l 307 5 12 11 i hd e l 230 6 i 9 08 291 5 11 48 amp 153 8 6 06 i P 76 9 i 3 03 l LU 3 i e 5 90 L 8 k 3 54 180 0 31 7 09 Frame C Accessories and Dimensions B 11 Figure B 6 PowerFlex 40 Replacement Plate Drive Dimensions Dimensions are in millimeters and inches 125 je 4 92 38 5 3 46 0 37 100 5 3 a 3 94 i 0 21 Frame B 123 5 x 4 86 98 5 u 95 3 88 0 37 ii O 272 10 71 284 260 F 01148 10 24 y y 4 E z O53 22B CCC 0 21 Frame C B 12 Accessories and Dimensions Figure B 7 IP66 NEMA Type UL Type 4X Dimensions are in millimeters and inches Weights are in kilograms and pounds 23 0 91 165 je gt 3 650 146 5 6 5 6 75 0 26 le a K 46 J B 7 1 81 OS00O E O O 0000 O 253 9 96 Si 27 10 0 63 Weight 5 2 11 5 82 5 g2 fmm am Accessories and Dimensions B 13 Figure B 8
30. 72 O 68 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Carrier Frequency kHz 3 28 Programming and Parameters Advanced Program Group continued A092 Auto Rstrt Tries Related Parameter s A055 A058 A061 A093 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 regulations 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 0 300 0 Secs Display 0 1 Secs A094 Start At PowerUp Stop drive before changing this parameter 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 Req
31. B 0 75 1 0 4 6 9 0 20W 1321 3R4 C 15 20 4 6 6 5 20W 1321 3R4 B 22 3 0 8 12 5 0 25 3 W 1321 3R8 C 40 50 12 18 2 5 31W 1321 3R12 B 55 75 12 18 2 5 31W 1321 3R12 B 75 10 0 18 27 1 5 43W 1321 3R18 B 11 0 15 0 25 37 5 1 2 52W 1321 3R25 B 0 75 1 0 2 3 20 0 11 3W 1321 3R2 B 15 20 4 6 6 5 20W 1321 3R4 B 22 3 0 4 6 6 5 20W 1321 3R4 B 40 50 8 12 5 0 25 3 W 1321 3R8 C 55 7 5 12 18 2 5 31W 1321 3R12 B 75 10 0 12 18 2 5 31W 1321 3R12 B 11 0 15 0 18 27 15 43W 1321 3R18 B 1 Catalog numbers listed are for 3 impedance open style units NEMA Type 1 and 5 impedance lable Refer to publication 1321 TD001 reactor types are also avai Table B E DC Bus Inductors Input Voltage 240V 50 60 Hz 3 Phase 480V 50 60 Hz 3 Phase 600V 50 60 H 3 Phase N Inductance kW HP Amps mh MTE Catalog Number 55 75 32 0 85 32RB001 75 10 0 40 05 40RB001 55 75 18 3 75 18RB004 75 10 0 25 4 0 25RB005 11 0 15 0 32 2 68 32RB003 55 75 12 6 0 12RB004 75 10 0 18 6 0 18RB005 11 0 15 0 25 4 0 25RB005 Use MTE RB Series or equivalent inductors B 4 Accessories and Dimensions Table B F EMC Line Filters Drive Ratings S Type Filter L Type Filter Input Voltage kW HP Catalog Number 1 Catalog Number 4 120V 50 60 Hz 0 4 0 5 a 22 RF018 BL 1 Phase 075 fio 3 22 RF018 BL 1 1 1 5
32. Display 0 1 Secs P035 Maximum Freq Si P039 or A067 eg P040 or A068 0 Accel Time x 9 le Decel Time x Time A068 Decel Time 2 Related Parameter s P040 A051 A054 A070 A077 A140 A147 When active sets the rate of deceleration for all speed decreases except jog Refer to the flowchart on page 1 24 for details Maximum Freq Decel Time Decel Rate Values Default 20 0 Secs Min Max 0 1 600 0 Secs Display 0 1 Secs P035 Maximum Freq Si P039 or A067 e P040 or A068 0 Accel Time x le Decel Time x Time A069 Internal Freq Related Parameter s P038 A162 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 If A051 A054 Digital Inx Sel is set to 16 MOP Up or 17 MOP Down this parameter acts as the MOP frequency reference Values Default 60 0 Hz Min Max 0 0 400 0 Hz Display 0 1 Hz 3 22 Advanced Program Group continued Programming and Parameters A070 Preset F
33. Indication Corrective Action Drive is Faulted 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 A054 Digital Inx Sel is set to option 7 Clear Fault Incorrect programming e P036 Start Source is set to option 0 Keypad or option 5 RS485 DSI Port e A051 A054 Digital Inx Sel is set to option 5 Local and the input is active None Check parameter settings Incorrect input wiring See 1 18 for wiring examples e 2 wire control requires Run Forward Run Reverse or Jog input e 3wire control requires Start and Stop inputs e Stop input is always required None Wire inputs correctly and or install jumper Incorrect Sink Source DIP switch setting None Set switch to match wiring scheme 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 A054 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 Troubleshooting 4 7 Drive does not respond to changes in speed command Cause s Indication Corrective Actio
34. NP Volts P032 Motor NP Hertz 3 26 Programming and Parameters Advanced Program Group continued A085 Start Boost Related Parameter s P031 P032 P034 P035 A084 A086 A087 A088 A125 Sets the boost voltage of P031 Motor NP Volts and redefines the Volts per Hz curve when A084 Boost Select 0 Custom V Hz and A125 Torque Perf Mode 0 V Hz Drive may add additional voltage unless Option 5 is selected Values Default 2 5 Min Max 0 0 25 0 Display 0 1 A088 Maximum Voltage P031 Motor NP Volts Voltage 4 4 A086 Break Voltage A085 Start Boost T A087 Break Frequency P032 Motor NP Hertz A034 Minimum Freq Frequency P035 Maximum Freq A086 Break Voltage Related Parameter s P031 P032 P034 P035 A084 A085 A087 A088 A125 Sets the frequency where break voltage is applied when A084 Boost Select 0 Custom V Hz and A125 Torque Perf Mode 0 V Hz Values Default 25 0 Min Max 0 0 100 0 Display 0 1 A087 Break Frequency Related Parameter s P031 P032 P034 P035 A084 A085 A086 A088 A125 Sets the frequency where break frequency is applied when A084 Boost Select 0 Custom V Hz and A125 Torque Perf Mode 0 V Hz Values Default 15 0 Hz Min Max 0 0 400 0 Hz Display 0 1 Hz Programming and Parameters 3 27 Advance
35. Program Analog In Filter A166 Advanced Program Motor NP Hertz P032 Basic Program Analog In Loss A122 Advanced Program Motor NP Volts P031 Basic Program Analog Out High A066 Advanced Program Motor OL Current P033 Basic Program Analog Out Sel A065 Advanced Program Motor OL Ret P043 Basic Program Anlg In 0 10V Hi A111 Advanced Program Motor OL Select A090 Advanced Program Anlg In 0 10V Lo A110 Advanced Program Opto Out Logic A064 Advanced Program Anlg In4 20mA Hi A113 Advanced Program Opto Outx Level A059 A062 Advanced Program Anlg In4 20mA Lo A112 Advanced Program Opto Outx Sel A058 A061 Advanced Program Anlg Loss Delay A165 Advanced Program Output Current d003 Display Anlg Out Setpt A109 Advanced Program Output Freq d001 Display Auto Rstrt Delay A093 Advanced Program Output Power d022 Display Auto Rstrt Tries A092 Advanced Program Output Powr Fetr d023 Display Autotune A127 Advanced Program Output Voltage d004 Display Boost Select A084 Advanced Program PID Deadband A138 Advanced Program Break Frequency A087 Advanced Program PID Diff Rate A136 Advanced Program Break Voltage A086 Advanced Program PID Feedback Sel A133 Advanced Program Bus Reg Mode A117 Advanced Program PID Integ Time A135 Advanced Program Comm Data Rate A103 Advanced Program PID Preload A139 Advanced Program Comm Format A107 Advanced Program PID Prop Gain A134 Advanced Program Comm Loss Action A105 Advanced Program PID Ref Sel A132 Advanced Program Comm Loss Time A106 Advanced Progra
36. Speed Reference 2 0 10V Input 1 10k Ohm Pot Recommended a 2 Watt minimum BEE N p 14 Q I sis Analog Input Bipolar Unipolar Voltage Unipolar Current 0 to 10V 100kohm P038 Speed Reference P038 Speed Reference P038 Speed Reference impedance 2 0 10V Input and 2 0 10V Input 3 4 20mA Input 4 20 mA 250 ohm A123 10V Bipolar Enbl impedance 1 Bi Polar In 10V Common Common O O OOOO O O S O OOOOOO 000 000000008 Analog Input PTC For Drive Fault Wire the PTC and External Resistor typically matched to the PTC Hot Resistance to I O Terminals 12 13 14 Wire R2 R3 Relay Output SRC to I O Terminals 5 amp 11 A051 Digital In1 Sel 3 Aux Fault A055 Relay Out Sel 10 Above Anlg V A056 Relay Out Level Voltage Trip Rell Re Reto 02000 _ Rete hot hip Re P Rete hot Re x 100 05 Installation Wiring 1 19 Input Output Connection Example 2 Wire SRC Control Internal Supply SRC External Supply SRC Non Reversing P036 Start Source 2 3 0r4 Input must be active for Stop Run the drive to run When input is opened the drive will stop as specified by P037 Stop Mode If desired a User Supplied 24V DC Each
37. active logically true TRUE 4 Step if Logic In1 is not active logically false FALSE 5 Step if Logic In2 is not active logically false FALSE 6 Step if either Logic In1 or Logic In2 is active logically true OR T Step if both Logic In1 and Logic In2 is active logically true AND 8 Step if neither Logic In1 or Logic In2 is active logically true NOR 9 Step if Logic In1 is active logically true and Logic In2 is not active XOR logically false A Step if Logic In2 is active logically true and Logic In1 is not active XOR logically false b Step after Stp Logic Time x and Logic In1 is active logically true TIMED AND Cc Step after Stp Logic Time x and Logic In2 is active logically true TIMED AND d Step after Stp Logic Time x and Logic In1 is not active logically false TIMED OR E Step after Stp Logic Time x and Logic In2 is not active logically false TIMED OR F Use logic programmed in Digit 1 IGNORE Appendix F PID Set Up PID Loop The PowerFlex 40 has a built in PID proportional integral differential control loop The PID loop is used to maintain a process feedback such as pressure flow or tension at a desired set point The PID loop works by subtracting the PID feedback from a reference and generating an error value The PID loop reacts to the error based on the PID Gains and outputs a frequency to try to reduce t
38. available See Appendix B for details A Chapter 1 Installation Wiring This chapter provides information on mounting and wiring the PowerFlex 40 Drive For information on See page For information on See page Opening the Cover 1 1 Fuses and Circuit Breakers 1 8 Mounting Considerations 1 3 Power Wiring 1 10 AC Supply Source Considerations 1 5 1 0 Wiring 1 14 Recommendations General Grounding Requirements 1 7 EMC Instructions 1 25 Most start up difficulties are the result of incorrect wiring Every precaution must be taken to assure that the wiring is done as instructed All items must be read and understood before the actual installation begins ATTENTION The following information is merely a guide for proper installation Rockwell Automation Inc cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this drive or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation Opening the Cover IP20 NEMA UL Type Open 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 IP66 NEMA UL Type 4X ATTENTION To avoid an electric shock hazard ensure isolation of mains supply from line inputs R S T L1 L2 L3 an
39. data bits only 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 3 RTU 8 N 2 4 RTU 8 E 2 5 RTU 8 0 2 A108 Language Selects the language displayed by the remote communications option Options English Default Fran ais Espa ol Italiano Reserved Portugu s Reserved 1 2 3 4 5 Deutsch 6 7 8 9 Reserved 10 Nederlands 3 32 Programming and Parameters Advanced Program Group continued A109 Anlg Out Setpt Related Parameter s A065 When A065 Analog Out Sel is set to option 18 19 or 20 this parameter sets the percentage of analog output desired Values Default 0 0 Min Max 0 0 100 0 Display 0 1 A110 Anlg In 0 10V Lo Related Parameter s d020 P034 P038 A122 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 Anlg In 0 10V Hil Values Default 0 0 Min Max 0 0 100 0 Display 0 1 P035 Maximum Freq P03
40. digital input draws 6 mA power source can be used Refer to the External Supply SRC example S 01 02 01 02 Stop Run 04 24V Common 0000 0800 0 2 Wire SNK Control Internal Supply SNK Non Reversing 01 02 Stop Run 04 880 jeeeeoe 2 Wire SRC Control Internal Supply SRC External Supply SRC Run FWD Run REV P036 Start Source 2 30r4 Input must be active for the drive to run When input is opened the drive will stop as specified by P037 Stop Mode If both Run Forward and Run Reverse Each digital input draws 6 mA inputs are closed at the same time an undetermined state could occur 01 01 02 Ta top Run 03 Foard 2 O Stop Run Forward Stop Run oo Reverse Stop Run Reverse 24V Common OO OQOQqO 0000 88 1 20 Input Output 2 Wire SNK Control Run FWD Run REV Installation Wiring Connection Example Internal Supply SNK Stop Run Forward Stop Run Reverse 00 Of 8 0 0 01 02 03 04 3 Wire SRC Control Non Reversing P036 Start Source 1 A momentary input will start the drive A stop Internal Supply SRC External Supply SRC
41. kilograms and pounds ododo F _ J Eb i i i 4 C 130 260 180 116 246 4 3 5 1 10 2 7 1 4 57 9 7 9 5 h o B 15 5 0 22 Figure B 2 IP30 NEMA UL Type 1 Option Kit without Communication Option mi mi Jo Te RISD fs a F Se SR 2 93 i iS Les at Frame B 22 JBAB os x Z Lis OOS OOOH 152 2 5 99 FT o BAS r gt NMN 7 Es 438 ee ASEM tt O Frame C 22 JBAC B 8 Accessories and Dimensions Figure B 3 1P30 NEMA UL Type 1 Option Kit with Communication Option Dimensions are in mi gt limeters and inches ll I Ea I O 25 0 Mos 4 77 5 3 05 CU H e 50 0 1 97 22 5 0 89 22 2 P 0 87 K Kh CJ 7 Wass 2 Y XY O Og 9 II SX WEY SX By PEN 88 E L 25 0 jes Frame B 22 JBCB ET j 60 0 2 36 l Frame C 22 JBCC Q j 108 7 4 28
42. load so drive output current does not exceed the current set by parameter P033 Motor OL Current 2 Verify A084 Boost Select setting Check for blocked or dirty heat sink fins Verify that ambient temperature has not exceeded 40 C 104 F for IP30 NEMA UL Type 1 installations or 50 C 122 F for P20 Open type installations 2 Check fan Check programming Check for excess load improper A084 Boost Select 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 k 1 Check parameters 2 Check for broken loose connections at inputs 4 4 Troubleshooting See page 4 1 for a description of fault types No F33 F38 F39 F40 F41 F42 F43 F48 F63 F64 F70 F71 F80 F81 F100 Fault Auto Rstrt Tries Phase U to Gnd Phase V to Gnd Phase W to Gnd Phase UV Short Phase UW Short Phase VW Short Params Defaulted SW OverCurrent Drive Overload Power Unit Net Loss SVC Autotune Comm Loss Parameter Checksum D a gt e Description Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A092 Auto Rstrt Tries A phase to ground fault has been detected between the drive and motor in this phase Excessive current has been detected between these two output terminals The drive
43. on start or enable Values Default 0 0 Hz Min Max 0 0 400 0 Hz Display 0 1 Hz Programming and Parameters 3 39 Advanced Program Group continued A140 Stp Logic 0 Related Parameter s P038 P039 P040 A051 A054 A141 Stp Logic 1 A055 A058 A061 A067 A068 A070 A077 A150 A157 A142 Stp Logic 2 A143 Stp Logic 3 A144 Stp Logic 4 A145 Stp Logic 5 A146 Stp Logic 6 A147 Stp Logic 7 Stop drive before changing this parameter Values Default O0F1 Min Max 0001 bAFF Display 4 Digits Parameters A140 A147 are only active if P038 Speed Reference is set to 6 Stp Logic These parameters can be used to create a custom profile of frequency commands Each step can be based on time status of a Logic input or a combination of time and the status of a Logic input Digits 0 3 for each Stp Logic x parameter must be programmed according to the desired profile A Logic input is established by setting a digital input parameters A051 A054 Digital Inx Sel to 23 Logic In1 and or 24 Logic In2 A time interval between steps can be programmed using parameters A150 A157 Stp Logic Time x See the table below for related parameters The speed for any step is programmed using parameters A070 A077 Preset Freq x Related Preset Frequency Parameter Related StepLogic Time Parameter StepLogic Parameter Can be activ
44. online at http Avww ab com certification ce docs Low Voltage Directive 73 23 EEC e EN50178 Electronic equipment for use in power installations EMC Directive 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 26 iD 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 8 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 Tab
45. 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 9 Advanced Program Group 3 14 Parameter Cross Reference by Name 3 44 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 items 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 ey 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 Refer to page 3 44 for an alphabetical listing of parameters See page 3 14 Display Gap See page 3 3 See page 3 14 Output Freq d001 Digital In1 Sel A051 Commanded Freq d002 Digital In2 Sel A052 Output Current d003 D
46. provide a signal that is proportional to several drive conditions Output Minimum Output Maximum Output Value DIP Switch Related Option Range Value A066 Analog Out High Position Parameter 0 OutFreq 0 10 0 10V OV 0Hz P035 Maximum Freq 0 10V d001 1 OutCurr 0 10 0 10V OV 0 Amps 200 Drive Rated Output Current 0 10V d003 2 OutVolt 0 10 0 10V OV 0 Volts 120 Drive Rated Output Volts 0 10V d004 3 OutPowr 0 10 0 10V OV 0 kW 200 Drive Rated Power 0 10V d022 4 TstData 0 10 0 10V OV 0000 65535 Hex FFFF 0 10V d019 5 OutFreg 0 20 0 20mA 0mA 0Hz P035 Maximum Freq 0 20mA d001 6 OutCurr 0 20 0 20mA OmA 0Amps 200 Drive Rated Output Current 0 20mA d003 7 OutVolt 0 20 0 20mA 0 mA 0 Volts 120 Drive Rated Output Volts 0 20mA d004 8 OutPowr 0 20 0 20mA OmA 0kW 200 Drive Rated Power 0 20mA d022 9 TstData 0 20 0 20mA 0 mA 0000 65535 Hex FFFF 0 20mA d019 10 OutFreq 4 20 4 20mA 4mA 0Hz P035 Maximum Freq 0 20mA d001 11 OutCurr 4 20 4 20mA 4mA 0Amps 200 Drive Rated Output Current 0 20mA d003 12 OutVolt 4 20 4 20mA 4 mA 0 Volts 120 Drive Rated Output Volts 0 20mA d004 13 OutPowr 4 20 4 20mA 4mA 0kW 200 Drive Rated Power 0 20mA d022 14 TstData 4 20 4 20mA 4 mA 0000 65535 Hex FFFF 0 20mA d019 15 OutTor
47. resistant PVC jacket overall or equivalent e Three copper grounds on 10 AWG and smaller 1 12 Installation Wiring 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 D 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 D Maximum Cable Length Recommendations Reflected Wave 380 480V Ratings Motor Insulation Rating Motor Cable Only 1000 Vp p 15 meters 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 Installation Wiring 1 13 Power Terminal Block The power terminal block is covered by a finger guard To remove
48. the current MOP reference command Options 0 Zero MOP Ref This option clamps A069 Internal Freq at 0 0 Hz when the drive is not running 1 Save MOP Ref Reference is saved in A069 Internal Freq Default A163 DB Threshold Related Parameter s P037 A080 A081 A082 Sets the DC bus Voltage Threshold for Dynamic Brake operation If the DC bus voltage falls below the value set in this parameter the Dynamic Brake will not turn on Lower values will make the Dynamic Braking function more responsive but may result in nuisance Dynamic Brake activation Values Default 100 0 Min Max 0 0 110 0 Display 0 0 value that causes the dynamic braking resistor to dissipate excessive power Parameter settings less than 100 should be carefully evaluated to ensure that the dynamic brake resistor s wattage rating is not exceeded In general values less than 90 are not needed This parameter s setting is especially important if parameter A082 DB Resistor Sel is set to 2 No Protection ATTENTION Equipment damage may result if this parameter is set a Programming and Parameters 3 43 Advanced Program Group continued A164 Comm Write Mode Determines whether parameter changes made over communication port are saved and stored in Non Volatile Storage NVS or RAM only If they are stored in RAM the values will be lost at power down Options 0 Save Default 1 RAM Only ATTENTION Ris
49. the source end only not at the drive end 1 8 Installation Wiring 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 Fuses and Circuit Breakers The PowerFlex 40 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 personal 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 40 has been UL tested and approved for use with input fuses The ratings in the table that follows are the m
50. was commanded to write default values to EEPROM Programmed A098 SW Current Trip has been exceeded Drive rating of 150 for 1 minute or 200 for 3 seconds has been exceeded Failure has been detected in the drive power section The communication network has faulted The autotune function was either cancelled by the user or failed RS485 DSI port stopped communicating The checksum read from the board does not match the checksum calculated Action Correct the cause of the fault and manually clear Check the wiring between the drive and motor 2 Check motor for grounded phase 3 Replace drive if fault cannot be cleared 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 Cycle power 2 Replace drive if fault cannot be cleared Cycle power Check communications cabling Check network adapter setting Check external network status estart procedure Dr oN 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 L
51. 0 NEMA UL Type Open Mount Type 4X Output Frame Input Voltage kW HP Current Catalog Number Size Catalog Number Catalog Number 120V 50 60 Hz 0 4 0 5 2 3A 22B V2P3N104_ B 22B V2P3F104 22B V2P3C104 nae 0 75 1 0 5 0A 22B V5PON104 B 22B V5POF104 22B V5P0C104 1 1 11 5 6 0A 22B V6PON104 B 22B V6P0F104 22B V6P0C104 ANV 50 60Hz 0 4 05 2 3A 22B A2P3N114 B TINNE garg 075 10 5 0A 22B ASPONTI4 B Type EMC 15 20 80A 22B A8PON114 B Filter 22 3 0 120A 22B A012N114 C 240V50 60Hz 0 4 05 23A 22B A2P3N104 B 22B A2P3F104 22B A2P3C 104 Pik 0 75 1 0 5 0A 22B A5PON104 B 22B A5POF104 22B A5P0C104 15 20 80A 22B A8PON104 B 22B ABPOF104 22B A8P0C104 22 3 0 12 0A 22B A012N104 C 22B A012F104 240V 50 60 Hz 0 4 0 5 23A 22B B2P3N104 B 22B B2P3F104 22B B2P3C 104 elias 0 75 1 0 5 0A 22B B5PON104 B 22B B5POF104 22B B5P0C104 15 20 80A 22B B8PON104 B 22B B8POF104 22B B8P0C104 22 3 0 12 0A 22B B012Ni04 B 22B B012F104 22B B012C104 3 7 5 0 17 54 22B B017N104 B 22B BO17F104 22B B017C104 55 7 5 24 0A 22B B024N104 C 22B B024F104 7 5 10 0 33 0A 22B B033N104 C 22B B033F104 480V 50 60 Hz 0 4 05 1 4A 22B D1P4N104 B 22B D1P4F104 22B D1P4C104 rae 0 75 10 234 22B D2P3N104 B 22B D2P3F104 22B D2P3C104 1 5 20 4 0A 22B D4PoNi04 B 22B D4P0F104 22B D4P0C104 22 3 0 6 0A 22B D6PON104 B 22B D6POF104 _ 22B D6P0C104 40 5 0 1054 22B DO10N104 B 22B D010F10
52. 0 instantaneous fault 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 460V AC Input Trip occurs at 810V DC bus voltage equivalent to 575V AC incoming line 460 600V AC Input Trip occurs at 1005V DC bus voltage equivalent to 711V 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 AC Input Trip occurs at 390V DC bus voltage equivalent to 275V AC incoming line 460 600V AC Input If P042 3 High Voltage trip occurs at 487V DC bus voltage 344V AC incoming line If P042 2 Low Voltage trip occurs at 390V DC bus voltage 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 except when no brake is specified Refer to Appendix B for DB resistor ordering information A 4 Supplemental Drive Information Category Environment Specification Altitude 1000 m 3300 ft max without derating Maximum Surrounding Air Temperature without derating IP30 NEMA UL Type 1 Flange Mount IP20 NEMA UL Type Open 10 to 50 C
53. 1 NonRec Fault e Value set in A092 Auto Rstrt Tries is exceeded e A092 Auto Rstrt Tries in not enabled e ANon resettable fault has occurred 22 EM Brk Cntrl EM brake is energized Program A160 EM Brk Off Delay and A161 EM Brk On Delay for desired action 23 Above Femd The current commanded frequency exceeds the value set in A059 or A062 Opto Outx Level Programming and Parameters 3 19 Advanced Program Group continued A059 Opto Out1 Level A062 Opto Out2 Level 7 32 bit parameter Determines the on off point for the opto outputs when A058 or A061 Opto Outx Sel is set to option 6 7 8 10 16 17 18 or 20 6 0 400 Hz 7 0 180 8 0 815 Volts 10 0 100 16 0 1 9999 Secs 17 1 9999 Counts 18 1 180 degs 20 0 1 23 0 400 Hz Values Default 0 0 Min Max 0 0 9999 Display 0 1 A064 Opto Out Logic Determines the logic Normally Open NO or Normally Closed NC of the opto outputs A064 Option Opto Out1 Logic Opto Out2 Logic 0 NO Normally Open NO Normally Open 1 NC Normally Closed NO Normally Open 2 NO Normally Open NC Normally Closed 3 NC Normally Closed NC Normally Closed Values Default 0 Min Max 0 3 Display 1 3 20 Programming and Parameters Advanced Program Group continued A065 Analog Out Sel Related Parameter s P035 A066 Sets the analog output signal mode 0 10V 0 20mA or 4 20mA The output is used to
54. 14 to 122 F 10 to 40 C 14 to 104 F Heatsink 10 to 40 C 14 to 104 F Drive 10 to 50 C 14 to 122 F IP66 NEMA UL Type 4X 10 to 40 C 14 to 104 F Cooling Method Convection 0 4 kW 0 5 HP drives Fan All other drive ratings and 0 4 kW 0 5 HP 1 Phase drives with Integral S Type EMC Filter 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 Control Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Analog Input Analog Output Within 0 05 of set output frequency Within 0 5 of maximum output frequency 10 Bit resolution 2 of full scale 10 Bit resolution Speed Regulation Open Loop with Slip Compensation 1 of base speed across a 60 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 progr
55. 140M C2E C10 100 C09 4 0 5 0 20 140M C2E C16 100 C23 5 5 7 5 25 140M D8E C20 100 C23 7 5 10 0 30 140M D8E C20 100 C23 11 15 50 140M F8E C32 100 043 600V AC 0 75 1 0 6 140M C2E B25 100 C09 3 Phase 1 5 2 0 6 140M C2E B40 100 C09 2 2 3 0 10 140M C2E B63 100 C09 4 0 5 0 15 140M C2E C10 100 C09 5 5 7 5 20 140M C2E C16 100 C16 7 5 10 0 25 140M C2E C16 100 C23 11 15 40 140M D8E C25 100 C30 1 Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Refer to the Bulletin 140M Motor Protectors Selection Guide publ ication 140M SG001 to determine the frame and breaking capacity required for your application 1 10 gt gt 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 protection 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 Ca
56. 15 Power 1 13 Three Wire Control 1 18 Two Wire Control 1 18 U UnderVoltage Fault F4 4 3 Ungrounded Supply 1 5 Unshielded Power Cables 1 10 W Watts Loss A 5 Wiring 1 1 Block Diagram 1 16 Examples 1 18 1 O Terminal Descriptions 1 17 Potentiometer 1 18 Power 1 10 PTC Example 1 18 Recommendations 1 14 Index 4 o www rockwellautomation com Power Control and Information Solutions Headquarters 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 Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 22B UM001E EN E January 2007 Supersedes October 2005 Copyright 2007 Rockwell Automation Inc All rights reserved
57. 20 Ohm resistors 2 pieces AK U0 RJ45 TR1 Terminal Block RJ45 Two position terminal block 5 pieces AK U0 RJ45 TB2P DriveExplorer Software Windows based software package that provides 9306 4EXPO1ENE CD ROM Version 3 01 an intuitive means for monitoring or configuring or later Allen Bradley drives 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 9303 4DTEO1ENE CD ROM Version 1 01 or later an intuitive means for monitoring or configuring Allen Bradley drives and communication adapters online and offline Compatibility indows 98 ME NT 4 0 Service Pack 3 or later 2000 and XP See www ab com drives driveexplorer htm for supported devices Accessories and Dimensions B 7 Product Dimensions Table B J PowerFlex 40 Frames Ratings are in kW and HP B 0 4 0 5 D403 0 4 0 5 2 2 3 0 2403 2 2 3 0 0 2 2 3 0 TA 1 i 0 75 1 0 0 A 1 by 37 Eo 0 75 1 0 4 0 Eo 15 2 0 4 0 5 0 1 1 1 5 1 5 2 0 1 5 2 0 1 5 2 0 cm 2 2 3 0 5 5 7 5 5 5 75 11 0 15 0 5 5 7 5 11 0 15 0 7 5 10 0 7 5 10 0 7 5 10 0 1 IP66 NEMA UL Type 4X rated drives are not availble in Frame C drive ratings Figure B 1 IP20 NEMA UL Type Open c gt Dimensions are in millimeters and inches o yl le Weights are in
58. 4 22B D010C104 55 75 12 0A 22B D012N104 C 22B D012F104 l 75 100 17 0A 22B D017N104 C 22B D017F104 11 0 15 0 24 0A 22B D024N104 C 22B D024F104 600V 50 60 Hz 0 75 1 0 1 7A 22B E1P7N104 B 22B E1P7F104 22B E1P7C104 ae 15 20 30A 22B E3PON104 B 22B E3P0F104 22B E3P0C104 22 3 0 4 2A 22B E4P2N104 B 22B E4P2F104 22B E4P2C104 40 5 0 6 6A 22B E6P6N104 B 22B E6P6F104 22B E6P6C104 55 75 99A 22B EQP9N104 C 22B E9P9F104 75 10 0 12 0A 22B E012Ni04 C 22B E012F104 11 0 15 0 19 0A 22B E019N104 C 22B E019F104 1 Meets IP40 54 65 NEMA 1 12 4 4X when installed in an enclosure of like rating 2 Requires use of external DC Bus Inductor or AC Line Reactor See Table B E for details B 2 Accessories and Dimensions Table B C Dynamic Brake Modules Drive Ratings Minimum Input Voltage kw HP Resistance Q Catalog Number 2 120V 50 60 Hz 0 4 0 5 48 AK R2 091P500 1 Phase 0 75 10 48 AK R2 091P500 11 15 48 AK R2 091P500 240V 50 60 Hz 0 4 0 5 48 AK R2 091P500 1 Phase 0 75 10 48 AK R2 091P500 15 2 0 48 AK R2 091P500 2 2 3 0 32 AK R2 047P500 240V 50 60 Hz 0 4 0 5 48 AK R2 091P500 3 Phase 0 75 1 0 48 AK R2 091P500 15 2 0 48 AK R2 091P500 2 2 3 0 32 AK R2 047P500 3 7 5 0 19 AK R2 047P500 55 75 13 AK R2 030P1K2 75 10 0 10 AK R2 030P1K2 480V 50 60 Hz 04 0 5 97 AK R2 360P500 3 Phase 0 75 1 0 97 AK R2 360P500 15 2 0 97 A
59. 4 Minimum Freq 0 A110 Anlg In 0 10V Lo A111 Anlg In 0 10V Hi A111 Anlg In 0 10V Hi Related Parameter s d020 P035 P038 A122 A123 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 Anlg In 0 10V Lo Values Default 100 0 Min Max 0 0 100 0 Display 0 1 A112 Anlg In4 20mA Lo Related Parameter s 021 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 A113 Anlg In4 20mA Hi Values Default 0 0 Min Max 0 0 100 0 Display 0 1 Programming and Parameters 3 33 Advanced Program Group continued A113 Anlg In4 20mA Hi 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 Anlg In4 20mA Lo Values Default 100 0 Min Max 0 0 100 0 Display 0 1 A114 Slip Hertz FLA 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
60. 5 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 Related Parameter s d015 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 Programming and Parameters 3 31 Advanced Program Group continued A105 Comm Loss Action Related Parameter s d015 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 Stop Stops drive via coast to stop 2 Stop Stops drive via P037 Stop Mode setting 3 Continu Last Drive continues operating at communication commanded speed saved in RAM A106 Comm Loss Time Related Parameter s d015 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 Related Parameter s d015 Selects the protocol RTU only data bits 8
61. 5 The Menu Structure below can be accessed through the following Human Interface Module options HIM Option Catalog Number Remote Panel Mount Small LCD Display 22 HIM C2S Remote Handheld LCD Display 22 HIM A3 User Display Main Menu HIM Reference fr _ 6 co ma vy Faults 1 Diagnostics Device Status gt Device Version gt PowerFlex 40 Product Data Series Firmware Groups Group Name Puente Linear List Parameter Number Name Changed Params Parameter Number Name Parameter Number Name v Parameter Name PowerFlex 40 Device Select Connected DSI Devices Memory Storage e5 HIM CopyCat gt Device gt HIM Device lt HIM Delete File Parameters HIM Setup Device Version gt Device Cat No Device Name Series Firmware Press to move between main menu tabs Press to select a tab or menu item Press GD to move between menu items Press 3 to move 1 level back in the menu structure gt View Fault Queue Device Status _ Clear Faults STS1 Clear Fault Queue STS2 STS3 STS4 Value Screen Limits Screen gt Files Screen Stats Screen gt Function File Name File Name File Name File Name gt Parameters _______ 001 Startup Display 002 Startup Param 004 User Disp Line 1 005 User Disp Line 2 006 Large Disp Param 007 LCD Contrast 008 Reset
62. 7 4 3 Motor Stalled F6 4 3 Net Loss F71 4 4 OverVoltage F5 4 3 Index 2 Parameter Checksum F100 4 4 Params Defaulted F48 4 4 Phase Short F41 F43 4 4 ee to Ground Short F38 F40 Power Loss F3 4 3 Power Unit F70 4 4 SVC Autotune F80 4 4 SW OverCurrent F63 4 4 UnderVoltage F4 4 3 File Monitor 3 3 Filter RFI 1 8 Frame Designations P 2 A 1 B 7 Fuses Minimum Recommendations 1 8 Ratings A 1 G General Precautions P 3 Ground Fault F13 4 3 Grounding Filter 1 8 General 1 7 H Heatsink OvrTmp Fault F8 4 3 HW OverCurrent Fault F12 4 3 I 1 0 Block Diagram 1 16 Terminal Block 1 15 Terminal Designations 1 17 Wiring 1 14 Wiring Examples 1 18 Wiring Multiple Drives 1 22 I O Board Fail Fault F122 4 5 Input Contactor 1 14 Input Fusing 1 8 Input Potentiometer 1 18 Input Power Conditioning 1 6 Installation of Drive 1 1 Integral Keypad 2 3 Interference EMC RFI 1 25 IP66 Installations 1 14 K Keypad 2 3 L LEDs 2 3 M Menu Structure 2 5 Minimum Clearances 1 3 Monitor File 3 3 Motor Cable Length 1 12 Changing Forward Direction of 1 13 Disconnect 1 12 Motor Overload Fault F7 4 3 Motor Stalled Fault F6 4 3 Motor Starter Bulletin 140M 1 8 Mounting Options and Clearances MOV Jumper Location and Removal 1 5 N NEMA UL Type 4X Installations 1 14 Net Loss Fault F71 4 4 0 Opening the Drive Cover 1 1 Operating Temperatures 1 3 Operato
63. 70 Preset Freq 0 101 A071 Preset Freq 1 110 A072 Preset Freq 2 111 A073 Preset Freq 3 15 Not Used 11 10 14 13 12 Writing 06 Reference The Speed Reference to a PowerFlex 40 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 Port in order to accept the Speed Reference Use Function Code 03 to read this register 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 40 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 0 1 Ready 0 Not Ready 1 1 Active Running 0 Not Active 2 1 Cmd Forward 0 Cmd Reverse 3 1 Rotating Forward 0 Rotating Reverse 4 1 Accelerating 0 Not Accelerating 5 1 Decelerating 0 Not Decelerating 6 1 Alarm 0 No Alarm 7 1 Faulted 0 Not Faulted 8448 8 1 At Reference 0 Not At Reference 9 1 Reference Controlled by Comm 10 1 Operation Cmd Controlled by Comm 11 1 Parameters have been locked 12 Di
64. 80 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 BrakeAuto 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 8 Ramp EM B CF Ramp to Stop with EM Brake Control Stop Command Clears active fault 9 Ramp EM Brk Ramp to Stop with EM Brake Control 1 Stop input also clears active fault 3 12 Programming and Parameters Basic Program Group continued P038 Speed Reference Related Parameter s d001 d002 d012 d020 d021 P039 P040 A051 A054 A069 AO70 A077 A110 A113 A123 A132 A140 A147 A150 A157 Sets the source of the speed reference to the drive 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 A054 Digital Inx Sel is set to option 2 4 5 6 11 12 13 14 15 and the digital input is active or if A132 PID Ref Sel is not set to option 0 the speed reference commanded by P038 Speed Reference will be overridden Refer to the flowchart on page 1 23 for more information on speed reference control priority Options 0 Drive Pot Default Frequency command from th
65. 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 1 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 mA Lu PROGRAM O FAULT O PROGRAM O FAULT O PROGRAM O FAULT O Dr Dr PROGRAM O FAULT O voor cut Lt te d00 og if noi POS i Fu Dori ciu PROGRAM FAULT a4 Se IJ PROGRAM won Wr amp ecu PROGRAM FAULT O Pos __ __ 1 PROGRAM FAULT The Basic Program Group page 3 9 contains the most commonly changed parameters 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 Remote HIM Menu Structure Start Up 2
66. D parameter 2 Step if Logic In1 is active logically true TRUE 3 Step if Logic In2 is active logically true TRUE 4 Step if Logic In1 is not active logically false FALSE 5 Step if Logic In2 is not active logically false FALSE 6 Step if either Logic In1 or Logic In2 is active logically true OR 7 Step if both Logic In1 and Logic In2 is active logically true AND 8 Step if neither Logic In1 or Logic In2 is active logically true NOR 9 Step if Logic In1 is active logically true and Logic In2 is not active XOR logically false A Step if Logic In2 is active logically true and Logic In1 is not active XOR logically false b Step after Stp Logic Time x and Logic In1 is active logically true TIMED AND C Step after Stp Logic Time x and Logic In2 is active logically true TIMED AND d Step after Stp Logic Time x and Logic In1 is not active logically false TIMED OR E Step after Stp Logic Time x and Logic In2 is not active logically false TIMED OR F Do not step OR no jump to so use Digit 0 logic IGNORE Table E E Digit 0 Defines what logic must be met to jump to the very next step Setting Description Logic 0 Skip Step jump immediately SKIP 1 Step based on the time programmed in the respective Stp Logic Time x TIMED parameter 2 Step if Logic In1 is active logically true TRUE 3 Step if Logic In2 is
67. Device 009 Device Type 010 M S Status Start Up Diagnostics Menu When a fault trips the drive use this menu to access detailed data about the drive Option Description Faults View fault queue or fault information clear faults or clear fault queue Device Status View status information about the drive or peripheral Device Version View the firmware version and hardware series of components Parameters Menu Use this menu to access drive parameters Parameters can be displayed in groups in a linear list or only those changed from their defaults Device Select Menu Use this menu to access the drive or peripheral that the drive is to access Memory Storage Menu Drive data can be saved to or recalled from HIM sets HIM sets are files stored in permanent nonvolatile HIM memory Description HIM Copycat Save data to a HIM set or load data from a HIM set to active drive Device gt HIM memory A maximum of 5 HIM set can be stored Device lt HIM Delete File Delete a HIM set HIM Setup Menu The HIM and drive have features that you can customize Option Description Parameters Access parameters in HIM to set display options Device Version View HIM version hardware series and firmware version Chapter 3 Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 40 parameters Parameters are programmed viewed edited using the integral keypad As an alternative
68. Display 0 1 Secs P035 Maximum Freq Si P039 or A067 e P040 or A068 0 Accel Time x la Decel Time x Time Programming and Parameters 3 13 Basic Program Group continued P040 Decel Time 1 Related Parameter s P038 P039 A051 A054 A068 A070 A077 A140 A147 Sets the rate of deceleration for all speed decreases Maximum Freq Decel Time Decel Rate Values Default 10 0 Secs Min Max 0 1 600 0 Secs Display 0 1 Secs P035 Maximum Freq Si P039 or A067 eg P040 or A068 0 Accel Time x le Decel Time x Time P041 Reset To Defalts Stop drive before changing this parameter Resets all parameter values to factory defaults Options 0 Ready Idle Default 1 Factory Rset e After the reset function is complete this parameter will set itself back to 0 e Causes an F48 Params Defaulted fault P042 Voltage Class Stop drive before changing this parameter Sets the voltage class of 600V drives Options 2 Low Voltage 480V 3 High Voltage Default 600V P043 Motor OL Ret Related Parameter s P033 Enables disables the Motor Overload Retention function When Enabled the value held in the motor overload counter is saved at power down and restored at power up A change to this parameter setting resets the counter Options 0 Disabled Default 1 Enabled 3 14 Programming and Parameters Advanced P
69. Dynamic Brake Modules Dimensions are in millimeters and inches Weights are in kilograms and pounds Frame A Frame B gt 90 0 61 0 _ 170 18 60 0 31 0 _ 240 59 0 0 67 7 2 301 1 22 B 2 32 1 vit a 316 0 335 0 386 0 405 0 12 44 13 19 15 20 15 94 H 82 Er ji 2 it ze M A S ees 13 0 N bay 0 51 Lh IOo ei Frame Catalog Number Weight A AK R2 091P500 AK R2 047P500 AK R2 360P500 1 1 2 5 B AK R2 030P1K2 AK R2 120P1K2 2 7 6 Figure B 9 Recommended External Brake Resistor Circuitry Three Phase AC Input Input Contactor M Power Off Power On l M A Power Source DB Resistor Thermostat B 14 Accessories and Dimensions Figure B 10 Bulletin 1321 3R Series Line Reactors Dimensions are in millimeters and inches Weights are in kilograms and pounds Catalog Number A B Cc D E Weight 1321 3R2 A 112 4 40 104 4 10 70 2 75 50 1 98 37 1 44 1 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 3R4 C 112 4 40 104 4 10 86 3 38 60 2 35 37 1 44 2
70. Inductor not connected Inductor 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 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
71. K R2 360P500 2 2 3 0 97 AK R2 120P1K2 4 0 5 0 77 AK R2 120P1K2 55 75 55 AK R2 120P1K2 75 10 0 39 AK R2 120P1K2 11 0 15 0 24 AK R2 120P1K2 600V 50 60 Hz 0 75 1 0 120 AK R2 360P500 3 Phase 15 2 0 120 AK R2 360P500 22 3 0 82 AK R2 120P1K2 4 0 5 0 82 AK R2 120P1K2 55 75 51 AK R2 120P1K2 75 10 0 51 AK R2 120P1K2 11 0 15 0 51 AK R2 120P1K2 1 The resistors listed in this tables are rated for 5 duty cycle Use of Rockwell resistors is always recommended The resistors listed have been carefully selected for optimizing performance in a variety of applications Alternative resistors may be used however care must be taken when making a selection Refer to the PowerFlex Dynamic Braking Resistor Calculator publication PFLEX AT001 3 Requires two resistors wired in parallel Accessories and Dimensions B 3 Table B D Bulletin 1321 3R Series Line Reactors Input Voltage 240V 50 60 Hz 3 Phase 480V 50 60 Hz 3 Phase 600V 50 60 Hz 3 Phase Maximum Fundamental Continuous Inductance Watts Catalog kw IHP Amps Amps mh Loss Number 0 4 05 4 6 12 0 21W 1321 3R4 D 0 75 1 0 8 12 3 0 29W 1321 3R8 B 15 20 8 12 1 5 19 5 W 1321 3R8 A 22 3 0 12 18 1 25 26W 1321 3R12 A 37 5 0 18 27 0 8 36W 1821 3R18 A 5 5 7 5 25 37 5 0 5 48W 1321 3R25 A 7 5 10 0 35 52 5 0 4 49W 1321 3R35 A 0 4 05 2 3 20 0 11 3W 1321 3R2
72. Loss 100 Parameter Checksum Error 122 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 www ab com drives for additional information C 6 RS485 DSI Protocol Notes Appendix D RJ45 DSI Splitter Cable The PowerFlex 40 drive provides a RJ45 port to allow the connection of a single peripheral device The RJ45 DSI Splitter Cable can be used to connect a second DSI peripheral device to the drive Connectivity Guidelines peripherals may not perform as intended if these Connectivity ATTENTION Risk of injury or equipment damage exists The Guidelines are not followed Precautions should be taken to follow these Connectivity Guidelines Two peripherals maximum can be attached to a drive If a single peripheral is used it must be connected to the Master port M on the splitter and configured for Auto default or Master Parameter 9 Device Type on the DSI MDI keypads and Parameter 1 Adapter Cfg on the Serial Converter are used to select the type Auto Master Slave Do not use the RJ45 Splitter Cable with a drive that has an internal network communication adapter installed Since only one additional peripheral can be
73. P035 Maximum Freq to drive output from exceeding insure that speed is not limited by limiting values programming Torque performance does not None Set motor nameplate full load amps match motor characteristics in parameter A126 Motor NP FLA Perform A127 Autotune Static Tune or Rotate Tune procedure Set A125 Torque Perf Mode to option 0 V Hz 4 8 Troubleshooting Motor operation is unstable 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 Boost Select 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 14 Choose correct input and program for reversing mode Digital input is incorrectly None Check input wiring See page 1 17 wired Motor wiring is improperly None Switch two motor leads phased for reverse Reverse is disabled None Check A095 Reverse Disable Drive does not power up Cause s Indication Corrective Action No input power to drive None Check the power circuit e Check the supply voltage e Check all fuses and disconnects Jumper between I O Terminals None Install jumper or connect DC Bus P2 and P1 not installed and or DC Bus
74. Parameter s d001 d013 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 23 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 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 AINIAIAT LI LIIL L 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 occ
75. V 3 Phase Output 22B D1P4x104 0 4 0 5 1 4 342 528 1 4 1 8 3 140M C2E B25 100 C07 22B D2P3x104 0 75 1 0 2 3 342 528 2 3 3 2 6 140M C2E B40 100 C07 22B D4P0x104 1 5 2 0 4 0 342 528 4 0 5 7 10 140M C2E B63 100 C09 22B D6P0x104 2 2 3 6 0 342 528 5 9 7 5 15 140M C2E C10 100 C09 22B D010x104 0 5 0 10 5 342 528 10 3 13 0 20 140M C2E C16 100 C23 22B D012x104 5 5 7 5 12 0 342 528 11 8 14 2 25 140M D8E C20 100 C23 22B D017x104 7 5 10 0 17 0 342 528 16 8 18 4 30 140M D8E C20 100 C23 22B D024x104 11 0 15 0 24 0 342 528 23 4 26 0 50 140M F8E C32 100 C43 460 600V AC 10 3 Phase Input 0 575V 3 Phase Output 22B E1P7x104 0 75 1 0 17 414 660 2 1 2 3 6 140M C2E B25 100 C09 22B E3P0x104 1 5 2 0 3 0 414 660 3 65 3 8 6 140M C2E B40 100 C09 22B E4P2x104 3 0 4 2 414 660 5 2 5 3 10 140M C2E B63 100 C09 22B E6P6x104 5 0 6 6 414 660 8 1 8 3 15 140M C2E C10 100 C09 22B E9P9x104 7 5 9 9 414 660 12 1 11 2 20 140M C2E C16 100 C16 22B E012x104 7 5 10 0 12 2 414 660 14 9 13 7 25 140M C2E C16 100 C23 22B E019x104 11 0 15 0 19 0 414 660 23 1 24 1 40 140M D8E C25 100 C30 1 Inthe Catalog Numbers listed x represents enclosure type Specifications are valid for all enclosure types IP66 NEMA UL Type 4X drive ratings are only available as Frame B drives Refer to Table B B 200 240V AC 1 Phase drives are also available with an integral EMC filter Catalog suffix ch
76. added the second peripheral can be connected directly to the RJ45 port on the drive The internal Comm is always the Master therefore the external peripheral must be configured as Auto for temporary connections or Slave for permanent connections If two peripherals will be powered up at the same time one must be configured as the Master and connected to the Master port M and the other must be connected as the Slave and connected to the Slave port S RJ45 DSI Splitter Cable DSI Cable Accessories RJ45 Splitter Cable Catalog Number AK U0 RJ45 SC1 se n E Slave Port a _ALRAAR I lt t Master Port ha PIN 1 PIN 8 RJ45 Two Position Terminal Block Adapter Catalog Number AK U0 RJ45 TB2P TB2 PIN 5 PIN 8 TB1 F l PIN 4 PIN 1 RJ45 Adapter with Integrated Termination Resistor Catalog Number AK U0 RJ45 TR1 JIE PIN 1 PIN 8 RJ45 DSI Splitter Cable D 3 Connecting One Temporary Peripheral DSI MDI Drive DSI MDI Serial Converter Hand Held Parameter 1 Adapter Cfg set to Auto default or Master and connected to Master port M on RJ45 Splitter Cable Parameter 9 Device Type set to Auto default or Master
77. al Preset Write Multiple Registers 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 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 40 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 Use Function Code 03 to read this register 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 No Command 6 Not Used 7 Not Used 00 No Command 01 Accel Rate 1 Enable 9 8 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 100 A0
78. al 03 e O Terminal 1 Stop stop according to the value set in P037 Stop Mode Programming and Parameters 3 11 Basic Program Group continued P037 Stop Mode Related Parameter s P036 A080 A081 A082 A105 A160 Active stop mode for all stop sources e g keypad run forward I O Terminal 02 run reverse I O Terminal 03 RS485 port except as noted below Important I 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 Hardware Enable Circuitry By default I O Terminal 01 is a coast to stop input The status of the input is interpreted by drive software If the application requires the drive to be disabled without software interpretation a dedicat ed hardware enable configuration can be utilized This is accomplished by removing the ENBL enable jumper on the control board In this case the drive will always coast to a stop regardless of the settings of P036 Start Source and P037 Stop Mode Options 0 Ramp CF Default Ramp to Stop Stop command clears active fault 1 Coast CF Coast to Stop Stop command clears active fault 2 DC Brake CF pe Injection Braking Stop Stop command clears active ault 3 DCBrkAuto cF DC Injection Braking Stop with Auto Shutoff e Standard DC Injection Braking for value set in A0
79. ammed 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 Protection Class 10 protection with speed sensitive response and power down overload retention function Supplemental Drive Information A 5 PowerFlex 40 Estimated Watts Loss Rated Load Speed amp PWM Voltage kW HP External Watts Internal Watts Total Watts Loss 100 120V 0 4 0 5 22 18 40 0 75 1 0 40 20 60 1 1 1 5 58 22 80 200 240V 0 4 0 5 22 18 40 0 75 1 0 40 20 60 1 1 2 0 63 22 85 2 2 3 0 100 25 125 3 7 5 0 150 30 180 5 5 7 5 200 35 235 7 5 10 265 40 305 380 480V 0 4 0 5 17 18 35 0 75 1 0 30 20 50 1 1 2 0 48 22 70 2 2 3 0 75 25 100 3 7 5 0 135 25 160 5 5 7 5 140 35 175 7 5 10 175 35 210 11 15 260 40 300 460 600V 0 75 1 0 30 20 50 1 5 2 0 48 22 70 2 2 3 0 75 25 100 4 0 5 0 135 25 160 5 5 7 5 140 35 175 7 5 10 175 35 210 11 15 260 40 300 A 6 Supplemental Drive Information Notes Appendix B Accessories and Dimensions Product Selection Table B A Catalog Number Description 22B A 1P5 N 1 1 4 Drive Voltage Rating Rating Enclosure HIM Emission Class Type Table B B PowerFlex 40 Drives Dn IP20 Flange IP66 NEMA UL rive Ratings IP2
80. anges from N104 to N114 Filter option is not available for IP66 NEMA UL Type 4X rated drives 3 Refer to the Bulletin 140M Motor Protectors Selection Guide publication 140M SG001 to determine the frame and breaking capacity required for your application Supplemental Drive Information A 3 Input Output Ratings Output Frequency 0 400 Hz Programmable Efficiency 97 5 Typical Duso Desa z2 i Come 2 EMC Directive 89 336 C lV EN 50178 EN 60204 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 18 24V ON 0 6V ON 0 6V OFF 18 24V OFF 4 20mA Analog 250 ohm input impedance 0 10V DC Analog 100k ohm input impedance External Pot 1 10k ohms 2 Watt minimum Control Output Programmable Output form C relay Opto Outputs Analog Outputs 10 bit Resistive Rating 3 0A at 30V DC 3 0A at 125V AC 3 0A at 240V AC 30V DC 50mA 0 10V 1k ohm Min Inductive Rating 0 5A at 30V DC 0 5A at 125V AC 0 5A at 240V AC Non inductive 4 20mA 525 ohm Max Fuses and Circuit Breakers Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent Recommended Circuit Breakers HMCP circuit breakers or equivalent Protective Features 2 Motor Protection t overload protection 150 for 60 Secs 200 for 3 Secs Provides Class 10 protection Overcurrent 200 hardware limit 30
81. are two PE terminals on the drive See Table 1 H for more information Parameter Configuration The following PowerFlex 40 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 Page 3 10 the network P038 Speed Reference Set to 5 RS485 DSI Port if the Speed Reference is Page 3 12 controlled from the network A103 Comm Data Rate Sets the data rate for the RS485 DSI Port All nodes Page 3 30 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 30 Each device on the network requires a unique node address A105 Comm Loss Action Selects the drive s response to communication Page 3 31 problems A106 Comm Loss Time Sets the time that the drive will remain in Page 3 31 communication loss before the drive implements A105 Comm Loss Action A107 Comm Format Sets the transmission mode data bits parity and stop Page 3 31 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 40 drives supports some of the Modbus function codes Modbus Function Code Decimal Command 03 Read Holding Registers 06 Preset Write Single Register 16 10 Hexadecim
82. ated independent of Active when A140 A147 Digit 0 or 1 Active when P038 6 Stp Logic StepLogic Parameters are set to 1 b C d or E A140 Stp Logic 0 A070 Preset Freq 0 A150 Stp Logic Time 0 A141 Stp Logic 1 A071 Preset Freq 1 A151 Stp Logic Time 1 A142 Stp Logic 2 A072 Preset Freq 2 A152 Stp Logic Time 2 A143 Stp Logic 3 A073 Preset Freq 3 A153 Stp Logic Time 3 A144 Stp Logic 4 A074 Preset Freq 4 A154 Stp Logic Time 4 A145 Stp Logic 5 A075 Preset Freq 5 A155 Stp Logic Time 5 A146 Stp Logic 6 A076 Preset Freq 6 A156 Stp Logic Time 6 A147 Stp Logic 7 A077 Preset Freq 7 A157 Stp Logic Time 7 How StepLogic Works The StepLogic sequence begins with a valid start command A normal sequence always begins with A140 Stp Logic 0 Digit 0 Logic For Next Step This digit defines the logic for the next step When the condition is met the program advances to the next step Step 0 follows Step 7 Example Digit 0 is set 3 When Logic In2 becomes active the program advances to the next step Digit 1 Logic to Jump to a Different Step For all settings other than F when the condition is met the program overrides Digit 0 and jumps to the step defined by Digit 2 Digit 2 Different Step to Jump When the condition for Digit 1 is met the Digit 2 setting determines the next step or to end the program Digit 3 Step Settings This digit defines what accel decel profile the speed command will follow and the directio
83. ated with firmware version 4 xx Parameter Number Description Page Speed Reference P038 Default value for IP66 NEMA UL 3 12 Type 4X rated drives is option 1 InternalFreq Comm Write Mode A164 New 3 43 Anlg Loss Delay A165 New 3 43 Analog In Filter A166 New 3 43 Relay Out Sel A055 Option added 3 15 Opto Outx Sel A058 A061 Option added 3 17 Analog Out Sel A065 Options added 3 20 Anlg In 0 10V Lo A110 3 32 Anlg In 0 10V Hi A111 Parameter setting can be changed 3 32 Anlg In4 20mA Lo A112 while drive is running 3 32 Anlg In4 20mA Hi A113 3 33 Comm Write Mode A164 Revised description 3 43 IP66 NEMA UL Type 4X Enclosure Additions Description of New or Updated Information Page s Enclosure code added to Catalog Number Explanation P 4 Cover removal and installation instructions P 1 MOV jumper location P 5 Conduit entry plate plug installation P 14 Dimension drawing B 7 soc 2 The information below summarizes the changes to the PowerFlex 40 User Manual since the February 2005 release Description of New or Updated Information See Page s Attention statement on bus regulation added P 3 Attention statement clarified 1 5 240V AC 3 Phase 3 7 kW 5 0 Hp drive fuse rating revised to 30 amps 1 9 A 2 Footnote added to Table 1 F indicating that stranded or solid core wire is 1 15 acceptable for signal a
84. ayed 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 Escape Back one step in programming menu Cancel a change to a parameter value and exit Program Mode Select Advance one step in programming menu Select a digit when viewing parameter value Up Arrow Scroll through groups and parameters A CY Down Arrow Increase decrease the value of a flashing digit Used to control speed of IP66 NEMA UL Type 4X rated drives via A069 Internal Freq in program mode Enter Advance one step in programming menu lt 5 Save a change to a parameter value aS Potentiometer Used to control speed of drive Default is active Controlled by parameter P038 Speed Reference X al a Start Used to start the drive Default is active Ch Controlled by parameter P036 Start Source Reverse Used to reverse direction of the drive Default is active A 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 1 IP66 NEMA UL Type 4X rated drives are not equipped with a
85. ble Types Acceptable for 200 600 Volt Installations 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 Do not route more than three sets of motor leads in a single conduit to minimize cross talk If more than three drive motor connections per conduit are required shielded cable must be used 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 Use copper wire only Wire gauge requirements and recommendations are based on 75 degree C Do not reduce wire gauge when using higher temperature 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 Armored Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided s
86. block Common must be connected to ground terminal protective earth If using the RS485 DSD port I O Terminal 16 should also be connected to ground terminal protective earth 1 16 Installation Wiring Figure 1 5 Control Wiring Block Diagram 4 Typical Typical Enable Jumper Stop 1 4 SRC Wiring SNK Wiring 01 Q alo i vi Start Run Fwo om 02 oo oo vu i 3 03 Direction Run REV ea SNK o Be SRC 04 Digital Common VY m Digital Input 1 a a a 06 Digital Input 2 eo oot v7 Digital Input 3 o o oo 08 Digital Input 4 ee a Opto Common 09 24 2a 24V DC ee 10V E 10V DC c qg 010V or 10V Input l i mi 14 Analog Common L i Pot must be Relay N O i 4 20mA Input 14 10k ohm elay N O e OY 15 2 Watt Min Analog Output Relay Common EA o 4 20mA 16 fF common g Relay N C R3 7A 7 7 Opto Output 1 24V Opto Output 2 30V DC w 18 50mA Non inductive 19 RS485 Shield 4 mE wae 0 10V _ lt Analog Output Select 4 i ENBL jumper 020ma V 01 02 03 04 05 06 07 08 09 RI R2 R3 SNK ODOODOOOO D m RS485 DOOD gt 11 12 13 14 15 16
87. bove Cur e Drive exceeds the current Amps value set in A056 Relay Out Level e Use A056 to set threshold Important Value for A056 Relay Out Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in A056 Relay Out Level e Use A056 to set threshold 9 Retries Exst Value set in A092 Auto Rstrt Tries is exceeded 10 Above Anlg V o e Analog input voltage I O Terminal 13 exceeds the value set in A056 Relay Out Level e Do not use if A123 10V Bipolar Enbl is set to 1 Bi Polar In e This parameter setting can also be used to indicate a PTC trip point when the input I O Terminal 13 is wired to a PTC and external resistor e Use A056 to set threshold 11 Logic In 1 An input is programmed as Logic In 1 and is active 12 Logic In 2 An input is programmed as Logic In 2 and is active 13 Logic 1 amp 2 Both Logic inputs are programmed and active 14 Logic 1 or 2 One or both Logic inputs are programmed and one or both is active 15 StpLogic Out Drive enters StepLogic step with Digit 3 of Command Word A140 A147 set to enable StepLogic output 16 Timer Out e Timer has reached value set in A056 Relay Out Level e Use A056 to set threshold 17 Counter Out e Counter has reached value set in A056 Re
88. celeration 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 50 S Curve Accel Time 10 Seconds S Curve Setting 50 S Curve Time 10 x 0 5 5 Seconds Total Time 10 5 15 Seconds Target L l l 1 2S Cuve Time p Accel Ti l g 112S Curve Time p 4 urve lime D4 ccel Time D4 urve ime p gt 2 5 Seconds 10 Seconds 2 5 Seconds l 4 Total Time to Accelerate Accel Time S Curve Time gt Programming and Parameters 3 25 Advanced Program Group continued me gt A084 Boost Select Related Parameter s d004 P031 P032 A085 086 A087 A12 Sets the boost voltage of P031 Motor NP Volts and redefines the Volts per Hz curve Active when A125 Torque Perf Mode 0 V Hz Drive may add additional voltage unless Option 5 is selected gt Options 0 Custom V Hz 1 30 0 VT 35 0 VT 40 0 VT 45 0 VT 0 0 no IR 0 0 2 5 CT Default for 4 0 5 5 7 5 amp 11 kW 5 0 7 5 10 amp 15 HP Drives 8 5 0 CT Default Constant Torque 9 7 5 CT 10 10 0 CT 11 12 5 CT 12 15 0 CT 13 17 5 CT 14 20 0 CT Variable Torque Typical fan pump curves N ODO o1 1 2 Motor NP Volts P031 Motor
89. contact for output relay A055 R2 Relay Common i Common for output relay R3 Relay N C Fault Normally closed contact for output relay A055 Analog Output Select DIP 0 10V Sets analog output to either voltage or current Setting must match Switch A065 Analog Out Sel Sink Source DIP Switch Source SRC Inputs can be wired as Sink SNK or Source SRC via DIP Switch setting 01 Stop 1 Coast The factory installed jumper or a normally closed po3e 1 input must be present for the drive to start 02 Start Run FWD Not Active Command comes from the integral keypad by default P036 P037 03 Direction Run REV Not Active To disable reverse operation see A095 Reverse P036 P037 Disable A095 04 Digital Common 5 For digital inputs Electronically isolated with digital inputs from analog I O and opto outputs 05 Digital Input 1 Preset Freq Program with A051 Digital In1 Sel A051 06 Digital Input 2 Preset Freq Program with A052 Digital In2 Sel A052 07 Digital Input 3 Local Program with A053 Digital In3 Sel A053 08 Digital Input 4 Jog Forward Program with A054 Digital In4 Sel A054 09 Opto Common For opto coupled outputs Electronically isolated with opto outputs from analog I O and digital inputs 11 24V DC a Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100mA 12 10V DC Referenced to Analog Common P038 Drive supplied power for 0 10V exte
90. ct that may restrict air flow through the drive heat sink and chassis Powerflex fe ras 120 mm 120 mm 4 7 in wr 4 7 in Mounting Option A Mounting Option B No clearance required between drives Ambient Operating Temperatures Table 1 A Enclosure and Clearance Requirements Ambient Temperature Enclosure Rating Minimum Mounting Minimum Maximum Clearances IP20 NEMA UL Type Open Use Mounting Option A 40 C 14 F 40 C 104 F IP66 NEMA UL Type 4X Use Mounting Option A IP30 NEMAJUL Type 1 1 Use Mounting Option B 50 C 122 F IP20 NEMA UL Type Open Use Mounting Option B 1 Rating requires installation of the PowerFlex 40 IP30 NEMA UL Type 1 option kit 1 4 Installation Wiring 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 IP20 NEMA UL Type Open applications Storage e Store within an ambient temperature range of 40 to 85 C e Store within a relative humidity range of 0 to 95 non condensing e Do not expose to a corrosive atmosphere Installation Wiring 1 5 AC Supply Source Considerations Ungrounded Distribution Systems referenced to ground These devices must be disconnected if the drive is ATTENTION PowerFlex 40 drives contain protective MOVs that are A installe
91. d Program Group continued A088 Maximum Voltage Related Parameter s d004 A085 A086 A087 Sets the highest voltage the drive will output Values Default Drive Rated Volts Min Max 20 Drive Rated Volts Display 1 VAC A089 Current Limit 1 Related Parameter s P033 A118 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 P033 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 Min Derate 2 Max Derate No Derate Min Derate Max Derate 2100 100 100 5 5 3 80 80 80 3 3 3 5 60 60 5 60 S 40 40 40 8 g 8 S 20 3 20 S 20 5 Ss 5 xz 0 0 an 0 25 50 75 100 125 150175 200 0 25 50 75 100 125 150 175 200 0 25 50 75 100 125 150 175 200 of P032 Motor NP Hertz of P032 Motor NP Hertz of P032 Motor NP Hertz A091 PWM Frequency Related Parameter s A124 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 ee 96 92 88 84 S 80 S 2
92. d on an ungrounded or resistive grounded 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 the jumper completely out of the drive chassis 3 Tighten the screw to keep it in place Figure 1 1 Jumper Location Typical IP20 NEMA UL Type Open Important Tighten screw after jumper removal Figure 1 2 Phase to Ground MOV Removal Three Phase ae AC Input a T L3 t Jumper 1 2 3 4 1 1 4 1 f 1 6 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 B 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 B 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
93. d wait three minutes for capacitors to discharge before removing the external cover Once the cover is removed verify that the voltage on the bus capacitors has discharged before performing any work on the drive Measure the DC bus voltage at the DC and DC terminals on the Power Terminal Block refer to page 1 13 for Power Terminal descriptions The voltage must be zero 1 Loosen the four captive cover screws 2 Pull cover straight off chassis IP66 NEMA UL Type 4X Cover Installation 1 Squarely align the cover on the chassis 2 Lightly tighten the four captive cover screws 3 Torque the cover screws using an alternating pattern 0 8 0 2 N m 7 0 2 0 lb in Installation Wiring Mounting Considerations e Mount the drive upright on a flat vertical and level surface 1 3 Frame Screw Size Screw Torque DIN Rail B M4 8 32 1 56 1 96 N m 14 17 Ib in 35 mm C M5 10 24 2 45 2 94 N m 22 26 lb in B IP Tye D M6 12 24 3 95 4 75 N m 35 42 Ib in e Protect the cooling fan by avoiding dust or metallic particles e Do not expose to a corrosive atmosphere e Protect from moisture and direct sunlight Minimum Mounting Clearances Refer to Appendix B for mounting dimensions l l lt gt 120 mm 4 7 in 8888 ododo Bcog Alten Bradey 8888 ododo B oO Alen Bradiey Powerflex Powerflex l o V o ZN Closest obje
94. e I O Common connection may occur Multiple Analog Connections 12 13 14 13 14 13 14 SQG OOOOOOOD COCOOOOOOD OGCVOOBOOOOD O2OOOO0 0000000 OOP 920000 l 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 wiper should be daisy chained to each drive All drives must be powered up for the analog signal to be read correctly Installation Wiring 1 23 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 A054 Digital Inx Sel is set to option 2 4 5 6 11 12 13 14 15 and the digital input is active or if A132 is not set to option 0 the speed reference commanded by P038 Speed Reference will be overridden See the chart below for the override priority Drive will Start and Run jog Inout A at Jog Speed A051 A052 rh Drive Stopped Yes Direction comes from 54 2 Not Running VO Terminal 03 Dir Run REV or A054 2 11 12 or Jog Forward Jog Reverse command Local Remote Input Enabled and Active Digital Inx Sel 5 Start Speed and Direction commands come from Integral Keypad
95. e 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 O Terminal 1 Stop coast to stop 3 2 W Lvl Sens Drive will restart after a Stop command when e Stop is removed and e Start is held active P036 Start Source is set to option 3 and the Run input is maintained 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 ATTENTION Hazard of injury exists due to unintended operation When 4 2 W Hi 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 Comm Port e Remote communications Refer to Appendix C for details e O Terminal 1 Stop coast to stop 6 Momt FWD REV e Drive will start after a momentary input from either the Run FWD Input I O Terminal 02 or the Run REV Input I O Termin
96. e logic functions without a separate controller StepLogic Function Steps through up to eight preset speeds based on programmed logic Programmed logic can include conditions that need to be met from digital inputs programmed as Logic In1 and Logic In2 before stepping from one preset speed to the next A timer is available for each of the eight steps and is used to program a time delay before stepping from one preset speed to the next The status of a digital output can also be controlled based on the step being executed Basic Logic Function Up to two digital inputs can be programmed as Logic In1 and or Logic In2 A digital output can be programmed to change state based on the condition of one or both inputs based on basic logic functions such as AND OR NOR The basic logic functions can be used with or without StepLogic Timer Function A digital input can be programmed for Timer Start A digital output can be programmed as a Timer Out with an output level programmed to the desired time When the timer reaches the time programmed into the output level the output will change state The timer can be reset via a digital input programmed as Reset Timer Counter Function A digital input can be programmed for Counter In A digital output can be programmed as Counter Out with an output level programmed to the desired number of counts When the counter reaches the count programmed into t
97. e potentiometer on the integral keypad Important This option is not available with IP66 NEMA UL Type 4X rated drives Internal frequency command comes from A069 Internal Freq 1 InternalFreq Internal frequency command from A069 Internal Freq Must IP66 NEMA UL Type be set when using MOP function 4X Default 2 0 10V Input External frequency command from the 0 10V or 10V analog input or remote potentiometer 3 4 20mA Input External frequency command from the 4 20mA analog input 4 Preset Freq External frequency command as defined by A070 A077 Preset Freq x when A051 A054 Digital Inx Sel are programmed as Preset Frequencies and the digital inputs are active 5 Comm Port External frequency command from the communications port Refer to Appendix C for details 6 Stp Logic External frequency command as defined by A070 A077 Preset Freq x and A140 A147 Stp Logic x 7 Anig In Mult External frequency command as defined by the product of the analog inputs shown in d020 Analog In 0 10V and d021 Analog In 4 20mA Analog In 0 10V x Analog In 4 20mA Speed Command Example 100 x 50 50 P039 Accel Time 1 Related Parameter s P038 P040 A051 A054 A067 A070 A077 A140 A147 Sets the rate of acceleration for all speed increases Maximum Freq Accel Time Accel Rate Values Default 10 0 Secs Min Max 0 0 600 0 Secs
98. el to the relay as shown to prevent damage to the output 24V Common Each Opto Output is rated 30V DC 50 mA Non inductive Analog Output A065 Analog Out Sel determines analog output type and drive conditions 0 10V 1k ohm minimum 0 20mA 4 20mA 525 ohm maximum A065 Analog Out Sel 0 through 14 The Analog Output Select D signal mode set in A065 Analog Out Sel P Switch must be set to match the analog output Common atte ans 1 22 Installation Wiring Typical Multiple Drive Connection Examples Input Output Multiple Digital Input Connections Customer Inputs can be wired per External Supply SRC Connection Example 02 04 02 04 02 04 22 QIO 2 SOOO E O GO 9 0 COCO 00008 O O TTI Customer Inputs 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 ATTENTION I O Common terminals should not be tied together when using SNK Internal Supply mode In SNK mode if power is removed from one drive inadvertent operation of other drives that share the sam
99. elated Parameter s d002 P034 P035 Status of the control terminal block control inputs Important Actual control commands may come from a source other than the control terminal block OGG 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 Dynamic Brake Transistor On 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 Read Only Min Max 0 1 Display 1 3 6 Programming and Parameters Display Group continued d014 Dig In Status Related Parameter s A051 A054 Status of the control terminal block digital inputs Jog 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 Digital In3 Sel I O Terminal 07 Bit 2 Digital In4 Sel I O Terminal 08 Bit 3 Values Default Read Only Min Max 0 1 Display 1 d015 Comm Status Related Parameter s A103 A107 Status of the communications ports ii I LNE 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 C
100. eq 6 Accel Time 2 Decel Time 2 1 1 1 A077 Preset Freq 7 Accel Time 2 Decel Time 2 e Anen a Digital Input is set to Accel 2 amp Decel 2 and the input is active that input overrides the settings in this able A078 Jog Frequency Related Parameter s P035 A051 A054 A079 Sets the output frequency when a jog command is issued Values Default 10 0 Hz Min Max 0 0 Maximum Freq Display 0 1 Hz Programming and Parameters 3 23 Advanced Program Group continued A079 Jog Accel Decel Related Parameter s A078 A051 A054 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 A080 DC Brake Time Related Parameter s P037 A081 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 99 9 Secs A setting of 99 9 Continuous 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 P037 Ramp to Stop Mode P037 DC Injection Braking Mode lt S gt a Speed DC Brake Time Volts Speed Volts Speed DC Brake Level
101. er Signal t PID Reference Desired System Pressure PID Set Up F 3 Trim Control In Trim Control the PID Output is added to the Speed Reference In Trim mode the output of the PID loop bypasses the accel decel ramp as shown Trim Control is used when A132 PID Ref Sel is set to option 5 6 7 or 8 P038 Speed Reference PID Loop l Accel Decel Ramp PID Ref PID Prop Gain PID A PID a l l Output i _ rror uputi PID Fdbk PID Integ Time SE T O a l l ff PID Diff Rate PID Enabled Example e Ina winder application the PID Reference equals the Equilibrium set point e The Dancer Pot signal provides PID Feedback to the drive Fluctuations in tension result in a PID Error value e The Master Speed Reference sets the wind unwind speed e As tension increases or decreases during winding the Speed Reference is trimmed to compensate Tension is maintained near the Equilibrium set point wor lt 0 Volts 7 PID Feedback al gt Dancer Pot Signal c lt 10 Volts PID Reference Equilibrium Set Point P038 Speed Reference _t F 4 PID Set Up PID Reference and Feedback Parameter A132 PID Ref Sel is used to enable the PID mode A132 10 PID Disabled and to select the source of the PID Reference If A132 PID Ref Sel is no
102. eter Values Default 0 Hz Min Max 0 400 Hz Display 1 Hz A120 Skip Freq Band Related Parameter s A119 Determines the bandwidth around A119 Skip Frequency A120 Skip Frequency Band is split applying 1 2 above and 1 2 below the actual skip frequency A setting of 0 0 disables this parameter Values Default 0 0 Hz Min Max 0 0 30 0 Hz Display 0 1 Hz Frequency Command Frequency Drive Output pfrequency f 4 a E 2x Skip r Frequency Band i ee SEEE ENEN eNO RON AE S i H i 1 L L Li Skip Frequency gt Time A121 Stall Fault Time Sets the time that the drive will remain in stall mode before a fault is issued Options 0 60 Seconds Default 1 120 Seconds 240 Seconds 360 Seconds 480 Seconds o A O N Flt Disabled Programming and Parameters 3 35 Advanced Program Group continued A122 Analog In Loss Related Parameter s A110 A111 A132 Selects drive action when an input signal loss is detected Signal loss is defined as an analog signal less than 1V or 2mA The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1 5V or 3mA If using a 0 10V analog input set A110 Anlg In 0 10V Lo to a minimum of 20 i e 2 volts Options 0 Disabled Default 1 Fault F29 F29 Analog Input Loss 2
103. formation needed to install start up and troubleshoot the PowerFlex 40 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 Reference Materials The following manuals are recommended for general drive information Title Publication Available Online at Wiring and Grounding DRIVES INO01 Guidelines for Pulse Width Modulated PWM AC Drives Preventive Maintenance of DRIVES TD001 Industrial Control and Drive System Equipment Safety Guidelines for the SGI 1 1 www rockwellautomation com Application Installation and literature Maintenance of Solid State Control A Global Reference Guide for 100 2 10 Reading Schematic Diagrams Guarding Against Electrostatic 8000 4 5 2 Damage P 2 Overview Manual Conventions e In this manual we refer to the PowerFlex 40 Adjustable Frequency AC Drive as drive PowerFlex 40 or PowerFlex 40 Drive e Parameter numbers and names are shown in this format P031 Motor NP Volts Name Number Group d Display Grou
104. g 0 10 0 10V OV 0 Amps 200 Drive Rated FLA 0 10V d029 16 OutTorg 0 20 0 20 mA OmA 0Amps 200 Drive Rated FLA 0 20mA d029 17 OutTorg 4 20 4 20 mA 4mA 0Amps_ 200 Drive Rated FLA 0 20mA d029 18 Setpnt 0 10 0 10V OV 0 100 0 Setpoint Setting 0 10V A109 19 Setpnt 0 20 0 20 mA 0 mA 0 100 0 Setpoint Setting 0 20mA A109 20 Setpnt 4 20 4 20 mA 4 mA 0 100 0 Setpoint Setting 0 20 mA A109 21 MinFreq 0 10 0 10V OV Min Freq P035 Maximum Freq 0 10V d001 22 MinFreq 0 20 0 20 mA 0 mA Min Freq P035 Maximum Freq 0 20mA d001 23 MinFreq 4 20 4 20 mA 4 mA Min Freq P035 Maximum Freq 0 20mA d001 Values Default 0 Min Max 0 23 Display 1 A066 Analog Out High Related Parameter s A065 Scales the Maximum Output Value for the A065 Analog Out Sel source setting Examples A066 Setting A065 Max Output Value 50 1 OutCurr 0 10 5V for 200 Drive Rated Output Current 90 8 OutPowr 0 20 18mA for 200 Drive Rated Power Values Default 100 Min Max 0 800 Display 1 Programming and Parameters 3 21 Advanced Program Group continued A067 Accel Time 2 Related Parameter s P039 A051 A054 A070 A077 A140 A147 When active sets the rate of acceleration for all speed increases except jog Refer to the flowchart on page 1 24 for details Maximum Freq Accel Time Accel hate Values Default 20 0 Secs Min Max 0 0 600 0 Secs
105. gital Input 1 Status 13 Digital Input 2 Status 14 Digital Input 3 Status 15 Digital Input 4 Status 1 This status is available only with firmware revision FRN 2 xx and higher Reading 03 Feedback The Feedback Output Frequency from the PowerFlex 40 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 123 equals 12 3 Hz and 300 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 40 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 T 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
106. gram Drive Type d017 Display Stall Fault Time A121 Advanced Program Elapsed Run Time d018 Display Start At PowerUp A094 Advanced Program EM Brk Off Delay A160 Advanced Program Start Boost A085 Advanced Program EM Brk On Delay A161 Advanced Program Start Source P036 Basic Program Fault Clear A100 Advanced Program Stop Mode P037 Basic Program Fault x Code d007 d009 Display SW Current Trip A098 Advanced Program Flux Current Ref A129 Advanced Program Testpoint Data d019 Display Flying Start En A096 Advanced Program Testpoint Sel A102 Advanced Program nternal Freq A069 Advanced Program Timer Status d026 Display R Voltage Drop A128 Advanced Program Torque Current d029 Display Jog Accel Decel A079 Advanced Program Torque Perf Mode A125 Advanced Program Jog Frequency A078 Advanced Program Var PWM Disable A124 Advanced Program Language A108 Advanced Program Voltage Class P042 Basic Program Chapter 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 40 drive Included is a listing and description of drive faults with possible solutions when applicable See e page For information on For information on See page Drive Status Fault Descriptions 4 3 Faults a 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
107. he error value to 0 To enable the PID loop parameter A132 PID Ref Sel must be set to an option other than 0 PID Disabled Exclusive Control and Trim Control are two basic configurations where the PID loop may be used F 2 PID Set Up Exclusive Control In Exclusive Control the Speed Reference becomes 0 and the PID Output becomes the entire Freq Command Exclusive Control is used when A132 PID Ref Sel is set to option 1 2 3 or 4 This configuration does not require a master reference only a desired set point such as a flow rate for a pump PID Loop i l PID Ref PID Prop Gain l A ae l rror utput 3 Accel Decel Freq l PID Fdbk PID Integ Time On ane Ramp I gt Command FF 7 l l PID Diff Rate PID Enabled Example e Ina pumping application the PID Reference equals the Desired System Pressure set point e The Pressure Transducer signal provides PID Feedback to the drive Fluctuations in actual system pressure due to changes in flow result in a PID Error value e The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value e The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow e When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference PID Feedback Pressure Transduc
108. he output level the output will change state The counter can be reset via a digital input programmed as Reset Counter StepLogic Basic Logic and Timer Counter Functions StepLogic Using Timed Steps To activate this function set parameter P038 Speed Reference to 6 Stp Logic Three parameters are used to configure the logic speed reference and time for each step e Logic is defined using parameters A140 A147 Stp Logic x e Preset Speeds are set with parameters AO70 A077 Preset Freq x e Time of operation for each step is set with parameters A150 A157 Stp Logic Time x The direction of motor rotation can be forward or reverse Figure E 1 Using Timed Steps Step0 Step1 Step2 Step3 Step4 Step5 Step6 Step7 a Forward Ob Reverse WwW Time StepLogic Sequence e Sequence begins with a valid start command e A normal sequence begins with Step 0 and transition to the next step when the corresponding StepLogic time has expired e Step 7 is followed by Step 0 e Sequence repeats until a stop is issued or a fault condition occurs StepLogic Basic Logic and Timer Counter Functions E 3 StepLogic Using Basic Logic Functions Digital input and digital output parameters can be configured to use logic to transition to the next step Logic In1 and Logic In2 are defined by programming parameters A051 A054 Digital Inx Sel to option 23 Logic In1 or option 24 Logic In2 Example
109. hield that can contain much of the noise generated by a typical AC Drive Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable Installation Wiring 1 11 Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications In addition the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks Refer to Reflected Wave in Wiring and Grounding Guidelines for PWM AC Drives publication DRIVES INO01A EN P Consideration should be given to all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment A good example of recommended cable is Belden 295xx xx determines gauge This cable has four 4 XLPE insulated conductors
110. igital In3 Sel A053 Output Voltage 004 Digital In4 Sel A054 DC Bus Voltage d005 Relay Out Sel A055 Drive Status d006 Relay Out Level A056 Fault 1 Code d007 Opto Out1 Sel A058 Fault 2 Code d008 Opto Out1 Level A059 Fault 3 Code d009 Opto Out2 Sel A061 Process Display d010 Opto Out2 Level A062 Control Source d012 Opto Out Logic A064 Contrl In Status d013 Analog Out Sel A065 Dig In Status d014 Analog Out High A066 Comm Status d015 Accel Time 2 A067 Control SW Ver d016 Decel Time 2 A068 Drive Type d017 Internal Freq A069 Elapsed Run Time d018 Preset Freq 0 A070 Testpoint Data d019 Preset Freq 1 A071 Analog In 0 10V d020 Preset Freq 2 A072 Analog In 4 20mA d021 Preset Freq 3 A073 Output Power d022 Preset Freq 4 A074 Output Power Fctr d023 Preset Freq 5 A075 Drive Temp d024 Preset Freq 6 A076 Counter Status d025 Preset Freq 7 A077 Timer Status d026 Jog Frequency A078 Stp Logic Status d028 Jog Accel Decel A079 Torque Current d029 DC Brake Time A080 DC Brake Level A081 DB Resistor Sel A082 S Curve A083 Boost Select A084 Start Boost A085 Break Voltage A086 Break Frequency A087 Maximum Voltage A088 Current Limit 1 A089 Motor OL Select A090 PWM Frequency A091 See page 3 9 Auto Rstrt Tries A092 Motor NP Volts P031 Auto Rstrt Delay A093 Motor NP Hertz P032 Start At PowerUp A094 Motor OL Current P033 Reverse Disable A095 Minimum Freq P034 Flying Start En A096 Maximum Freq P035 Compensation A097 Start Source P036 SW Current Trip A098 S
111. in A059 or A062 Opto Outx Level e Do not use if A123 10V Bipolar Enbl is set to 1 Bi Polar In e This parameter setting can also be used to indicate a PTC trip point when the input I O Terminal 13 is wired to a PTC and external resistor e Use A059 or A062 to set threshold 11 Logic In 1 An input is programmed as Logic In 1 and is active 12 Logic In 2 An input is programmed as Logic In 2 and is active 13 Logic 1 amp 2 Both Logic inputs are programmed and active 14 Logic 1 or 2 One or both Logic inputs are programmed and one or both is active 15 StpLogic Out Drive enters StepLogic step with Digit 3 of Command Word A140 A147 set to enable StepLogic output 16 Timer Out e Timer has reached value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold 17 Counter Out e Counter has reached value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold 18 Above PF Ang e Power Factor angle has exceeded the value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold 19 Anlg In Loss Analog input loss has occurred Program A122 Analog In Loss for desired action when input loss occurs 20 ParamControl Enables the output to be controlled over network communications by writing to A059 or A062 Opto Outx Level 0 Off 1 On 2
112. 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 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 Ww RGN KCNA GN The integral keypad provides visual notification of a mo E g g mies fault condition by displaying the following oA EN FTN 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 Access 007 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
113. inimum recommended values for use with each drive rating The devices listed in this table are provided to serve as a guide Bulletin 140M Self Protected Combination Controller UL489 Circuit Breakers When using Bulletin 140M 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 140M can be used in single and group motor applications e Bulletin 140M can be used up stream from the drive without the need for fuses Installation Wiring 1 9 Table 1 C 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 4 0 5 15 140M C2E C16 100 C12 1 Phase 0 75 1 0 35 140M D8E C20 100 C23 1 1 1 5 40 140M F8E C32 100 C37 240V AC 0 4 0 5 10 140M C2E B63 100 C09 1 Phase 0 75 1 0 20 140M C2E C16 100 C12 1 5 2 0 30 140M D8E C20 100 C23 2 2 3 0 40 140M F8E C32 100 C37 240V AC 0 4 0 5 6 140M C2E B40 100 C07 3 Phase 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 C23 3 7 5 0 30 140M F8E C25 100 C23 5 5 7 5 40 140M F8E C32 100 C37 7 5 10 0 60 140M G8E C45 100 C60 480V AC 0 4 0 5 3 140M C2E B25 100 C07 3 Phase 0 75 1 0 6 140M C2E B40 100 C07 1 5 2 0 10 140M C2E B63 100 C09 2 2 3 0 15
114. ins 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 undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations overhauling loads and eccentric loads However it can also cause either of the following two conditions to occur 1 Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes 2 Actual deceleration times can be longer than commanded deceleration times However a Stall Fault is generated if the drive remains in this state for 1 minute If this condition is unacceptable the bus regulator must be disabled see parameter A117 In addition installing a properly sized dynamic brake resistor will provide equal or better performance in most case
115. ion Catalog Number LCD Display Remote Panel Digital speed contro 22 HIM C2S Mount CopyCat capable IP66 NEMA Type 4X 12 indoor use only Includes 2 9 meter cable LCD Display Remote Panel Digital speed contro 22 HIM C2 Mount CopyCat capable IP66 NEMA Type 4X 12 indoor use only Includes 2 9 meter cable LCD Display Remote Handheld Digital speed contro 22 HIM A3 Full numeric keypad CopyCat capable IP30 NEMA Type 1 Includes 1 0 meter cable Panel mount with optional Bezel Kit Bezel Kit Panel mount for LCD Display Remote 22 HIM B1 Handheld unit IP30 NEMA Type 1 DSI HIM Cable 1 0 Meter 3 3 Feet 22 HIM H10 DSI HIM to RJ45 cable 2 9 Meter 9 51 Feet 22 HIM H30 Table B H IP30 NEMA 1 UL Type 1 Kit Drive Item Description Frame Catalog Number IP30 NEMA 1 UL Type 1 Field installed kit Converts drive to IP30 B 22 JBAB Kit NEMA 1 UL Type 1 enclosure Includes conduit box with mounting screws and C 22 JBAC plastic top panel IP30 NEMA 1 UL Type 1 Field installed kit Converts drive to P30 B 22 JBCB Kit for Communication NEMA 1 UL Type 1 enclosure Includes Option communication option conduit box with c 20 JBCC mounting screws and plastic top panel B 6 Accessories and Dimensions Table B I Communication Option Kits and Accessories Item Communication Adapters Description Embedded communication options for use with the PowerFlex 4 Class drives Requires a Communication Adapter Cover IP20 NEMA UL Type
116. k of equipment damage exists If a controller is programmed to write parameter data to Non Volatile Storage NVS frequently the NVS will quickly exceed its life cycle and cause the drive to malfunction Do not create a program that frequently uses configurable outputs to write parameter data to NVS unless A164 Comm Write Mode is set to option 1 A165 Anlg Loss Delay Related Parameter s A122 Sets the length of time after power up during which the drive will not detect an analog signal loss The drive response to an analog signal loss is set in A122 Analog In Loss Values Default 0 0 Secs Min Max 0 0 20 0 Secs Display 0 1 Secs A166 Analog In Filter Sets level of additional filtering of the analog input signals A higher number increases filtering and decreases bandwidth Each setting doubles the applied filtering 1 2x filter 2 4x filter etc No additional filtering is applied when set to 0 Values Default 0 Min Max 0 14 Display 1 3 44 Programming and Parameters Parameter Cross Reference by Name Parameter Name No Group Parameter Name No Group 10V Bipolar Enbl A123 Advanced Program Maximum Freq P035 Basic Program Accel Time 1 P039 Basic Program Maximum Voltage A088 Advanced Program Accel Time 2 A067 Advanced Program Minimum Freq P034 Basic Program Analog In 0 10V d020 Display MOP Reset Sel A162 Advanced Program Analog In 4 20mA 021 Display Motor NP FLA A126 Advanced
117. l are used to set the desired time in seconds Parameters A055 Relay Out Sel A058 Opto Out Sel and A061 Opto Out2 Sel are set to option 16 Timer Out and causes the output to change state when the preset level is reached Example e Drive starts up and accelerates to 30 Hz e After 30Hz has been maintained for 20 seconds a 4 20mA analog input becomes the reference signal for speed control e The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active e Parameters are set to the following options 038 Speed Reference 3 4 20mA Input A051 Digital In1 Sel 4 Preset Freq A052 Digital In2 Sel 18 Timer Start A055 Relay Out Sel 16 Timer Out A056 Relay Out Level 20 0 Secs A071 Preset Freq 1 30 0 Hz e The control terminal block is wired such that a start command will also trigger the timer start e The relay output is wired to I O Terminal 05 Digital Input 1 so that it forces the input on when the timer starts e After the timer is complete the output is turned off releasing the preset speed command The drive defaults to following the analog input reference as programmed StepLogic Basic Logic and Timer Counter Functions E 5 Output gt Frequency Start gt Relay Out gt Photo Eye gt
118. lay Out Level e Use A056 to set threshold 18 Above PF Ang e Power Factor angle has exceeded the value set in A056 Relay Out Level e Use A056 to set threshold 19 Anlg In Loss Analog input loss has occurred Program A122 Analog In Loss for desired action when input loss occurs 20 ParamControl Enables the output to be controlled over network communications by writing to A056 Relay Out Level 0 Off 1 On 21 NonRec Fault e Value set in A092 Auto Rstrt Tries is exceeded e A092 Auto Rstrt Tries in not enabled e ANon resettable fault has occurred 22 EM Brk Cntrl EM brake is energized Program A160 EM Brk Off Delay and A161 EM Brk On Delay for desired action 23 Above Femd The current commanded frequency exceeds the value set in A056 Relay Out Level Programming and Parameters 3 17 Advanced Program Group continued A056 Relay Out Level Related Parameter s A055 A058 A061 7 32 bit parameter Sets the trip point for the digital output relay if the value of A055 Relay Out Sel is 6 7 8 10 16 17 18 or 20 A055 Setting A056 Min Max 6 0 400 Hz 7 0 180 8 0 815 Volts 10 0 100 16 0 1 9999 Secs 17 1 9999 Counts 18 1 180 degs 20 0 1 23 0 400 Hz Values Default 0 0 Min Max 0 0 9999 Display 0 1 A058 Opto Out Sel Related Parameter s P033 A056 A092 A140 A147 A150 A157 A061 Opto O
119. le 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 Distribution Second Environment Integral 10 meters 33 feet 1 meter 3 feet 10 meters 33 feet 1 meter 3 feet External S Type External L Type 100 meters 328 feet 5 meters 16 feet 1 Refer to Appendix B for details on optional external filters Equivalent to EN55011 Class A 3 Equivalent to EN55011 Class B Figure 1 6 Connections and Grounding Shielded Enclosure IP 30 NEMA 1 UL Type 1 Option Kit j 2 EMI Fittings and Metal Conduit at EMI Filter Lda eo 2 2 F g L3 L3 T L3 f Berna Ground Connection Shielded Motor Cable Ni 1 2 Building Structure Steel 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 Integral EMI filters are available on 240V 1 Phase drives Installation Wiring 1 27 EN61000 3 2 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 vo
120. lt Descriptions on page 4 3 for an explanation of the fault code Variable Torque Fan Pump Applications For improved motor tuning performance when using a premium efficient motor on a variable torque load set A084 Boost Select to option 2 35 0 VT Integral Keypad Start Up 2 3 2 PUJ i PROGRAM RUN FWD REV e VOLTS AMPS HERTZ FAULT Oo O Gee Sal A VO amp Go Qo Menu Description PE J Display Group View Only m Consists of commonly viewed drive operating conditions oO Basic Program Group f Consists of most commonly used programmable functions Advanced Program Group Consists of remaining programmable functions A E Fault Designator Consists of list of codes for specific fault conditions Displayed only when fault is present No LED LED State Description RunDirection 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 displ
121. ltage power network Installations on a public low voltage power network may require additional external harmonic mitigation Other drive ratings meet the current harmonic requirements of EN61000 3 2 without additional external mitigation 1 28 Installation Wiring Notes Chapter 2 Start Up This chapter describes how to start up the PowerFlex 40 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
122. m PID Setpoint A137 Advanced Program Comm Node Addr A104 Advanced Program PID Trim Hi A130 Advanced Program Comm Status d015 Display PID Trim Lo A131 Advanced Program Comm Write Mode A164 Advanced Program Preset Freq x A070 A077 Advanced Program Commanded Freq d002 Display Process Display d010 Display Compensation A097 Advanced Program Process Factor A099 Advanced Program Contrl In Status d013 Display Process Time Hi A116 Advanced Program Control Source d012 Display Process Time Lo A115 Advanced Program Control SW Ver d016 Display Program Lock A101 Advanced Program Counter Status d025 Display PWM Frequency A091 Advanced Program Current Limit x A089 A118 Advanced Program Relay Out Level A056 Advanced Program DB Resistor Sel A082 Advanced Program Relay Out Sel A055 Advanced Program DB Threshold A163 Advanced Program Reset To Defalts P041 Basic Program DC Brake Level A081 Advanced Program Reverse Disable A095 Advanced Program DC Brake Time A080 Advanced Program S Curve A083 Advanced Program DC Bus Voltage d005 Display Skip Freq Band A120 Advanced Program Decel Time 1 P040 Basic Program Skip Frequency A119 Advanced Program Decel Time 2 A068 Advanced Program Slip Hertz FLA A114 Advanced Program Dig In Status d014 Display Stp Logic Status d028 Display Digital Inx Sel A051 A054 Advanced Program Stp Logic x A140 A147 Advanced Program Drive Status d006 Display Stp Logic Time x A150 A157 Advanced Program Drive Temp d024 Display Speed Reference P038 Basic Pro
123. n No value is coming from the The drive Run indicator is lit e Check d012 Control Source for source of the command and output is 0 Hz correct source e Ifthe 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 A054 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 23 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 4003 Output Current with acceleration times force the A089 Current Limit 1 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 Boost Select 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
124. n of the command for the current step In addition if a relay or opto output parameters A055 A058 and A061 is set to 15 StpLogic Out this parameter can control the status of that output Any StepLogic parameter can be programmed to control a relay or opto output but you can not control different outputs based on the condition of different StepLogic commands 3 40 Programming and Parameters StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter The following is a listing of the available settings for each digit Refer to Appendix E for details AINIAIAT LEIL L Logic For Next Step Digit 0 Logic to Jump to a Different Step Digit 1 Different Step to Jump Digit 2 Step Settings Digit 3 Digit 3 Settings Required Accel Decel StepLogic Commanded Setting Param Used Output State Direction 0 Accel Decel 1 Off FWD 1 Accel Decel 1 Off REV 2 Accel Decel 1 Off No Outpu 3 Accel Decel 1 On FWD 4 Accel Decel 1 On REV 5 Accel Decel 1 On No Outpu 6 Accel Decel 2 Off FWD 7 Accel Decel 2 Off REV 8 Accel Decel 2 Off No Outpu 9 Accel Decel 2 On FWD A Accel Decel 2 On REV b Accel Decel 2 On No Outpu Digit 2 Settings Digit 1 and Digit 0 Settings 0 Jump to Step 0 0 Skip Step Jump Immediately 1 Jump to Step 1 1 Step Based on Stp Logic Time x 2 Jump to Step 2 2 Step if Logic In1 is Active 3 Jump to Step 3 3 Step if
125. nd I O wiring Analog Input PTC wiring example added 1 18 The following parameters have been added P043 Motor OL Ret 3 13 A163 DB Threshold 3 42 Option 27 EM Brk Rise added to parameters A051 A054 Digital Inx Sel 3 14 Attention statement added to parameter A082 DB Resistor Sel 3 24 Parameter A117 Bus Reg Mode new description provided 3 33 Parameter A129 Flux Current Ref maximum value corrected to 3 36 Motor NP FLA Explanation of Electronic Motor Overload Protection clarified A 4 Watts Loss table added A 5 Two footnotes regarding Flange Mount drives added to Table B A B 1 Communication Adapters External Comm Options Compact I O added to B 6 Table B I External brake resistor circuitry diagram added B 13 Catalog Numbers for Frame B EMC Line Filters corrected B 15 Catalog Numbers for Frame C EMC Line Filters corrected B 16 Modbus Function Code 16 added O M Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Appendix A Appendix B Appendix C Appendix D Appendix E Appendix F 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 SiZesSs spse sienos t porani at P 2 General Precautions P 3 Catalog Number Explanation p 4 Opening the Cover
126. np S Drive will Start and Run A Drive Stopped Yes at Jog Speed A051 A052 A053 Not Running or A054 2 11 12 Drive will use A079 Jog Accel Decel Either P039 Accel Time 1 P040 Decel Time 1 RS485 DSI Port or Controls Speed A067 Accel Time 2 A068 Decel Time 2 can be selected when RS485 DSI port is active nput is programmed as Accel 2 amp Decel 2 A051 A052 A053 A067 Accel Time 2 A068 Decel Time 2 is active when input is active P039 Accel Time 1 P040 Decel Time 1 A067 Accel Time 2 A068 Decel Time 2 determined by the active Preset Frequency See A070 A077 Preset Freq 0 7 Speed is controlled by Preset Freq x Either P039 Accel Time 1 P040 Decel Time 1 Speed is controlled or by Stp Logic A067 Accel Time 2 A068 Decel Time 2 can be selected by the Digit 3 setting of the Step Logic parameters See A140 A147 Stp Logic 0 7 P039 Accel Time 1 P040 Decel Time 1 are used Installation Wiring 1 25 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
127. o guard against possible injury and or equipment damage it is ATTENTION Rotation of the motor in an undesired direction can occur during this A recommended that the motor be disconnected from the load before proceeding If the Autotune routine fails an F80 SVC Autotune fault is displayed A128 IR Voltage Drop Related Parameter s A127 Value of volts dropped across the resistance of the motor stator Values Default Based on Drive Rating Min Max 0 0 230 0 VAC Display 0 1 VAC A129 Flux Current Ref Related Parameter s A127 Value of amps for full motor flux Values Default Based on Drive Rating Min Max 0 00 Motor NP FLA Display 0 01 Amps Programming and Parameters 3 37 Advanced Program Group continued A130 PID Trim Hi Sets the maximum positive value that is added to a PID reference when PID trim is used Values Default 60 0 Min Max 0 0 400 0 Display 0 1 A131 PID Trim Lo Sets the minimum positive value that is added to a PID reference when PID trim is used Values Default 0 0 Min Max 0 0 400 0 Display 0 1 A132 PID Ref Sel Related Parameter s P038 A122 Stop drive before changing this parameter Enables disables PID mode and selects the source of the PID reference Refer to Appendix F for details Options 0 PID Disabled Default PID Setpoint 0 10V Input 4 20mA Input Comm Port Setpnt Trim
128. ommunication 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 10 Hrs d019 Testpoint Data Related 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 Analog In 0 10V 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 Analog In 4 20mA 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 d022 Output Power Output power present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 00 Drive Rated Power x 2 Display 0 01 kW d023 Output Powr Fctr The angle in electrical degrees between motor voltage and mot
129. op drive before changing this parameter Set to the motor nameplate rated frequency Values Default 60 Hz Min Max 15 400 Hz Display 1 Hz P033 Motor OL Current Related Parameter s A055 A058 A061 A089 A090 A098 A114 A118 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 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 d001 d002 d013 P035 A085 A086 A087 A110 A112 Sets the lowest frequency the drive will output continuously Values Default 0 0 Hz Min Max 0 0 400 0 Hz Display 0 1 Hz P035 Maximum Freq Related Parameter s d001 d002 d013 P034 A065 A078 A085 A086 A087 A111 A113 O Stop drive before changing this parameter Sets the highest frequency the drive will output Values Default 60 Hz Min Max 0 400 Hz Display 1 Hz 3 10 Programming and Parameters Basic Program Group continued P036 Start Source Related Parameter s d012 P037 Stop drive before changing this parameter Sets the control scheme used to start the drive Refer to Start and Speed Reference Control on page 1 23 for details about how other drive settings can override the setting of this parameter Important For all settings except option 3 the drive must receiv
130. or current Values Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg 3 8 Programming and Parameters Display Group continued d024 Drive Temp Present operating temperature of the drive power section Values Default Read Only Min Max 0 120 degC Display 1 degC d025 Counter Status The current value of the counter when counter is enabled Values Default Read only Min Max 0 9999 Display 1 d026 Timer Status 7 32 bit parameter The current value of the timer when timer is enabled Values Default Read Only Min Max 0 0 9999 Secs Display 0 1 Secs d028 Stp Logic Status When P038 Speed Reference is set to 6 Stp Logic this parameter will display the current step of the StepLogic profile as defined by parameters A140 A147 Stp Logic x Values Default Read Only Min Max 0 7 Display 1 d029 Torque Current The current value of the motor torque current Values Default Read Only Min Max 0 00 Drive Rated Amps x 2 Display 0 01 Amps Programming and Parameters 3 9 Basic Program Group P031 Motor NP Volts Related Parameter s d004 A084 A085 A086 A087 Stop drive before changing this parameter Set to the motor nameplate rated volts Values Default Based on Drive Rating Min Max 20 Drive Rated Volts Display 1 VAC P032 Motor NP Hertz Related Parameter s A084 A085 A086 A087 A090 St
131. oss Action Set P041 Reset To Defalts to option 1 Reset Defaults Troubleshooting 4 5 Q No e Description Action F122 O Board Fail Failure has been detected in the 1 Cycle power EATE ec 2 Replace drive if fault cannot be cleared See page 4 1 for a description of fault types 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 Improper boost setting at initial None Set A084 Boost Select to option 2 start up 35 0 VT Drive is Faulted 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 A054 Digital Inx Sel is set to option 7 Clear Fault 4 6 Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block Cause s
132. ow the point where the PID begins to go unstable Adjust the integral gain leave the proportional gain set as in Step 1 After a step change in the PID Feedback If the response is too slow see Figure F 2 or the PID Feedback does not become equal to the PID Reference decrease A135 PID Integ Time If there is a lot of oscillation in the PID Feedback before settling out see Figure F 3 increase A135 PID Integ Time At this point the differential gain may not be needed However if after determining the values for A134 PID Prop Gain and A135 PID Integ Time Response is still slow after a step change increase A136 PID Diff Rate Response is still unstable decrease A136 PID Diff Rate PID Set Up F 9 The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains Figure F 1 Unstable PID Reference PID Feedback Time Figure F 2 Slow Response Over Damped PID Reference _ 7 PID Feedback Time Figure F 3 Oscillation Under Damped PID Reference PID Feedback Time Figure F 4 Good Response Critically Damped PID Reference l z E PID Feedback Time F 10 PID Set Up Notes A AC Supply Ground 1 7 Source 1 5 Ungrounded 1 5 Acceleration Rate 1 24 Advanced Program Group Parameters 3 14 Ambient Temperatures 1 3 Analog Input Loss Fault F29 4 3 Armored Cable 1
133. ower wires by at least 0 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 ATTENTION Driving the 4 20mA analog input from a voltage source could cause component damage Verify proper configuration prior to applying input signals Installation Wiring 1 15 Control Wire Types Table 1 F Recommended Control and Signal Wire Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 8 mm 18AWG twisted pair 100 300V or equiv shield with drain 60 degrees C Belden 8770 0 8 mm 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 Stranded or solid wire 1 0 Terminal Block Table 1 G I O Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Torque B amp C 1 3mm 16 AWG 10 13 mm 26 AWG 0 5 0 8 N m 4 4 7 Ib in 3 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
134. p 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 Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not Recommended Drive Frame Sizes Similar PowerFlex 40 drive sizes are grouped into frame sizes to simplify spare parts ordering dimensioning etc A cross reference of drive catalog numbers and their respective frame sizes is provided in Appendix B gt gt BP 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 conta
135. potentiometer 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 This example provides basic 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 power 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
136. quency reference A054 Start source is not changed Options 44 20mA In Ctrl Selects 4 20mA control as the frequency reference Start Cont source is not changed 15 PID Disable Disables PID function Drive uses the next valid non PID speed reference 16 MOP Up Increases the value of A069 Internal Freq at the current Accel rate if P038 Speed Reference is set to 1 InternalFreq Default for A069 is 60 Hz 17 MOP Down Decreases the value of A069 Internal Freq at the current Decel rate if P038 Speed Reference is set to 1 InternalFreq Default for A069 is 60 Hz 18 Timer Start Clears and starts the timer function May be used to control the relay or opto outputs 19 Counter In Starts the counter function May be used to control the relay or opto outputs 20 Reset Timer Clears the active timer 21 Reset Countr Clears the active counter 22 Rset Tim amp Cnt Clears the active timer and counter 23 Logic Ini Logic function input number 1 May be used to control the relay or opto outputs see parameters A055 A058 A061 Options 11 14 May be used in conjunction with StepLogic parameters A140 A147 Stp Logic x 24 Logic In2 Logic function input number 2 May be used to control the relay or opto outputs see parameters A055 A058 A061 Options 11 14 May be used in conjunction with StepLogic parameters A140 A147 Stp Logic x 25 Current Lmt2 When active A118 C
137. r Interface 2 3 Output Disconnect 1 12 OverVoltage Fault F5 4 3 P Parameter Descriptions 3 1 Types 3 1 Viewing and Editing 2 4 2 5 Parameter Checksum Fault F100 Parameter Cross Reference by Name 3 44 Parameters Advanced Program Group 3 14 Display Group 3 3 Program Group 3 9 Params Defaulted Fault F48 4 4 PE Ground 1 7 Phase Short Fault F41 F43 4 4 Phase to Ground Fault F38 F40 4 4 Potentiometer Wiring 1 18 Power Cables and Wiring 1 10 Power Conditioning 1 6 Power Loss Fault F3 4 3 Power Unit Fault F70 4 4 Powering Up the Drive 2 1 Precautions General P 3 Preferences Setting 2 6 Product Selection B 1 Program Group Parameters 3 9 Programming 3 1 PTC Analog Input Wiring 1 18 R Ratings A 1 Reflective Wave Protection 1 12 Removing Cover 1 1 Repeated Start Stop 1 14 nepeded Start Stop Precautions RFI see EMC RFI RWR Reflective Wave Reducer S Safety Ground 1 7 Saving Data Viewing 2 6 Setting Preferences 2 6 Shielded Power Cables 1 10 Short Circuit Protection 1 8 Sink Source 1 17 Software 3 1 Speed Control of 2 2 Start and Speed Reference Selection and Control 1 23 Start Stop Drive 2 2 Motor 1 14 Starting Stopping The Motor 1 14 Start Up Checklist 2 1 Static Discharge ESD P 3 Status LEDs 2 3 Index 3 Supply Source AC 1 5 SVC Autotune Fault F80 4 4 SW OverCurrent Fault F63 4 4 System Grounding 1 7 T Terminal Block I O 1
138. req 0 Related Parameter s P038 P039 P040 A051 A053 A071 Preset Freq 1 A067 A068 A140 A147 A150 A157 A072 Preset Freq 2 A073 Preset Freq 3 A074 Preset Freq 4 A075 Preset Freq 5 A076 Preset Freq 6 A077 Preset Freq 7 Values A070 Default 0 0 Hz A071 Default 5 0 Hz A072 Default 10 0 Hz A073 Default 20 0 Hz A074 Default 30 0 Hz A075 Default 40 0 Hz A076 Default 50 0 Hz A077 Default 60 0 Hz Min Max 0 0 400 0 Hz Display 0 1 Hz Provides a fixed frequency command value when A051 A053 Digital Inx Sel is set to 4 Preset Frequencies An active preset input will override speed command as shown in the flowchart on page 1 23 1 To activate A070 Preset Freq 0 set P038 Speed Reference to option 4 Preset Freq 0 3 Input State Input State Input State of Digital In 1 of Digital In 2 of Digital In 3 I O Terminal 05 I O Terminal 06 I O Terminal 07 when A051 4 when A052 4 when A053 4 Frequency Source Accel Decel Parameter Used 0 0 0 A070 Preset Freq 0 Accel Time 1 Decel Time 1 1 0 0 A071 Preset Freq 1 Accel Time 1 Decel Time 1 0 1 0 A072 Preset Freq 2 Accel Time 2 Decel Time 2 1 1 0 A073 Preset Freq 3 Accel Time 2 Decel Time 2 0 0 1 A074 Preset Freq 4 Accel Time 1 Decel Time 1 1 0 1 A075 Preset Freq 5 Accel Time 1 Decel Time 1 0 1 1 A076 Preset Fr
139. reset Speed and are active Refer to the flowchart on page 1 23 for more information on speed reference control priority 5 Local When active sets integral keypad as start source and A053 Default potentiometer on the integral keypad as speed source Important Speed source for IP66 NEMA UL Type 4X rated drives comes from A069 Internal Freq 6 Comm Port e When active sets communications device as default start speed command source e Can only be tied to one input 7 Clear Fault When active clears an active fault 8 RampStop CF Causes drive to immediately ramp to a stop regardless of how P037 Stop Mode is set 9 CoastStop CF Causes drive to immediately coast to a stop regardless of how P037 Stop Mode is set 10 DClnjStop CF Causes drive to immediately begin a DC Injection stop regardless of how P037 Stop Mode is set 11 Jog Forward A054 Default Drive accelerates to A078 Jog Frequency according to A079 Jog Accel Decel and ramps to stop when input becomes inactive A valid start will override this command 12 Jog Reverse Drive accelerates to A078 Jog Frequency according to A079 Jog Accel Decel and ramps to stop when input becomes inactive A valid start will override this command Programming and Parameters 3 15 A051 13 10V In Ctrl Selects 0 10V or 10V control as the fre
140. rnal potentiometer Maximum output current is 15mA 13 10V nA Not Active For external 0 10V unipolar or 10V bipolar input P038 supply input impedance 100k ohm or A051 A054 potentiometer wiper A123 A132 14 Analog Common For 0 10V In or 4 20mA In Electronically isolated with analog inputs and outputs from digital I O and opto outputs 15 4 20mA In 2 Not Active For external 4 20mA input supply P038 input impedance 250 ohm A051 A054 A132 16 Analog Output OutFreq 0 10 The default analog output is 0 10V To coverttoa A065 A066 current value change the Analog Output Select DIP Switch to 0 20mA Program with A065 Analog Out Sel Max analog value can be scaled with A066 Analog Out High Maximum Load 4 20mA 525 ohm 10 5V 0 10V 1k ohm 10mA 17 Opto Output 1 MotorRunning Program with A058 Opto Out Sel A058 A059 A064 18 Opto Output 2 At Frequency Program with A061 Opto Out2 Sel A061 A062 A064 19 RS485 DSI Shield Terminal should be connected to safety ground PE when using the RS485 DS communications port 1 See Footnotes 1 and 4 on page 1 16 0 10V In and 4 20mA In are distinct input channels and may be connected simultaneously Inputs may be used independently for speed control or jointly when operating in PID mode 1 18 Installation Wiring 1 0 Wiring Examples Input Output Connection Example Potentiometer P038
141. rogram Group A051 Digital In1 Sel I O Terminal 05 A052 Digital In2 Sel I O Terminal 06 A053 Digital In3 Sel I O Terminal 07 A054 Digital In4 Sel I O Terminal 08 Related Parameter s d012 d014 P038 P039 P040 A067 A068 A070 A077 A078 A079 A118 A140 A147 Stop drive before changing this parameter Selects the function for the digital inputs Refer to the flowchart on page 1 23 for more information on speed reference control priority Options 0 Not Used Terminal has no function but can be read over network communications via d014 Dig In Status 1 Acc amp Dec 2 e When active A067 Accel Time 2 and A068 Decel Time 2 are used for all ramp rates except Jog e Can only be tied to one input Refer to the flowchart on page 1 24 for more information on Accel Decel selection 2 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 set in A079 Jog Accel Decel e A valid Start command will override this input 3 Aux Fault When enabled an F2 Auxiliary Inout fault will occur when the input is removed 4 Preset Freq A051 amp A052 Default Refer to A070 A077 Preset Freq x Important Digital Inputs have priority for frequency control when programmed as P
142. s P 4 Overview Catalog Number Explanation 1 3 4 5 6 8 9 10 11 42 1 13 14 4 AA Optional Code Code Version 22B PowerFlex 40 3 No Brake IGBT 4 Standard Code Rating 0 Not Filtered Code Voltage Ph 1 Filtered V 120V AC 1 eave 1 Code Interface Module Code Purpose B 240VAC 3 1 Fixed Keypad AA Reserved for D 480V AC 3 thru custom firmware E 600V AC 3 ZZ Code Enclosure N Panel Mount IP20 NEMA UL Type Open C Panel Mount IP66 NEMA UL Type 4X F Flange Mount IP20 NEMA UL Type Open H Replacement Plate Drive IP20 NEMA UL Type Open Contact factory for ordering information Output Current Output Current 100 120V 50 60 Hz Input 200 240V 50 60 Hz Input Code Amps kW HP Code Amps P 2P3 2 3 0 4 0 5 2P3 23 0 4 0 5 5PO 5 0 0 75 1 0 5PO 5 0 0 75 1 0 6PO 6 0 1 1 1 5 8PO 8 0 1 5 2 0 012 12 2 2 3 0 017 17 5 3 7 5 0 024 24 5 5 7 5 033 33 7 5 10 Output Current Output Current 380 480V 50 60 Hz Input 500 600V 50 60 Hz Input Code Amps kW HP Code Amps kW HP 1P4 14 0 4 0 5 1P7 17 0 75 1 0 2P3 2 3 0 75 1 0 3P0 3 0 1 5 2 0 4PO 4 0 1 5 2 0 4P2 4 2 2 2 3 0 6PO 6 0 2 2 3 0 6P6 6 6 4 0 5 0 010 10 5 4 0 5 0 9P9 9 9 5 5 7 5 012 12 5 5 7 5 012 12 2 7 5 10 017 17 7 5 10 019 19 11 15 024 24 11 15 1 Position 12 of the Catalog Number now indicates drive type All PowerFlex 40 drives are equipped with RS485 communication Additional accessories options and adapters are
143. starts regulating from there PID Enabled PID Output Freq Cmd PID Pre load Value gt 0 PID Limits A130 PID Trim Hi and A131 PID Trim Lo are used to limit the PID output and are only used in trim mode PID Trim Hi sets the maximum frequency for the PID output in trim mode PID Trim Lo sets the reverse frequency limit for the PID output in trim mode Note that when the PID reaches the Hi or Lo limit the PID regulator stops integrating so that windup does not occur PID Set Up F 7 PID Gains The proportional integral and differential gains make up the PID regulator A134 PID Prop Gain The proportional gain unitless affects how the regulator reacts to the magnitude of the error The proportional component of the PID regulator outputs a speed command proportional to the PID error For example a proportional gain of 1 would output 100 of max frequency when the PID error is 100 of the analog input range A larger value for PID Prop Gain makes the proportional component more responsive and a smaller value makes it less responsive Setting PID Prop Gain to 0 00 disables the proportional component of the PID loop A135 PID Integ Time The integral gain units of seconds affects how the regulator reacts to error over time and is used to get rid of steady state error For example with an integral gain of 2 seconds the output of the integral gain component would integrate up to 100 of max frequency
144. t set to 0 PID Disabled PID can still be disabled by select programmable digital input options parameters A051 A054 such as Jog Local or PID Disable Table F A A132 PID Ref Sel Options Option 0 PID Disabled Description Disables the PID loop default setting 1 PID Setpoint Selects Exclusive Control A137 PID Setpoint will be used to set the value of the PID Reference 2 0 10V Input Selects Exclusive Control Selects the 0 10V Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 3 4 20mA Input Selects Exclusive Control Selects the 4 20mA Input 4 Comm Port Selects Exclusive Control The reference word from a communication network see Appendix C for details on the reference word such as Modbus RTU or DeviceNet becomes the PID Reference The value sent over the network is scaled so that P035 Maximum Freq x 10 100 reference For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 reference 5 Setpnt Trim Selects Trim Control A137 PID Setpoint will be used to set the value of the PID Reference 6 0 10V Trim Selects Trim Control Selects the 0 10V Input Note that the PID will not function with a bipolar analog input It will ignore any negative voltages and treat them like a zero 7
145. tant Firmware version FRN 2 xx also allows PID Feedback scaling from an analog input Examples Scale Function For a 0 5 volt signal the following parameter settings are used so that a 0 volt signal 0 PID Reference and a 5 volt signal 100 PID Reference e A110 Anlg In 0 10V Lo 0 0 e A111 Anlg In 0 10V Hi 50 0 e A132 PID Ref Sel 0 0 10V Input Input Volts 0 10 20 30 40 50 60 70 80 90 100 PID Reference Invert Function For a 4 20mA signal the following parameter settings are used so that a 20mA signal 0 PID Reference and a 4mA signal 100 PID Reference e A112 Anlg In 4 20mA Lo 100 0 e A113 Anlg In 4 20mA Hi 0 0 e A132 PID Ref Sel 3 4 20mA Input 24 20 4 20mA Input 0 10 20 30 40 50 60 70 80 90 100 PID Reference F 6 PID Set Up PID Deadband Parameter A138 PID Deadband is used to set a range in percent of the PID Reference that the drive will ignore Example e PID Deadband is set to 5 0 e The PID Reference is 25 0 e The PID Regulator will not act on a PID Error that falls between 20 0 and 30 0 PID Preload The value set in A139 PID Preload in Hertz will be pre loaded into the integral component of the PID at any start or enable This will cause the drive s frequency command to initially jump to that preload frequency and the PID loop
146. tempts to correct this condition 2 Mechanical Some motor load combinations have mechanical resonances which can be excited by the drive current regulator This setting slows down the current regulator response and attempts to correct this condition 3 Both A098 SW Current Trip Related Parameter s P03 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 output frequency 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 3 30 Programming and Parameters Advanced Program Group continued A100 Fault Clear Stop drive before changing this parameter Resets a fault and clears the fault queue Used primarily to clear a fault over network communications Options 0 Ready Idle Default 1 Reset Fault 2 Clear Buffer 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 Related Parameter s d019 Used by Rockwell Automation field service personnel Values Default 400 Min Max O FFFF Display 1 Hex A103 Comm Data Rate Related Parameter s d01
147. the Sink SNK Source SRC Setup DIP Switch is set to match your control wiring scheme See Figure 1 5 on page 1 16 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 O1 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 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 To change the speed reference of an IP66 NEMA UL Type 4X rated drive access parameter A069 Internal Freq and press Enter or Sel to enter program mode Use the Up Arrow or Down Arrow key to adjust the speed reference Press the Enter key to save the new value Important To disable reverse operation see A095 Reverse Disable If a fault appears on power up refer to Fau
148. this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations that can cause an explosion in a hazardous environment which may WARNING Identifies information about practices or circumstances lead to personal injury or death property damage or economic loss Important Identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences drive or motor to alert people that dangerous voltage may be present Burn Hazard labels may be located on or inside the equipment e g drive or motor to alert people that surfaces may be at dangerous temperatures Shock Hazard labels may be located on or inside the equipment e g PowerFlex is a registered trademark of Rockwell Automation Inc DriveExplorer DriveExecutive and SCANport are trademarks of Rockwell Automation Inc PLC is a registered trademark of Rockwell Automation Inc Summary of Changes The information below summarizes the changes to the PowerFlex 40 User Manual since the October 2005 release Parameter Updates The following parameters have been added or upd
149. top Mode P037 Process Factor A099 Speed Reference P038 Fault Clear A100 Accel Time 1 P039 Program Lock A101 Decel Time 1 P040 Testpoint Sel A102 Reset To Defalts P041 Comm Data Rate A103 Voltage Class P042 Comm Node Addr A104 Motor OL Ret P043 Comm Loss Action A105 Comm Loss Time Comm Format Language Anlg Out Setpt Anlg In 0 10V Lo Anlg In 0 10V Hi Anlg In4 20mA Lo Anlg In4 20mA Hi Slip Hertz FLA Process Time Lo Process Time Hi Bus Reg Mode Current Limit 2 Skip Frequency Skip Freq Band Stall Fault Time Analog In Loss 10V Bipolar Enbl Var PWM Disable Torque Perf Mode Motor NP FLA Autotune IR Voltage Drop Flux Current Ref PID Trim Hi D Trim Lo D Ref Sel D Feedback Sel D Prop Gain D Integ Time D Diff Rate D Setpoint D Deadband D Preload p Logic 0 p Logic 1 p Logic 2 p Logic 3 p Logic 4 p Logic 5 p Logic 6 p Logic 7 p Logic Time 0 p Logic Time 1 p Logic Time 2 p Logic Time 3 p Logic Time 4 p Logic Time 5 p Logic Time 6 p Logic Time 7 EM Brk Off Delay EM Brk On Delay MOP Reset Sel DB Threshold Comm Write Mode Anlg Loss Delay Analog In Filter ANDNDNANDNDNAANADNDDNNDOONDVUVVVVGVVVVV Q Programming and Parameters 3 3 Display Group d001 Output Freq Related Parameter s d002 d010 P034 P035 P038 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
150. top drive before changing this parameter Provides an automatic method for setting A128 IR Voltage Drop and A129 Flux Current Ref which affect sensorless vector performance Parameter A126 Motor NP FLA must be set to the motor nameplate full load amps before running the Autotune procedure Options 0 Ready Idle Default 1 Static Tune 2 Rotate Tune Ready 0 Parameter returns to this setting following a Static Tune or Rotate Tune Static Tune 1 A temporary command that initiates a non rotational motor stator resistance test for the best possible automatic setting of A128 IR Voltage Drop A start command is required following initiation of this setting The parameter returns to Ready 0 following the test at which time another start transition is required operate the drive in normal mode Used when motor cannot be uncoupled from the load Rotate Tune 2 A temporary command that initiates a Static Tune followed by a rotational test for the best possible automatic setting of A129 Flux Current Ref A start command is required following initiation of this setting The parameter returns to Ready 0 following the test at which time another start transition is required to operate the drive in normal mode Important Used when motor is uncoupled from the load Results may not be valid if a load is coupled to the motor during this procedure procedure T
151. twork 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 FRONT TxRxD 4 DARD 4 PRD 4 120 ohm resistor 120 ohm resistor TxRxD TxRxD TxRxD SS EE PIN 1 Shield y Shed y Shield y PIN 8 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 40 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 RS485 DSI Protocol 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 Control Terminal 19 on the PowerFlex 40 must also be connected to PE ground there
152. uires 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 W 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 Programming and Parameters 3 29 Advanced Program Group continued A095 Reverse Disable Related Parameter s d006 Stop drive before changing this parameter 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 reverse disabled Options 0 Rev Enabled Default 1 Rev 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 Some drive motor combinations have inherent instabilities which are exhibited as non sinusodial motor currents This setting at
153. ur 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 d010 Process Display Related Parameter s d001 A099 7 32bit parameter 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 Programming and Parameters 3 5 Display Group continued d012 Control Source Related Parameter s P036 P038 A051 A054 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 23 and 1 24 for details odaig Start Command Digit 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 Digit 1 0 Drive Potentiometer 1 A069 Internal Freq 2 0 10V Input Remote Potentiometer 3 4 20mA Input 4 A070 A077 Preset Freq x A051 A053 Digital Inx Sel must be set to 4 5 RS485 DSI Port 6 StepLogic Control Parameters A140 A147 9 Jog Freq Reserved Digit 2 Reserved Digit 3 Values Default Read Only Min Max 0 9 Display 1 d013 Conirl In Status R
154. urrent Limit 2 determines the drive current limit level 26 Anlg Invert Inverts the scaling of the analog input levels set in A110 Anlg In 0 10V Lo and A111 Anlg In 0 10V Hi or A112 Anlg In4 20mA Lo and A113 Anlg In4 20mA Hil 27 EM Brk Rise If EM brake function is enabled this input releases the brake ATTENTION Ifa hazard of injury due to movement of equipment or A material exists an auxiliary mechanical braking device must be used A055 Relay Out Sel Related Parameter s P033 A056 A092 A140 A147 A150 A157 A160 A161 Sets the condition that changes the state of the output relay contacts Options 0 Ready Fault Default Relay changes state when power is applied This indicates 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 MotorRunning Motor is receiving power from the drive 3 Reverse Drive is commanded to run in reverse direction 3 16 A055 Options Cont Programming and Parameters 4 Motor Overld Motor overload condition exists a Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq e Drive exceeds the frequency Hz value set in A056 Relay Out Level e Use A056 to set threshold 7 A
155. ut2 Sel Determines the operation of the programmable opto outputs Options 0 Ready Fault Opto outputs are active when power is applied This indicates that the drive is ready for operation Opto outputs are inactive when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency A061 Default 2 MotorRunning Motor is receiving power from the drive A058 Default 3 Reverse Drive is commanded to run in reverse direction 4 Motor Overld Motor overload condition exists 5 Ramp Reg Ramp regulator is modifying the programmed accel decel times to avoid an overcurrent or overvoltage fault from occurring 6 Above Freq e Drive exceeds the frequency Hz value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold 7 Above Cur e Drive exceeds the current Amps value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold Important Value for A059 or A062 Opto Outx Level must be entered in percent of drive rated output current 8 Above DCVolt e Drive exceeds the DC bus voltage value set in A059 or A062 Opto Outx Level e Use A059 or A062 to set threshold 9 Retries Exst Value set in A092 Auto Rstrt Tries is exceeded 3 18 A058 A061 Options Cont Programming and Parameters 10 Above Anlg V e Analog input voltage I O Terminal 13 exceeds the value set
156. when the PID error is 100 for 2 seconds A larger value for PID Integ Time makes the integral component less responsive and a smaller value makes it more responsive Setting PID Integ Time to 0 disables the integral component of the PID loop A136 PID Diff Rate The Differential gain units of 1 seconds affects the rate of change of the PID output The differential gain is multiplied by the difference between the previous error and current error Thus with a large error the D has a large effect and with a small error the D has less of an effect This parameter is scaled so that when it is set to 1 00 the process response is 0 1 of Maximum Freq when the process error is changing at 1 second A larger value for PID Diff Rate makes the differential term have more of an effect and a small value makes it have less of an effect In many applications the D gain is not needed Setting PID Diff Rate to 0 00 factory default disables the differential component of the PID loop F 8 PID Set Up Guidelines for Adjusting the PID Gains 1 Adjust the proportional gain During this step it may be desirable to disable the integral gain and differential gain by setting them to 0 After a step change in the PID Feedback 3 If the response is too slow increase A134 PID Prop Gain If the response is too quick and or unstable see Figure F 1 decrease A134 PID Prop Gain Typically A134 PID Prop Gain is set to some value bel
157. with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Other types of shielded cable are available but the selection of these types may limit the allowable cable length Particularly some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield This construction can greatly increase the cable charging current required and reduce the overall drive performance Unless specified in the individual distance tables as tested with the drive these cables are not recommended and their performance against the lead length limits supplied is not known Recommended Shielded Wire Location Rating Type Description Standard 600V 90 C 194 F e Four tinned copper conductors with XLPE insulation Option 1 XHHW2 RHW 2 e Copper braid aluminum foil combination shield and tinned Sheen S007 copper drain wire Belden 29501 29507 PVC jacket or equivalent Standard Tray rated 600V 90 C e Three tinned copper conductors with XLPE insulation Option 2 194 F RHH RHW 2 le 5 mil single helical copper tape 25 overlap min with three Anixter OLF 7xxxxx or bare copper grounds in contact with shield equivalent e PVC jacket Class amp Il Tray rated 600V 90 C je Three bare copper conductors with XLPE insulation and Division amp II 194 F RHH RHW 2 impervious corrugated continuously welded aluminum armor Anixter 7V 7xxxx 3G e Black sunlight
158. y Related Parameter s P037 Sets the time the drive remains at minimum frequency before the relay or an opto output is energized and the drive ramps to the commanded frequency The relay or opto output is typically connected to a user supplied electromechanical brake coil relay Set P037 Stop Mode to 8 Ramp EM B CF or 9 Ramp EM Brk to enable the electromechanical brake option Set A055 Relay Out Sel A058 or A061 Opto Outx Sel to 22 EM Brk Cntr to control brake operation Values Default 2 00 Secs Min Max 0 01 10 00 Secs Display 0 01 Secs Frequency Minimum Freq gt L Time A M a Start EM Brk Stop EM Brk Drive Stops Commanded Energized Off Commanded De Energized On 3 42 Programming and Parameters Advanced Program Group continued A161 EM Brk On Delay Related Parameter s P037 Sets the time the drive remains at minimum frequency before the relay or an opto output is de energizing and the drive stops The relay or opto output is typically connected to a user supplied electromechanical brake coil relay Set P037 Stop Mode to 8 Ramp EM B CF or 9 Ramp EM Brk to enable the electromechanical brake option Set A055 Relay Out Sel A058 or A061 Opto Outx Sel to 22 EM Brk Cntr to control brake operation Values Default 2 00 Secs Min Max 0 01 10 00 Secs Display 0 01 Secs A162 MOP Reset Sel Related Parameter s A069 Set the drive to save

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