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22D-UM001 - Literature Library

1. GOCE Cee 1 Input Present 0 Input Not Present Home Limit Bit 0 Find Home Bit 1 Hold Step Bit 2 Pos Redefine Bit 3 Sync Enable Bit 4 Traverse Disable Bit 5 Logic In 1 Bit 6 Logic In 2 Bit 7 Values Default 0 Min Max 0 1 Display 1 Bit 0 Home Limit In Positioning mode this indicates the drive is at the home position 1 Find Home When set the next start command causes the drive to find home Set this bit to 0 after completing the homing routine 2 Hold Step In Positioning mode this input over rides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released 3 Pos Redefine In Positioning mode this input resets the home position to the current position of the machine Set this bit to 0 after completing the homing routine 4 Sync Enable Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization When this bit is reset to zero the drive will accelerate to the new commanded frequency based on E214 Sync Time setting 5 Traverse Disable When set the traverse function will be disabled 6 Logic In 1 This provides an identical function as the Logic In1 Digital Input option This bit is logically ORed with a digital input A051 A054 set to option 23 Logic In1 It can be used to move throu
2. 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 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 Unit 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 Doonoo Term
3. Related Preset Frequency Parameter Related StepLogic Time Parameter Can be activated independent of Active when A140 A147 Digit 0 or 1 Step StepLogic Parameter StepLogic Parameters are set to 1 b C dor E 0 A140 Stp Logic 0 A070 Preset Freq 0 A150 Stp Logic Time 0 1 A141 Stp Logic 1 A071 Preset Freq 1 A151 Stp Logic Time 1 2 A142 Stp Logic 2 A072 Preset Freq 2 A152 Stp Logic Time 2 3 A143 Stp Logic 3 A073 Preset Freq 3 A153 Stp Logic Time 3 4 A144 Stp Logic 4 A074 Preset Freq 4 A154 Stp Logic Time 4 5 A145 Stp Logic 5 A075 Preset Freq 5 A155 Stp Logic Time 5 6 A146 Stp Logic 6 A076 Preset Freq 6 A156 Stp Logic Time 6 7 A147 Stp Logic 7 A077 Preset Freq 7 A157 Stp Logic Time 7 The position for any step is programmed using parameters E230 E245 Step Units x Step StepLogic Position Parameters 0 E230 Step Units 0 amp E231 Step Units F 0 1 E232 Step Units 1 amp E233 Step Units F 1 2 E234 Step Units 2 amp E235 Step Units F 2 3 E236 Step Units 3 amp E237 Step Units F 3 4 E238 Step Units 4 amp E239 Step Units F 4 5 E240 Step Units 5 amp E241 Step Units F 5 6 E242 Step Units 6 amp E243 Step Units F 6 7 E244 Step Units 7 amp E245 Step Units F 7 Programming and Parameters 3 45 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 F
4. 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 NI O O OIN 1 2 Motor NP Volts P031 Motor NP Volts P032 Motor NP Hertz Programming and Parameters 3 29 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 A084 Boost Select 5 0 0 no IR Values Default 2 5 Min Max 0 0 25 0 Display 0 1 A088 Maximum Voltage P031 Motor NP Volts Voltage 4 A086 Break Voltage A085 Start Boost 4 L l gt gt 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 Displ
5. Input Output 2 Wire SRC Control Non Reversing 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 desired a User Supplied 24V DC power source can be used Refer to the External Supply SRC example Connection Example Internal Supply SRC Installation Wiring External Supply SRC Stop Run D O OOOOOE 01 02 Stop Run 24V Common OKARA O 01 02 04 Each digital input draws 6 mA 2 Wire SNK Control Non Reversing Internal Supply SNK Stop Run Oj 01 02 04 2 Wire SRC Control 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 inputs are closed at the same time an undetermined state could occur Internal Supply SRC External Supply SRC O O Stop Run Forward O O Stop Run Reverse 000008 01 02 03 Stop Run Forward Stop Run Reverse 24V Common 01 02 03 04 Q OGO Each digital input draws 6 mA 2 Wire SNK Control Run FWD Run REV Internal
6. Preset Freq A051 amp A052 Default In Velocity mode P038 9 selects a preset frequency Refer to A070 A077 Preset Freq x In Positioning mode P038 9 selects a preset frequency and position Refer to E230 E244 Step Units x Important Digital Inputs have priority for frequency and position control when programmed as Preset Speed and are active Refer to the flowchart on page 1 27 for more information on speed reference control priority Reserved Comm Port e When active sets communications device as default start speed command source e Can only be tied to one input Clear Fault A053 Default When active clears an active fault RampStop CF Causes drive to immediately ramp to a stop regardless of how P037 Stop Mode is set CoastStop CF Causes drive to immediately coast to a stop regardless of how P037 Stop Mode is set 10 DCinjStop CF Causes drive to immediately begin a DC Injection stop regardless of how P037 Stop Mode is set 1 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 3 16 A051 A054 Options Cont Programming and Parameters 12 Jog Reverse Drive accelerates to A078 Jog Frequency according to A079 Jog Accel Decel and ramps to s
7. 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 Idle 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 To 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 Pro
8. 2 1 Display Fault Reset 0 2 3 Drive Programming Tools 2 3 Programming and Parameters Troubleshooting About Parameters 0 3 1 Parameter Organization 3 2 Basic Display Group 3 3 Basic Program Group 3 9 Advanced Program Group 3 15 Enhanced Program Group 3 49 Advanced Display Group 3 62 Parameter Cross Reference by Name 3 66 Drive Status seri cee ee ee ba oa 4 1 Faults erien e nnd tages oF aaa 4 1 Fault Descriptions 4 3 Common Symptoms and Corrective Actions 4 6 Supplemental Drive Information Drive Fuse amp Circuit Breaker Ratings A 1 Specifications 0000 A 2 Accessories and Dimensions Product Selection 08 B 1 Product Dimensions B 7 2 Table of Contents Appendix C Appendix D Appendix E Appendix F Appendix G Appendix H Index RS485 DSI Protocol RJ45 DSI Splitter Cable Network Wiring 000 C 1 Parameter Configuration C 3 Supported Modbus Function Codes C 3 Writing 06 Logic Command Data C 4 Writing 06 Reference C 5 Reading 03 Logic Status Data C 6 Reading 03 Feedback C 7 Reading 03 Drive Error Codes C 7 Reading 03 and Writing 06 Drive Parameters meere te E ia C 8 Add
9. 3 54 Programming and Parameters Enhanced Program Group continued E212 Traverse Dec Related Parameter s E210 Sets time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency Refer to the diagram at E210 Max Traverse Values Default 0 00 Secs Min Max 0 00 30 00 Secs Display 0 01 Secs E213 P Jump Related Parameter s 210 Sets the frequency amplitude that is added to or subtracted from the commanded frequency Refer to the diagram at E210 Max Traverse Values Default 0 00 Hz Min Max 0 00 300 0 Hz Display 0 01 Hz E214 Sync Time Related Parameter s A051 A054 d302 Enables the function that holds the drive at the current frequency even if the commanded frequency changes Used with A051 A054 Digital Inx Sel option 31 Sync Enable Values Default 0 0 Secs Disabled Min Max 0 0 3200 0 Secs Display 0 1 Secs la 214 Sync Time New Drive 2 Reference Hertz New Drive 1 Reference I Speed Sync Bit L__ d302 Fiber Status Change Ref s Drive 1 and 2 Sync Enable Input Time E215 Speed Ratio Stop drive before changing this parameter Enables the function that scales the drive speed command Values Default 1 00 Min Max 0 01 99 99 Display 0 01 Programming and Parameters 3 55 Enhanced Program Group continued E216 Motor Fdbk Type Stop drive before
10. 36 Pos Redefine In Positioning mode this input resets the home position to the current position of the machine Refer to Appendix F for detailed information on positioning 3 52 Programming and Parameters Enhanced Program Group continued E203 Accel Time 3 Related Parameter s A067 E205 Accel Time 4 Sets the rate of acceleration for all speed increases when selected by digital inputs Refer to graphic at A067 Accel Time 2 Maximum Freq Accel Time Acce Rite Values Default 5 0 Secs E203 30 0 Secs E205 Min Max 0 0 600 0 Secs Display 0 1 Secs E204 Decel Time 3 Related Parameter s A067 E206 Decel Time 4 Sets the rate of deceleration for all speed decreases when selected by digital inputs Refer to graphic at A067 Accel Time 2 Maximum Freq Decel Time Decel Rate Values Default 5 0 Secs E204 30 0 Secs E206 Min Max 0 0 600 0 Secs Display 0 1 Secs E207 Comm Write Mode Saves parameter values in active drive memory RAM or in drive non volatile memory EEPROM Important Parameter values set prior to selecting option 1 RAM only will be saved in drive non volatile memory EEPROM Options 0 EEPROM Default 1 RAM only E208 Power Loss Mode Sets the reaction to a loss of input power Options 0 Coast Default Drive will fault and motor will coast to stop 1 Decel Drive will decelerate and attempt to keep the DC
11. Control Inputs Digital Bandwidth 10 Rad Secs for open and closed loop Quantity 2 Dedicated for start and stop 5 Programmable Current 6mA Type Source Mode SRC 18 24V ON 0 6V OFF Sink Mode SNK 0 6V ON 18 24V OFF Analog Quantity 2 Isolated 10 to 10V and 4 20mA Specification Resolution 10 bit 0 to 10V DC Analog 100k ohm input impedance 4 20mA Analog 250 ohm input impedance External Pot 1 10k ohm 2 Watt minimum Encoder Type Incremental dual channel Supply 12V 250 mA 12V 10 mA minimum inputs isolated with differential transmitter 250 kHz maximum Quadrature 90 27 degrees at 25 degrees C Duty Cycle 50 10 Requirements Encoders must be line driver type quadrature dual channel or pulse single channel 3 5 26V DC output single ended or differential and capable of supplying a minimum of 10 mA per channel Allowable input is DC up to a maximum frequency of 250 kHz The encoder 1 0 automatically scales to allow 5V 12V and 24V DC nominal voltages Supplemental Drive Information A 5 Category Specification Control Outputs Relay Quantity 1 Programmable Form C Specification Resistive Rating 3 0A at 30V DC 3 0A at 125V 3 0A at 240V AC Inductive Rating 0 5A at 30V DC 0 5A at 125V 0 5A at 240V AC Opto Quantity 2 Programmable Specification 30V DC 50mA Non inductive Analog Quantity 1 Non Isolated 0 10V or 4 20mA Specification Resolution 10 bit 0
12. End Program Normal Stop End Program Coast to Stop Be oO eo NI om A w N End Program and Fault F2 Velocity 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 TIMED 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 0 Step after Stp Logic Time x and Logic In2 is active logically true TIMED AND d Step after Stp Logic Tim
13. Sets the time between restart attempts when A092 Auto Rstrt Tries is set to a value other than zero Values Default 1 0 Secs Min Max 0 0 120 0 Secs Display 0 1 Secs 3 32 Programming and Parameters Advanced Program Group continued 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 Requires a digital input configured for Run or Start and a valid start contact This parameter will not function if parameter P036 Start Source is set to 4 2 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 A095 Reverse Disable Related Parameter s b006 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 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 conditi
14. 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 shield that can contain much of the noise generated by a typical AC Drive Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable 1 10 Location Standard Option 1 Installation Wiring 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 pub
15. 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 7 on page B 12 or equivalent must be supplied Values Default 0 Min Max 0 99 Display 1 A083 S Curve Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve Time is added 1 2 at the beginning and 1 2 at the end of the ramp Values Default 0 Disabled Min Max 0 100 Display 1 Example 50 S Curve Accel Time 10 Seconds S Curve Setting 50 ae S Curve Time 10 x 0 5 5 Seconds i Total Time 10 5 15 Seconds i Targev2 l 112S Curve Time 4 Accel Time oe 1 2 S Curve Time g 2 5 Seconds 10 Seconds 2 5 Seconds l 4 Total Time to Accelerate Accel Time S Curve Time p 3 28 Programming and Parameters Advanced Program Group continued U 0 A086 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 A084 Boost Select Related Parameter s b004 P031 P032 A085 ion Options 0 Custom V Hz 1 30 0 VT 35 0 VT 40 0 VT 45 0 VT Variable Torque Typical fan pump curves 0 0 no IR 0 0
16. 0 4 0 5 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 5W 1321 3R8 A 2 2 3 0 12 18 1 25 26W 1321 3R12 A 3 7 15 0 18 27 0 8 36W 1321 3R18 A 5 5 75 25 37 5 0 5 48W 1321 3R25 A 7 5 10 0 35 52 5 0 4 49W 1321 3R35 A 04 05 2 3 20 0 11 3W 1321 3R2 B 0 75 1 0 4 6 9 0 20W 1321 3R4 C 15 20 4 6 6 5 20W 1321 3R4 B 22 30 8 12 5 0 25 3 W 1321 3R8 C 40 50 12 18 2 5 31W 1321 3R12 B 5 5 75 12 18 2 5 31W 1321 3R12 B 7 5 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 30 4 6 6 5 20W 1321 3R4 B 40 50 8 12 5 0 25 3 W 1321 3R8 C 5 5 75 12 18 2 5 31W 1321 3R12 B 7 5 10 0 12 18 2 5 31W 1321 3R12 B 11 0 15 0 18 27 1 5 43W 1321 3R18 B 1 Catalog numbers listed are for 3 impedance open style units NEMA Type 1 and 5 impedance able Refer to publication 1321 TDO001 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 Hz 3 Phase Inductance kW HP Amps mh Catalog Number 5 5 7 5 32 0 85 1321 DC32 1 7 5 10 0 40 0 5 1321 DC40 2 5 5 75 18 3 75 1321 DC18 4 75 10 0 25 40 1321 DC25 4 11 0 15 0 32 2 68 1321 DC32 3 5 5 7 5 12 6 0 1321 DC12 2 7 5 10 0 18 6 0 1321 DC18 4 11 0 15 0 25 4 0 1321 DC25 4 B 4 Accessories and Dimensions Table B F
17. Adjustable Frequency AC Drive FRN 1 xx 3 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 com literature describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in who
18. Dimensions Index Drive B 7 Minimum Clearances 1 2 DIP Switch Locations 1 15 Discharging Bus Capacitors P 3 Display 2 3 ee Systems Ungrounded Drive Frame Size P 2 B 7 Drive Grounding 1 6 Drive Overload Fault 4 4 Drive Ratings A 1 DriveExecutive 3 1 DriveExplorer 3 1 E Earthing see Grounding EMC RFI Grounding Filter 1 7 Interference 1 29 Enclosure Rating Changing 1 2 Encoder Interface 1 18 Wire Routing 1 18 Encoder Wiring 1 19 Enhanced Program Group Parameters 3 49 ESD Static Discharge P 3 F Fault Reset and Display 2 3 Faults Auto Rstrt Tries 4 4 Auxiliary Input 4 3 Comm Loss 4 4 Drive Overload 4 4 Ground Fault 4 3 Heatsink OvrTmp 4 3 HW OverCurrent 4 3 I O Board Fail 4 5 Motor Overload 4 3 Motor Stalled 4 3 OverVoltage 4 3 Parameter Checksum 4 5 Phase Short 4 4 Index 2 Phase to Ground Short 4 4 Power Loss 4 3 Power Unit 4 4 SW OverCurrent 4 4 UnderVoltage 4 3 Filter RFI 1 7 Frame Designations P 2 A 1 B 7 Fuses Input 1 7 Ratings A 1 G General Precautions P 3 Ground Fault 4 3 Grounding Filter 1 7 General 1 6 H Hardware Enable Circuitry Enable Circuitry 1 20 Heatsink OvrTmp Fault 4 3 HW OverCurrent Fault 4 3 0 Wiring 1 13 Wiring Examples 1 22 1 26 O Board Fail Fault 4 5 Input Contactor 1 13 Input Fusing 1 7 Input Potentiometer 1 22 Input Power Conditioning 1 5 Installation 1 1 Integral Display 2 3 Interfere
19. F111 Enable Hardware F122 1 O Board Fail Description Requires differential encoder One of the 2 encoder channel signals is missing The checksum read from the board does not match the checksum calculated DriveGuard Safe Off Option Series B board is installed and the ENBL enable jumper has not been removed DriveGuard Safe Off Option Series B board has failed Hardware Enable circuitry has failed Failure has been detected in the drive control and I O section 1 See page 4 1 for a descri ption of fault types 3 1 2 Set option 1 Reset Defaults 1 2 2 Troubleshooting 4 5 Action 1 2 Check Wiring If P038 Speed Reference 9 Positioning and E216 Motor Fdbk Type 5 Quad Check swap the Encoder channel inputs see page 1 18 or swap any two motor leads Replace encoder P041 Reset To Defalts to Remove the ENBL enable jumper Cycle power Remove power to the drive Replace DriveGuard Safe Off Option Series B board Replace drive Cycle power Replace drive if fault cannot be cleared 4 6 Troubleshooting 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 Check the supply voltage Check all fuses and disconnects Check the motor Verify that the motor is connect
20. J 6001 i dacs MID NE 7m S m o aa U v a Frame B 22 JBCB 205 0 8 07 gt o ni lt 130 0 5 1 P 180 0 7 1 gt lt 92 2 3 68 1160 457 285 PT ima 22 2 0 87 H 00 O 320 F 12 6 OGO 179 8 10 2 OOo iF e 9 7 571 a ceRy om Q IANN 109 8 P A l SOU 7 4 32 74 J4 Was 4 0 See a g l Yy y Frame C 22 JBCC Accessories and Dimensions B 9 Figure B 3 PowerFlex 40P Flange Mount Drives Dimensions are in millimeters and inches lt _106 3 4 19 te 244 X fg 94 3 e 631 9 61 214 8 71 2 48 8 43 gt II alo o Y Te vet lll A ora 20A DG01 sli 250 ki e o E mo
21. 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 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 01 Stop coast to stop e 1 0 Terminal 03 Run REV 5 Comm Port Default Remote communications Refer to Appendix C for details e O Terminal 01 Stop coast to stop 6 Momt FWD REV Drive will start after a momentary input from either the Run FWD Input I O Terminal 02 or the Run REV Input I O Terminal 03 e O Terminal 01 Stop stop according to the value set in P037 Stop Mode 1 If 1 O Terminal 01 is used as hardware enable and 3 wire control is needed program one of the digital inputs for the desired 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 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
22. e Step 7 is followed by Step 0 e Sequence repeats until a stop is issued or a fault condition occurs Velocity StepLogic Basic Logic and Timer Counter Functions E 3 Velocity StepLogic Using Basic Logic Functions Digital input and digital output parameters can be configured to use logic to transition to the next step Logic In and Logic In2 are defined by programming parameters A051 A054 Digital Inx Sel to option 23 Logic In1 or option 24 Logic In2 Example 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 _ Step Step2 Step 3 Frequency Logic Int gt Logic In2 gt a 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 Lo
23. encoder or other feedback may cause A unintended speed or motion 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 Encoder Encoder or Pulse Train 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 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 2 0 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 00 1 Secs Min Max 0 00 99 99 1 Secs Display 0 01 1 Secs Programming and Parameters 3 43 Advanced Program Group continued 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 on start or enable Values Default 0 0 Hz Min Max 0 0 500 0 Hz Displ
24. separate apparatus ground only one point of the daisy chain of I O Terminal 04 should be connected ATTENTION 1 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 same I O Common connection may occur Multiple Analog Connections SO OOOOOODO OOCOOOOOOD O00 12 13 14 13 14 13 14 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 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 Jog Input Enabled and Active A051 A052 A053 or A054 2 11 12 Drive Stopped Not Running Yes Driv
25. the drive will continuously read a position of 0 home and the position routine will not function correctly 2 Automatic Homing to Limit Switch Program the following drive parameters A051 A054 Digital Inx Sel 34 Find Home Program one of the digital inputs to option 34 Find Home A051 A054 Digital Inx Sel 33 Home Limit Program one of the digital inputs to option 33 Home Limit Normally the Home Limit input would be wired to a proximity switch or photo eye and will indicate the system is in the home position Encoder Usage and Position StepLogic Application F 9 E223 Find Home Freq This parameter sets the frequency the drive will use while it is moving to the home position during the automatic homing routine E224 Find Home Dir This parameter sets the direction the drive will use while it is moving to the home position during the automatic homing routine To begin the automatic homing routine activate the Find Home input and then initiate a valid start command The drive will then ramp to the speed set in E223 Find Home Freq and in the direction set in E224 Find Home Dir until the digital input defined as Home Limit is activated If the drive passes this point too quickly it will then reverse direction at 1 10th E223 Find Home Freq to the point where the Home Limit switch reactivates Approximately one second after the routine finds home the drive will stop Alterna
26. 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 38 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 parameter Values Default 0 Hz Min Max 0 500 Hz Display 1Hz 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 eS 2x Skip Skip Frequency Frequency Band A121 Stall Fault Time Sets the time that the drive will remain in stall mode before
27. 03 04 05 06 07 08 09 CPA RE OODDDDODD Ean HAAHSADAG 0S M ZOLO Resistive 3 0A 3 0A 3 0A Inductive 0 5A 0 5A 0 5A See Control Wiring Block Diagram Notes on next page 1 16 Installation Wiring Control Wiring Block Diagram Notes 1 Important I O Terminal 01 is always a coast to stop input except when P036 Start Source is set to 3 Wire 2 W Lvl Sens or Momt FWD REV control In three wire control I O Terminal 01 is controlled by P037 Stop Mode All other stop sources are controlled by P037 Stop Mode P036 Start Source Stop I O Terminal 01 Stop 3 Wire Per P037 Per P0370 2 Wire Per P037 Coast 2 W Lvl Sens Per P037 Per P0370 2 W Hi Speed Per P037 Coast RS485 Port Per P037 Coast Momt FWD REV Per P037 Per P037 6 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 1 0 Terminal 02 to command a start Use a maintained input o for I O Terminal 03 to change direction The function of I O Terminal 03 is fully programmable Program with E202 Digital Term 3 Match the Voltage Range Select DIP Switch setting with the control scheme for proper Uni Polar or Bipolar analog input operation When using an opto output with an inductive load such as a relay install a rec
28. 3 Traverse Dec Digit 4 Values Default Read Only Min Max 0 1 Display 1 d303 Slip Hz Meter Displays the current amount of slip being applied to the motor frequency Values Default Read Only Min Max 0 0 25 0 Hz Display 0 1 Hz d304 Speed Feedback Related Parameter s E218 d305 7 32bit parameter Displays the value of the actual motor speed whole number portion whether measured by encoder pulse train feedback or estimated Values Default Read Only Min Max 0 64000 RPM Display 1 RPM Programming and Parameters 3 63 Advanced Display Group continued d305 Speed Feedback F Related Parameter s 1304 Displays the value of the actual motor speed fractional portion whether measured by encoder pulse train feedback or estimated Values Default Read Only Min Max 0 0 0 9 Display 0 1 d306 Encoder Speed Related Parameter s d307 7 32 bit parameter Provides a monitoring point that reflects the speed whole number portion measured from the feedback device This shows the encoder or pulse train speed even if this is not used directly to control the motor speed Values Default Read Only Min Max 0 64000 Display 1 d307 Encoder Speed F Related Parameter s d306 Provides a monitoring point that reflects the speed fractional portion measured from the feedback device This shows the encoder or pulse train speed even if this is not used directly to control the
29. 50000 Display 1 E226 Counts Per Unit Related Parameter s E230 E245 Sets the number of encoder counts equal to one user defined unit For additional information refer to Appendix F Values Default 4096 Min Max 1 32000 Display 1 3 58 Programming and Parameters Enhanced Program Group continued E230 Step Units 0 Related Parameter s E226 E232 Step Units 1 E234 Step Units 2 E236 Step Units 3 E238 Step Units 4 E240 Step Units 5 E242 Step Units 6 E244 Step Units 7 7 32 bit parameter Sets the position in whole number user defined units the drive must reach at each step For additional information refer to Appendix F Values Default 0 Min Max 0 64000 Display 1 Input State Input State Input State of Digital In 1 of Digital In 2 of Digital In 3 VO Terminal 05 I O Terminal 06 I O Terminal 07 Position Freq when A051 4 when A052 4 when A053 4 Source Source Accel Decel Parameter Used o 0o 0 E230 A00 Accel Time 1 Decel Time 1 1 0 0 E232 A071 Accel Time 1 Decel Time 1 0 1 0 E234 A072 Accel Time 2 Decel Time 2 1 1 0 E236 A073 Accel Time 2 Decel Time 2 0 0 1 E238 A074 Accel Time 1 Decel Time 1 1 0 1 E240 A075 Accel Time 1 Decel Time 1 0 1 1 E242 A076 Accel Time 2 Decel Time 2 1 1 1 E244 A077 Accel Time 2 Decel Time 2 2 Wren a Digital Input is set to
30. 7 and back to Step 0 based on the times programmed into A150 A157 Stp Logic Time x This can be used when the desired position is based only on time In addition this mode only accepts absolute positions in a positive direction from home This option provides an easy way to implement a simple positioning program or to test the basic positioning setup For additional flexibility one of the other settings should be used 1 Preset Input directly commands movement to any step based on the status of the digital inputs programmed for Preset Freq This setting ignores the Step Logic Commands settings and instead the drive will move directly to whatever step is currently commanded by AQ70 A077 Preset Freq x and E230 E244 Step Units x This is useful when an application needs direct access to any position step based on discrete inputs This mode moves in the forward direction from Home and is an absolute move Important Advanced Step Logic options such as incremental move are not available in this mode 2 Step Logic provides a highly flexible mode of operation This can be used to move through the steps Step 0 to Step 7 and back to Step 0 or can jump to a different step at any time based on time or the status of digital inputs or communication commands In this mode the drive always starts at Step 0 of the Step Logic profile 3 Preset StpL is identical to option 2 Step Logic except the drive will u
31. A f amp 756 20A DGO1 i 180 p i ew 7 96 220 008 3 78 D CE nom o R Y4 lt k 100 N 5 3 113 3 94 0 21 445 Frame B 110 5 4 35 a B5 e 95 x 3 88 L 0 37 f i f Ee i 272 20A DG01 10 71 FA 284 260 i 14 18 10 24 22D ccc 136 ee 5 35 ith D o lt E oi o Om yy ear is k 130 J 53 123 5 5 12 0 21 4 86 Frame C B 12 Accessories and Dimensions Figure B 6 Dynamic Brake Modules Dimensions are in millimeters and inches Weights are in kilograms and pounds Frame A Frame B 30 0 61 0 170 1 18 60 0 31 0_ 2 40 59 0 5 0 67 2 36 1 22 ei H i i x A 316 0 335 0 386 0 405 0 12 44 13 19 15 20 15 94 gs EE A DANOER i amp i Ra y c 13 0_ eS 0 51 7 r y AER 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 7 Recommended External Brake Resistor Circuitry Three Phase AC Input Input Contactor M Power Off Power On i M ATA A Power Source DB Resistor Thermostat Accessories and Dimensions B 13 Figure B 8 Bulletin 1321 3R Series Line Reactors Dimen
32. A163 Advanced Program DC Brake Level A081 Advanced Program DC Brake Time A080 Advanced Program DC Bus Voltage b005 Display Decel Time 1 P040 Basic Program Decel Time 2 A068 Advanced Program Decel Time 3 E204 Enhanced Program Decel Time 4 E206 Enhanced Program Dig In Status b014 Display Digital Inx Sel A051 A054 Advanced Program Digital Term 3 E202 Enhanced Program Drive Status b006 Display Drive Status 2 d301 Advanced Display Drive Temp b024 Display Drive Type b017 Display Elapsed Run Time b018 Display EM Brk Off Delay A160 Advanced Program EM Brk On Delay A161 Advanced Program Encoder Pos Tol E225 Enhanced Program Parameter Name No Group Encoder PPR E218 Enhanced Program Encoder Speed d306 Advanced Display Encoder Speed F d307 Advanced Display Enh Control Word E248 Enhanced Program Fault Clear A100 Advanced Program Fault x Code b007 b009 Display Fault 4 Code d310 Advanced Display Fault 5 Code d311 Advanced Display Fault 6 Code d312 Advanced Display Fault 7 Code d313 Advanced Display Fault 8 Code d314 Advanced Display Fault 9 Code d315 Advanced Display Fault 10 Code d316 Advanced Display Fibers Status d302 Advanced Display Find Home Dir E224 Enhanced Program Find Home Freq E223 Enhanced Program Flux Current Ref A129 Advanced Program Flying Start En A096 Advanced Program Half Bus Enable E209 Enhanced Program nternal Freq A069 Advanced Program R Voltage Drop A128 Advanced Program Jog Accel Decel A079 Advanced Prog
33. C2E C16 100 C23 1655 5 5 7 5 25 140M D8E C20 100 C23 2069 7 5 10 0 30 140M D8E C20 100 C23 2069 11 15 50 140M F8E C32 100 043 2069 600V AC 0 75 1 0 6 140M C2E B25 100 C09 1655 3 Phase 1 5 2 0 6 140M C2E B40 100 C09 1655 2 2 3 0 10 140M D8E B63 100 C09 1655 4 0 5 0 15 140M D8E C10 100 C09 1655 5 5 7 5 20 140M D8E C16 100 C16 2069 7 5 10 0 25 140M D8E C16 100 C23 2069 11 15 40 140M F8E C25 100 C30 2069 1 Recommended Fuse Type UL Class J CC T or Type BS88 600V 550V or equivalent The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary See Bulletin 140M Motor Protection Circuit Breakers Application Ratings Manual Self Protected Type E Combination Motor Controller UL listed for 208 Wye or Delta 240 Wye or Delta 480Y 277 or 600Y 347 Not UL listed for use on 480V or 600V Delta Delta corner ground or high resistance ground systems When using a Manual Self Protected Type E Combination Motor Controller the drive must be installed in a ventilated or non ventilated enclosure with the minimum volume specified in this column Application specific thermal considerations may require a larger enclosure gt gt Installation Wiring 1 9 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 regardi
34. Catalog Number 2 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 22 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 0 4 05 97 AK R2 360P500 3 Phase 0 75 1 0 97 AK R2 360P500 15 2 0 97 AK R2 360P500 22 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 2 2 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 Di 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 mensions B 3 Maximum Fundamental Continuous Inductance Watts Catalog kW HP Amps Amps mh Loss Number
35. 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 e If the DriveGuard Safe Off Option Series B is installed use only low voltage Class 2 circuits e When using the DriveGuard Safe Off Option Series B the installation must meet all the requirements listed in the DriveGuard Safe Off Option Series B User Manual publication PFLEX UMO003 e InCE installations input power must be a Balanced Wye with Center Ground configuration 1 600 Volt class drives are not CE Certified 1 30 Dp 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 2004 A1 2012 1 Grounding as described in Figure 1 8 Refer to page 1 7 for additional grounding recommendations 2 Output power control I O and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or equivalent attenuation 3 Allowable cable length in Table 1 L is not exceeded Table 1 L Allowable Cable Length Filter Type EN61800 3 2004 A1 2012 EN61800 3 2004 A1 2012 First Environment Restricted First Environment Unrestricted Distribution or Second Distribution Environment 2 External S Type 10 meters 33 feet 1 meter 3 feet External L Type 100 met
36. Counts 1 180 degs 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 3 22 Programming and Parameters Advanced Program Group continued 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 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 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 b001 1 OutCurr 0 10 0 10V OV 0 Amps 200 Drive Rated Output Current 0 10V b003 2 OutVolt 0 10 0 10V OV 0 Volts 120 Drive Rated Output Volts 0 10V b004 3 OutPowr 0 10 0 10V OV 0kW 200 Drive Rated Power 0 10V b022 4 TstData 0 10 0 10V OV 0000 65535 Hex FFFF 0 10V b019 5 OutFreq 0 20 0 20mA 0 mA 0 Hz P035 Maximum Freq 0 20mA b001 6 OutCurr 0 20 0 20mA OmA 0Amps 200 Drive Rated Output Current 0 20mA b00 7 OutVolt 0 20 0 20mA OmA 0Volt
37. Details Reference P036 Start Source Set to 5 Comm Port if Start is controlled from the Page 3 10 network P038 Speed Reference Set to 5 Comm 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 34 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 34 Each device on the network requires a unique node address A105 Comm Loss Action Selects the drive s response to communication Page 3 34 problems A106 Comm Loss Time Sets the time that the drive will remain in Page 3 34 communication loss before the drive implements A105 Comm Loss Action A107 Comm Format Sets the transmission mode data bits parity and stop Page 3 35 bits for the RS485 DSI Port All nodes on the network must be set to the same setting E207 Comm Write Mode Set to 0 EEPROM when programming drive Page 3 52 Set to 1 RAM only to only write to volatile memory Supported Modbus Function Codes The peripheral interface DSI used on PowerFlex 40P drives supports some of the Modbus function codes Modbus Function Code Decimal Command 03 Read Holding Registers 06 Preset Write Single Register 16 10 Hexadecimal Preset Write Multiple Registers Important Modbus devices can be 0 based registers are numbered s
38. 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 3 40 Programming and Parameters Advanced Program Group continued 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 A127 Autotune Related Parameter s A125 A126 A128 A129 Stop 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
39. I l E Output _ rror utput PID Fdbk PID Integ Time O44 i S ao l tf tooa EE L 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 wou lt 0 Volts PID Reference N gt PID Feedback Equilibrium Set Point Dancer Pot Signal N mme lt 10 Volts P038 Speed Reference g G 4 PID Set Up PID Reference and Feedback Parameter A132 PID Ref Sel is used to enable the PID mode A132 0 PID Disabled and to select the source of the PID Reference If A132 PID Ref Sel is not 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 G 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 Selec
40. Max 0 8 Display 1 b029 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 b004 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 Stop drive before changing this parameter Set to the motor nameplate rated frequency Values Default 60 Hz Min Max 15 500 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 b001 b002 b013 P035 A085 A086 A087 A110 A112 Sets the lowest frequency the drive will output continuously Values Default 0 00 Hz Min Max 0 00 500 0 Hz Display 0 01 Hz P035 Maximum Freq Related Parameter s b001 b002 b013 P034 A065 A078 A085 A086 A087 A111 A113 S
41. Programming and Parameters 3 25 Advanced Program Group continued A070 Preset Freq 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 00 Hz A071 Default 5 00 Hz A072 Default 10 00 Hz A073 Default 20 00 Hz A074 Default 30 00 Hz A075 Default 40 00 Hz A076 Default 50 00 Hz A077 Default 60 00 Hz Min Max 0 00 500 0 Hz Display 0 01 Hz Provides a fixed frequency command value when A051 A053 Digital Inx Sel is set to 4 Preset Freq An active preset input will override speed command as shown in the flowchart on page 1 27 1 To activate AO70 A077 in Velocity mode set P038 Speed Reference to option 4 Preset Freq In Positioning mode set P038 Speed Reference to option 9 Positioning and E222 Positioning Mode to option 1 Preset Input Input State Input State Input State Position of Digital In 1 of Digital In 2 of Digital In 3 Source I O Terminal 05 I O Terminal 06 I O Terminal 07 Freq when when A051 4 when A052 4 when A053 4 Source P038 9 Accel Decel Parameter Used 0 0 0 A070 E230 Accel Time 1 Decel Time 1 1 0 0 A071 E232 Accel Time 1 Decel Time 1 0 1 0 A072 E234 Acc
42. Rated Amps x 1 8 Display 0 1 Amps Ramp to Stop Mode DC Injection Braking Mode lt 2 a a Speed DC Brake Time Volts Speed Volts Speed DC Brake Time DC Brake Level DC Brake Level Time 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 Programming and Parameters 3 27 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 For more information on external dynamic brake kits refer to the External Dynamic Brake Kit Installation Instructions publication RA INO04
43. and or install See 1 22 for wiring examples e 2 wire control requires Run Forward Run Reverse or Jog input e 3 wire control requires Start and Stop inputs e Stop input is always required jumper If using the DriveGuard Safe Off Option Series B board verify that inputs are active Incorrect Sink Source DIP Switch setting None Set switch to match wiring scheme Drive does not respond to changes in speed command Cause s Indication Corrective Action No value is coming from the source of the command The drive Run indicator is lit and output is 0 Hz Check b012 Control Source for correct source e Ifthe source is an analog input check wiring and use a meter to check for presence of signal e Check b002 Commanded Freq to verify correct command Incorrect reference source is being selected via remote device or digital inputs None e Check b012 Control Source for correct source e Check b014 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 27 4 8 Troubleshooting Motor and or drive will not accelerate to commanded speed Cause s Indication Corrective Action Acceleration time is excessive None Reprogra
44. 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 dedicated hardware enable configuration can be utilized This is accomplished by removing the ENBL enable jumper on the control board In this case I O Terminal 01 will always cause the drive to coast to a stop regardless of the settings of P036 Start Source and P037 Stop Mode DriveGuard Safe Off Option Series B The addition of the DriveGuard Safe Off Option Series B board when used with suitable safety components provides protection according to EN ISO 13849 1 2008 AC 2009 Performance Level d Safety Category 3 for safe off and protection against restart 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 DC Injection Braking Stop Stop command clears active fault 3 DCBrkAuto cF 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 the drive detects that the motor is stopped Stop command clears active fault 4 Ramp Ramp to Stop 5 Coas
45. 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 Table 1 B Input Power Conditions Input Power Condition Corrective Action Install Line Reactor or Isolation Transformer e or Bus Inductor 5 5 amp 11 kW 7 5 amp 15 HP drives only Install Line Reactor e or Isolation Transformer Low Line Impedance less than 1 line reactance Greater than 120 kVA supply transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V lightning Phase to ground voltage exceeds 125 of normal Remove MOV jumper to ground line to 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 ea
46. is active Refer to E210 Max Traverse 33 Home Limit In Positioning mode this indicates the drive is at the home position Refer to Appendix F for detailed information on positioning 34 Find Home In Positioning mode this causes the drive to return to the Home position when a start is issued It does this by using the Find Home Freq and Find Home Direction until the Home Limit input is activated If it passes this point it then runs in the reverse direction at 1 10th the frequency of Find Home Freq until the Home Limit is activated again As long as this input is active any start command will cause the drive to enter the homing routing However it only functions if in Positioning mode Once the Find Home routine has finished the drive will stop Refer to Appendix F for detailed information on positioning 35 Hold Step In Positioning mode this input over rides other inputs and causes the drive to remain at it s current step running at zero speed once it reaches its position until released While in Hold the drive will ignore any digital input command which would normally result in a move to a new step However timers continue to run Therefore when the Hold is removed the drive must see any required digital inputs transition even if they already transitioned during the hold but it does not reset any timer Refer to Appendix F for detailed information on positioning
47. position regulator For faster response the filter should be reduced and or the gain should be increased For smoother response with less overshoot the filter should be increased and or the gain should be reduced In general the gain will have a larger effect on most systems than the filter Homing Routine This drive supports incremental encoders only Therefore when the drive powers up it will reset the current position to zero If this is known to be correct the position routine can be started without further adjustment However in most applications the drive will need to be homed after each power up and prior to starting the position routine This can be accomplished in one of the following two ways 1 Manual Homing Program the following drive parameters A051 A054 Digital Inx Sel 36 Pos Redefine Program one of the digital inputs to option 36 Pos Redefine Then move the system into the home position via a run command a jog command or by manually moving the system into the home position Then toggle the Pos Redefine input This will set the drive to Home at its current position and d308 Units Traveled H and d309 Units Traveled L are set to zero Alternately the Pos Redefine bit in E248 Enh Control Word can be toggled instead of utilizing a digital input Important The Pos Redefine input or bit must be returned to inactive before starting the position routine Otherwise
48. potentiometer 3 4 20mA Input External frequency command from the 4 20mA analog input 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 Default 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 If Step Logic based positioning control is desired select option 9 Positioning and adjust E222 Positioning Mode 7 Anig In Mult External frequency command as defined by the product of the analog inputs shown in b020 Analog In 0 10V and b021 Analog In 4 20mA Analog In 0 10V x Analog In 4 20mA Speed Command Example 100 x 50 50 8 Encoder External frequency command directly from encoder or pulse train input Use E216 Motor Fdbk Type to select encoder type 9 Positioning External position as defined by E222 and 230 E245 Refer to Appendix F for detailed information on positioning Programming and Parameters 3 13 Basic Program Group continued 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 AcceliRale Valu
49. speed bandwidth improvement F 2 Encoder Usage and Position StepLogic Application Wiring Notes The encoder can supply 5V or 12V power 250 mA maximum for an encoder Be sure the DIP switch is set properly for the encoder In general 12V will provide higher noise immunity The pulse train encoder inputs can handle 5V 12V or 24V inputs The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary If a pulse train or single channel input is used it must be wired between the A signal and A signal common channels Important A quadrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forward direction matches the motor forward direction If the drive is reading encoder speed but the position regulator or other encoder function is not working properly remove power to the drive and swap the A and A NOT encoder channels or swap any two motor leads Drives using FRN 2 xx and greater will fault when an encoder is incorrectly wired and E216 Motor Fdbk Type is set to option 5 Quad Check Positioning Overview The PowerFlex 40P includes a simple position regulator which can be used in a variety of position applications without the need for multiple limit switches or photo eyes This can be used as a stand alone controller for simple applications up to 8 positions or in conjunction with a controller for more flexibility Please
50. the decimal point is fixed For example a decimal 100 equals 1 00 Hz and 543 equals 5 43 Hz 8193 RS485 DSI Protocol Reading 03 Logic Status Data The PowerFlex 40P Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 Logic Status Parameter E249 Cmd Stat Select is used to select Velocity or Position Bit definitions Velocity Bit Definitions Logic Status E249 0 Velocity Address Decimal Bit s Description 1 Ready 0 Not Ready 1 Active Running 0 Not Active 1 Cmd Forward 0 Cmd Reverse 1 Rotating Forward 0 Rotating Reverse 1 Accelerating 0 Not Accelerating 1 Decelerating 0 Not Decelerating Not Used 1 Faulted 0 Not Faulted 8448 N D O A w rm Oo 1 At Reference 0 Not At Reference Ko 1 Reference Controlled by Comm 1 Operation Cmd Controlled by Comm 1 Parameters have been locked ine Digital Input 1 Status oo Digital Input 2 Status Digital Input 3 Status a Digital Input 4 Status Position Bit Definitions Logic Status E249 1 Position 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 Acc
51. 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 Velocity StepLogic Basic Logic and Timer Counter Functions E 5 Output gt Frequency Start gt Relay Out gt Photo Eye gt Digital Int gt Counter In Digital In2 gt Reset Counter Limit Switch gt Note that a Reset Timer input is not required for this example since the Timer Start input both clears and starts the timer E 6 Velocity StepLogic Basic Logic and Timer Counter Functions Counter Function Digital inputs and outputs control the counter function and are configured with parameters AOS 1 A054 Digital Inx Sel set to 19 Counter In and 21 Reset Countr 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 Out1 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
52. to 10V DC Analog 1k ohm minimum 4 20mA Analog 525 ohm maximum Table A C PowerFlex 40P Estimated Watts Loss Rated Load Speed amp PWM Voltage kW HP External Watts Internal Watts Total Watts Loss 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 22D B 2P3 N 1 0 4 Drive Voltage Rating Rating Enclosure HIM Emission Class Version Table B B PowerFlex 40P Drives as IP20 Flange rive Ratings IP20 NEMA Type Open Mount Plate Drive Output Frame Input Voltage kW HP Current Catalog Number Size _ Catalog Number Catalog Number 240V 50 60 Hz 0 4 0 5 2 3A 22D B2P3N104 B 22D B2P3F104 22D B2P3H204 a 0 75 1 0 5 0A 22D B5PON104 B 22D B5P0F104 22D B5P0H204 15 2 0 8 0A 22D B8P0N104 B 22D B8P0F104 22D B8P0H204 2 2 3 0 12 0A 22D B012N104 B 22D B012F104 22D B
53. to save 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 A164 PID Invert Error When set to Inverted changes the sign of the PID error This causes an increase in the drive output frequency with PID Feedback greater than PID Setpoint and a decrease in drive output frequency with PID Feedback less than PID Setpoint Options 0 Not Inverted Default 1 Inverted Programming and Parameters
54. use only Includes 2 9 meter cable LCD Display Remote Handheld Digital speed control 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 Cc 22 JBAC plastic top panel IP30 NEMA 1 UL Type 1 Field installed kit Converts drive to IP30 B 22 JBCB Kit for Communication NEMA 1 UL Type 1 enclosure Includes Option communication option conduit box with mounting screws and plastic top panel c 22 JBCC Table B I Other Options ltem Catalog Number DriveGuard Safe Off Option When used with suitable safety components 20A DG01 Board provides protection according to EN ISO 13849 1 2008 AC 2009 Category 3 for safe off and protection against restart Accessories and Dimensions Table B J Communication Option Kits and Accessories Item Communication Adapters Description Embedded communication options for use with the PowerFlex 4 Class drives Requires a Communication Adapter
55. within the rated value of the drive 3 Verify that any digital control power is 24 volts 4 Verify that the Sink SNK Source SRC Setup DIP Switch is set to match your control wiring scheme See Figure 1 5 on page 1 15 for location Important The default control scheme is Source SRC The Stop terminal is jumpered to allow starting from comms If the control scheme is changed to Sink SNK the jumper must be removed from I O Terminals 01 and 11 and installed between I O Terminals 01 and 04 5 Verify that the Stop input is present or the drive will not start Important If I O Terminal 01 is used as a stop input the jumper between I O Terminals 01 and 11 must be removed 2 2 Start Up Applying Power to the Drive 6 Apply AC power and control voltages to the drive Start Stop Direction and Speed Control Factory default parameter values allow the drive to be controlled from comms No programming is required to start stop change direction and control speed directly from comms Important To disable reverse operation see A095 Reverse Disable If a fault appears on power up refer to Fault Descriptions on page 4 3 for an explanation of the fault code 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 Start Up Display Fault Reset Me
56. 0 140M D8E C16 100 C16 2069 22D E012 7 5 10 0 12 2 414 660 14 9 13 7 25 140M D8E C16 100 C23 2069 22D E019 11 0 15 0 19 0 414 660 23 1 24 1 40 140M F8E C25 100 C30 2069 Ratings apply to all drive types Panel Mount N104 Flange Mount F104 and Plate Drive H204 2 The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary See Bulletin 140M Motor Protection Circuit Breakers Application Ratings 3 Manual Self Protected Type E Combination Motor Controller UL listed for 208 Wye or Delta 240 Wye or Delta 480Y 277 or 600Y 347 Not UL listed for use on 480V or 600V Delta Delta corner ground or high resistance ground systems 9 When using a Manual Self Protected Type E Combination Motor Controller the drive must be installed in a ventilated or non ventilated enclosure with the minimum volume specified in this column Application specific thermal considerations may require a larger enclosure Category Agency Certification Table A B Specifications Specification Supplemental Drive Information A 3 Listed to UL508C and CAN CSA 22 2 Certified to AS NZS 1997 Group 1 Class A Marked for all applicable European Directives EMC Directive 2004 108 EC EN 61800 3 2004 A1 2012 LV Directive 2006 95 EC EN 61800 5 1 2007 EN 60204 1 2006 A1 2009 AC 2010 Machine Directive 2006 42 EC EN 62061 Certified to EN ISO 13849
57. 00 reference For example with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 reference 10 Encoder Trim Selects Trim Control Encoder or Pulse train will be used as a trim input for the PID Feedback A133 PID Feedback Sel is used to select the source of the PID feedback Table G 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 40P 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 3 Encoder Encoder or Pulse train will be used as an input for the PID Feedback PIDSetUp G5 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 or PID Feedback Examples Scale Function For a 0 5 volt signal the following parameter settings are used so that a0 volt signal 0 P
58. 012H204 3 7 5 0 17 5A 22D B017N104 B 22D B017F104 22D B017H204 5 5 7 5 24 0A 22D B024N104 0 22D B024F104 22D B024H204 7 5 10 0 33 0A 22D B033N104 C 22D B033F104 22D B033H204 480V 50 60 Hz 0 4 0 5 1 4A 22D D1P4N104 B 22D D1P4F104 22D D1P4H204 anan 0 75 1 0 23A 22D D2P3N104 B 22D D2P3F104 22D D2P3H204 1 5 2 0 4 0A 22D D4P0N104 B 22D D4P0F104 22D D4P0H204 2 2 3 0 6 0A 22D D6P0N104 B 22D D6POF104 22D D6P0H204 4 0 5 0 10 5A 22D D010N104 B 22D D010F 104 22D D010H204 5 5 7 5 12 0A 22D D012N104 c 22D D012F104 22D D012H204 7 5 10 0 17 0A 22D D017N104 0 22D D017F104 22D D017H204 11 0 15 0 24 0A 22D D024N104 Cc 22D D024F104 22D Do24H204 600V 50 60 Hz 0 75 1 0 1 7A 22D E1P7N104 B 22D E1P7F104 22D E1P7H204 ae 1 5 20 3 0A 22D E3PON104 B 22D E3P0F104 22D E3P0H204 2 2 3 0 4 2A 22D E4P2N104 B 22D E4P2F104 22D E4P2H204 4 0 5 0 6 6A 22D E6P6N104 B 22D E6P6F104 22D E6P6H204 5 5 7 5 9 9A 22D E9P9N104 C 22D E9P9F104 22D E9P9H204 7 5 10 0 12 0A 22D E012N104 c 22D E012F104 22D E012H204 11 0 15 0 19 0A 22D E019N104 C 22D E019F104 22D E019H204 1 Meets IP40 54 65 NEMA 1 1 2 4 4X when installed in an enclosure of like rating 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
59. 098 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 Action Correct the cause of the fault and manually clear 2 C Check the wiring between the drive and motor Check motor for grounded phase Replace drive if fault cannot be cleared Check the motor and drive output terminal wiring for a shorted condition Replace drive if fault cannot be cleared Clear the fault or cycle power to the drive Program the drive parameters as needed heck load requirements and A098 SW Current Trip setting R P ESE educe load or extend Accel Time Cycle power Replace drive if fault cannot be cleared Cycle power Check communications cabling Check network adapter setting Check external network status estart procedure If adapter was not intentionally disconnected check wiring to the port Replace wiring port expander adapters or complete drive as required Check connection An adapter was intentionally disconnected Turn off using A105 Comm Loss Action Connecting I O Terminal 04 to ground may improve noise immunity is a No Fault F91 Encoder Loss F100 Parameter Checksum
60. 1 2008 AC 2009 Performance Level d Safety Category 3 Meets Functional Safety FS when used with the DriveGuard Safe Off Option Series B The drive is also designed to meet the appropriate portions of the following specifications NFPA 70 US National Electrical Code NEMA ICS 3 1 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems IEC 146 International Electrical Code Protection Bus Overvoltage Trip 200 240V AC Input 380 460V AC Input 460 600V AC Input 405V DC bus equivalent to 290V AC incoming line 810V DC bus equivalent to 575V AC incoming line 1005V DC bus equivalent to 711V AC incoming line Bus Undervoltage Trip 200 240V AC Input 380 480V AC Input 460 600V AC Input P042 3 High Voltage P042 2 Low Voltage 210V DC bus equivalent to 150V AC incoming line 390V DC bus equivalent to 275V AC incoming line 487V DC bus equivalent to 344V AC incoming line 390V DC bus equivalent to 275V AC incoming line Power Ride Thru 100 milliseconds Logic Control Ride Thru 0 5 seconds minimum 2 seconds typical Electronic Motor Overload Protection Provides class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL 508C File 29572 Overcurrent 200 hardware limit 300 instantaneous fault
61. 100 012 1655 22D B012 2 2 3 0 12 0 180 264 5 5 15 5 25 140M C2E C16 100 C23 1655 22D B017 3 7 5 0 17 5 180 264 8 6 21 0 30 140M F8E C25 100 C23 1655 22D B024 5 5 7 5 24 0 180 264 11 8 26 1 40 140M F8E C32 100 C37 2069 22D B033 7 5 10 0 33 0 180 264 16 3 34 6 60 140M G8E C45 100 C60 2069 380 480V AC 10 3 Phase Input 0 460V 3 Phase Output 22D D1P4 0 4 0 5 1 4 342 528 1 4 1 8 3 140M C2E B25 100 C07 1655 22D D2P3 0 75 1 0 2 3 342 528 2 3 3 2 6 140M C2E B40 100 C07 1655 22D D4P0 1 5 2 0 4 0 342 528 4 0 5 7 10 140M C2E B63 100 C09 1655 22D D6P0 2 2 3 0 6 0 342 528 5 9 7 5 15 140M C2E C10 100 C09 1655 22D D010 4 0 5 0 10 5 342 528 10 3 13 0 20 140M C2E C16 100 C23 1655 22D D012 5 5 7 5 12 0 342 528 11 8 14 2 25 140M D8E C20 100 C23 2069 22D D017 7 5 10 0 17 0 342 528 16 8 18 4 30 140M D8E C20 100 C23 2069 22D D024 11 0 15 0 24 0 342 528 23 4 26 0 50 140M F8E C32 100 C43 2069 460 600V AC 10 3 Phase Input 0 575V 3 Phase Output 22D E1P7 0 75 1 0 1 7 414 660 2 1 2 3 6 140M C2E B25 100 C09 1655 22D E3P0 1 5 2 0 3 0 414 660 3 65 3 8 6 140M C2E B40 100 C09 1655 22D E4P2 2 2 3 0 4 2 414 660 5 2 5 3 10 140M D8E B63 100 C09 1655 22D E6P6 4 0 5 0 6 6 414 660 8 1 8 3 15 140M D8E C10 100 C09 1655 22D E9P9 5 5 7 5 9 9 414 660 12 1 11 2 2
62. 143 A144 A145 A146 A147 A150 A151 A152 A153 A154 A155 A156 A157 A160 A161 A162 A163 A164 E230 E232 E234 E236 E238 E240 E242 E244 E246 E247 E248 E249 d312 d313 d314 d315 d316 Programming and Parameters 3 3 Basic Display Group b001 Output Freq Related Parameter s b002 b010 P034 P035 P038 Output frequency present at T1 T2 amp T3 U V amp W Values Default Read Only Min Max 0 00 P035 Maximum Freq Display 0 01 Hz b002 Commanded Freq Related Parameter s b001 b013 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 27 for details Values Default Read Only Min Max 0 00 P035 Maximum Freq Display 0 01 Hz b003 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 b004 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 b005 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 Basic Displa
63. 2 P1 Terminals P2 and P1 Remove this jumper only when a DC 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 Single phase operation requires a 65 derate of drive rated current Table 1 E Power Terminal Block Specifications 1 3 mm 16 AWG 1 7 2 2 N m 16 19 lb in C 8 4 mm 8 AWG 1 3 mm 16 AWG 2 9 3 7 N m 26 33 lb in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Installation Wiring 1 13 Common Bus Precharge Notes If drives with internal precharge are used with a disconnect switch to the common bus then an auxiliary contact on the disconnect must be connected to a digital input of the drive The corresponding input parameter AO51 A054 must be set to option 29 Precharge Enable This provides the proper precharge interlock guarding against possible damage to the drive when connected to a common DC bus 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
64. 20 this parameter sets the percentage of analog output desired Values Default 0 0 Min Max 0 0 100 0 Display 0 1 3 36 Programming and Parameters Advanced Program Group continued A110 Anlg In 0 10V Lo Related Parameter s b020 P034 P038 A122 A123 Stop drive before changing this parameter Sets the analog input level that corresponds to P034 Minimum Freq if a 0 10V input is used by P038 Speed Reference When A123 10V Bipolar Enbl is set to 1 Bi Polar In this parameter is ignored Analog inversion can be accomplished by setting this value larger than A111 Anlg In 0 10V Hi Values Default 0 0 Min Max 0 0 100 0 Display 0 1 P035 Maximum Freq P034 Minimum Freq 0 A110 Anlg In 0 10V Lo A111 Anlg In 0 10V Hi A111 Anlg In 0 10V Hi Related Parameter s b020 P035 P038 A122 A123 Stop drive before changing this parameter 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 b021 P034 P038 Stop drive before changing this parameter Sets the analog input level that corresponds to P034 Minimum Freq if a 4 20mA input is used by P038 Speed Reference Ana
65. 20mA Hi 27 EM Brk Rise If EM brake function is enabled this input releases the brake Refer to A160 EM Brk Off Delay for additional information material exists an auxiliary mechanical braking device must be used ATTENTION Ifa hazard of injury due to movement of equipment or E202 Options Cont 28 Acc Dec Sel2 Programming and Parameters 3 51 If active can determine which Accel Decel time will be used for Option all ramp rates except jog Can 28 1 Description be applied to one input only 0 lo lAcclDect 0 1 Acc Dec 2 1 0 Acc Dec 3 1 1 Acc Dec 4 29 Precharge En Forces drive into precharge state Typically controlled by auxiliary contact on the disconnect at the DC input to the drive If this input is assigned it must be energized for the pre charge relay to close and for the drive to run If itis de energized the pre charge relay will open and the drive will coast to a stop 30 Inertia Dcel Forces drive into Inertia Ride Through state The drive will attempt to regulate the DC bus at the current level 31 Sync Enable Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization When this input is released the drive will accelerate to the commanded frequency in E214 Sync Time 32 Traverse Dis When an input is programmed the traverse function will be disabled while this input
66. 29507 or equivalent e PVC jacket Standard Option 2 Tray rated 600V 90 C 194 F RHH RHW 2 Anixter OLF 7xxxxx or equivalent e Three tinned copper conductors with XLPE insulation e 5 mil single helical copper tape 25 overlap min with three bare copper grounds in contact with shield e PVC jacket Class amp Il Division amp Tray rated 600V 90 C 194 F RHH RHW 2 Anixter 7V 7xxxx 3G or equivalent e Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor Black sunlight resistant PVC jacket overall e Three copper grounds on 10 AWG and smaller Installation Wiring 1 11 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 recommendat
67. 3 49 Enhanced Program Group E201 LED Display Opt Selects which parameters can be viewed by the drive s LED interface E201 Option Parameter Set 0 All Basic Display Group b and Advanced Display Group d parameters 1 All Basic Display Group b001 b029 parameters 2 Basic Display Group parameters b001 b007 and b010 3 Basic Display Group parameter b001 b004 Values Default 2 Min Max 0 3 Display 1 E202 Digital Term 3 Stop drive before changing this parameter Sets the function of I O Terminal 03 Options 0 Start Source Default Input functions as defined by P036 Start Source 1 Acc Dec Sel1 If active can determine which Accel Decel time will be used for all ramp rates except jog Can be applied to one input only Refer to A067 Accel Time 2 for details 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 Refer to A070 A077 Preset Freq x Important Digital Inputs have priority for frequency control when programmed as Preset Speed and are active Refer to the flowchart on page 1 27 for mo
68. A062 A064 19 RS485 DSI Shield Terminal should be connected to safety ground PE when using the RS485 DSI communications port 1 See Footnotes 1 and 6 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 Encoder Interface The PowerFlex 40P Encoder Interface can source 5 or12 volt power and accept 5 12 or 24 volt single ended or differential inputs VCmB B A A Table 1 J Terminal Description No Signal Description V 5V 12V Power Cm Power Return Internal power source 250 mA isolated B Encoder B NOT ture B t B EncoderB Quadrature B inpu A Encoder A NOT A EncoderA NoT Single channel pulse train or quadrature A input Output DIP switch selects 12 or 5 volt power supplied at terminals V and Cm for the encoder 1 When using 12V Encoder power 24V I O power maximum output current at 1 0 Terminal 11 is 50 mA Important A quadrature encoder provides rotor speed and direction Therefore the encoder must be wired such that the forward direction matches the motor forward direction If the drive is reading encoder speed but the position regulator or other encoder function is not wor
69. AC 1 4 SW OverCurrent Fault 4 4 System Grounding 1 6 T Terminal Block I O 1 14 Power 1 12 Three Wire Control 1 22 1 26 Two Wire Control 1 22 1 26 U UnderVoltage Fault 4 3 Ungrounded Supply 1 4 Unshielded Power Cables 1 9 W Watts Loss A 5 Wire Control 1 14 Wiring 1 1 Block Diagram 1 15 1 17 Encoder 1 19 I O 1 13 I O Examples 1 22 1 26 Potentiometer 1 22 Power 1 9 PTC Example 1 22 Index 4 Notes e 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 22D UM001D EN E July 2015 Supersedes Publication 22C UM001C EN E June 2013 Copyright 2015 Rockwell Automation Inc All rights reserved
70. Above PF Ang e Power Factor angle has exceeded the value set in A059 or A061 A062 Opto Outx Level Options e Use A059 or A062 to set threshold Cont 49 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 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 At Position The drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with E225 Encoder Pos Tol 24 At Home The drive is in Positioning mode and has reached the home position Tolerance is adjusted with E225 Encoder Pos Tol 25 Safe Off The DriveGuard Safe Off option is installed and both safe off inputs are active A059 Opto Outi 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 A058 amp A061 Setting A059 amp A062 Min Max 6 0 500 Hz 7 0 180 8 0 815 Volts 10 0 100 16 0 1 9999 Secs 1 9999
71. Accel 2 amp Decel 2 and the input is active that input overrides the settings in this able E231 Step Units F 0 Related Parameter s E226 E233 Step Units F 1 E235 Step Units F 2 E237 Step Units F 3 E239 Step Units F 4 E241 Step Units F 5 E243 Step Units F 6 E245 Step Units F 7 7 32bit parameter Sets the position in fractional user defined units the drive must reach at each step For additional information refer to Appendix F Values Default 0 00 Min Max 0 00 0 99 Display 0 01 Programming and Parameters 3 59 Enhanced Program Group continued E246 Pos Reg Filter Sets the error signal filter in the position regulator For additional information refer to Appendix F Values Default 8 Min Max 0 15 Display 1 E247 Pos Reg Gain Sets the gain adjustment for the position regulator For additional information refer to Appendix F Values Default 3 0 Min Max 0 0 200 0 Display 0 1 3 60 Programming and Parameters Enhanced Program Group continued E248 Enh Control Word Allows control of positioning and other functions via parameter control for use over comms The functions replicate the digital input options and function in the same way For additional information refer to Appendix F Important The Find Home and Position Redefine bits must be returned to 0 following the homing routine and before starting the drive
72. BL 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 120 Ohm resistors 2 pieces AK U0 RJ45 TR1 Terminal Block RJ45 Two position terminal block 5 pieces AK U0 RJ45 TB2P DriveTools SP Software DriveExplorer Software CD ROM Version 3 01 or later DriveExecutive software CD ROM Version 1 01 or later 1 Windows based software packages that provide an intuitive means for monitoring or configuring Allen Bradley drives and communication adapters online Compatibility Windows 95 98 ME NT 4 0 Service Pack 3 or later 2000 XP and CE See www ab com drives driveexplorer htm for supported devices 9303 4DTSO1ENE 9306 4EXP01ENE 9303 4DTEO1ENE Accessories and Dimensions B 7 Product Dimensions Table B K PowerFlex 40P Frames Ratings are in kW and HP Figure B 1 IP 30 NEMA 1 UL Type 1 Option Kit without Communication Option Dimensions are in millimeters and inches lt 100 0 3 94 gt 148 0 5 83 79 1 3 11 87 049 y i 136 0 5 35 gt le 64 1 2 52
73. Bus voltage above the undervoltage level Programming and Parameters 3 53 Enhanced Program Group continued E209 Half Bus Enable Enables disables the power ride through function which allows the drive to maintain power to the motor at 50 drive input voltage during short term power sag conditions Options 0 Disabled Default 1 Enabled recovers The input impedance should be equal or greater than the ATTENTION To guard against drive damage a minimum line A impedance must be provided to limit inrush current when the power line equivalent of a 5 transformer with a VA rating 6 times the drive s input VA rating E210 Max Traverse Related Parameter s E211 E212 E213 Sets the amplitude of triangle wave speed modulation Values Default 0 00 Hz Disabled Min Max 0 00 300 0 Hz Display 0 01 Hz t 212 Traverse Dec p 211 Traverse Inc E210 Max Traverse ai 213 P Jump y S E213 P Jump P ERTEN Si SE a an ne es eet b001 Output Freq Hertz Traverse Bit L d302 Fiber Status ___ Traverse Enable Bit Seconds E211 Traverse Inc Related Parameter s E210 Sets time required for the Traverse function to accelerate from the minimum to the maximum traverse frequency Refer to the diagram at E210 Max Traverse Values Default 0 00 Secs Min Max 0 00 30 00 Secs Display 0 01 Secs
74. Communications 9 Jogging Speed Command Digit 3 amp 2 01 A069 Internal Freq 02 0 10V Input Remote Potentiometer 03 4 20mA Input 04 A070 A077 Preset Freq x A051 A053 Digital Inx Sel must be set to 4 05 RS485 DSI Port 06 StepLogic Control Parameters A140 A147 07 Analog Input Multiply 08 PID Control 09 Jogging 10 Encoder or Pulse Train Reference 11 Positioning Control Reserved Digit 4 Values Default Read Only Min Max 0 112 Display 1 b013 Contrl In Status Related Parameter s b002 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 oadd 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 I O 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 Basic Display Group continued b014 Dig In Status Related Parameter s A051 A054 Status of the control terminal block digital inputs ANIA MPT L l 1 Input Present 0 I
75. Cover Ordered Separately ControlNet DeviceNet EtherNet IP LonWorks PROFIBUS DP Catalog Number 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 cards 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 Communication Adapter Cover B Frame Drive 22D CCB C Frame Drive 22D CCC Universal Serial Bus Provides serial communication via DF1 protocol 1203 USB USB Converter Module for use with DriveExplorer and DriveTools SP software Includes 2m USB cable 1 20 HIM H10 cable 1 22 HIM H10 cable 1 Serial Converter Module Provides serial communication via DF1 protocol 22 SCM 232 RS485 to RS232 for use with DriveExplorer and DriveTools SP software Includes DSI to RS232 serial converter 1 1203 SFC serial cable 1 22 RJ45CBL C20 cable 1 DriveExplorer Lite CD 1 Remote Handheld HIM Wireless Interface Module with Bluetooth 22 WIM N1 technology IP30 NEMA Type 1 Panel Mount with optional bezel kit Remote Panel Mount Wireless Interface Module with Bluetooth 22 WIM N4S HIM technology IP66 NEMA Type 4X 12 indoor use only DSI Cable 2 0 meter RJ45 to RJ45 cable male to male connectors 22 RJ45C
76. Decel Time 2 can be selected by Step Logic parameters A140 A147 or Position Logic parameters E230 E245 P039 Accel Time 1 P040 Decel Time 1 are used Installation Wiring 1 29 EMC Instructions CE Conformity Conformity with the Low Voltage LV Directive and Electromagnetic Compatibility EMC Directive has been demonstrated using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex Drives comply with the EN standards listed below when installed according to the User Manual CE Declarations of Conformity are available online at http www ab com certification ce docs Low Voltage Directive 2006 95 EC e EN61800 5 1 2007 Electronic equipment for use in power installations EMC Directive 2004 108 EC e EN61800 3 2004 A1 2012 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 encoder cover is not intact 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
77. EMC Line Filters Drive Ratings S Type Filter L Type Filter Input Voltage kw HP Catalog Number 1 Catalog Number 2 240V 50 60 Hz 0 4 0 5 22 RF021 BS 22 RF021 BL 3 Phase 0 75 1 0 22 RF021 BS 22 RF021 BL 15 2 0 22 RF021 BS 22 RF021 BL 22 3 0 22 RF021 BS 22 RF021 BL 37 5 0 22 RF021 BS 22 RF021 BL 55 75 22 RF034 CS 22 RF034 CL 75 10 0 22 RF034 CS 22 RF034 CL 480V 50 60 Hz 0 4 05 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 22 3 0 22 RF012 BS 22 RF012 BL 40 5 0 22 RF012 BS 22 RF012 BL 55 75 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 20 z 22 RF8P0 BL 22 3 0 7 22 RF8P0 BL 4 0 5 0 22 RF8P0 BL 55 75 E 22 RF015 CL 7 5 10 0 z 22 RF015 CL 11 0 15 0 E 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 2 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 3 Filter must be Series C or later Accessories and Dimensions B 5 Table B G Human Interface Module HIM Option Kits and Accessories Item Description Catalog Number LCD Display Remote Panel Digital speed control 22 HIM C2S Mount CopyCat capable IP66 NEMA Type 4X 12 indoor
78. Ground Fault Trip Phase to ground on drive output Short Circuit Trip Phase to phase on drive output Environment _ Altitude 1000 m 3300 ft max without derating Above 1000 m 3300 ft derate 3 for every 305 m 1000 ft Maximum Surrounding Air Temperature without derating IP20 Open Type IP30 NEMA Type 1 UL Type 1 Flange and Plate Mount 10 to 50 C 14 to 122 F 10 to 40 C 14 to 104 F Heatsink 10 to 40 C Drive 10 to 50 C 14 to 104 F 14 to 122 F Cooling Method Convection 0 4 kW 0 5 HP drives and all Flange and Plate drives Fan All other drive ratings Storage Temperature 40 to 85 degrees C 40 to 185 degrees F Atmosphere Important Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the drive is not going to be installed for a period of time it must be stored in an area where it will not be exposed to a corrosive atmosphere Relative Humidity 0 to 95 non condensing Shock operating 15G peak for 11ms duration 1 0 ms Vibration operating 1G peak 5 to 2000 Hz A 4 Supplemental Drive Information Category Specification Electrical Voltage Tolerance 200 240V 10 380 480V 10 460 600V 10 Frequency Tolerance 48 63 Hz Input Phases Three phase input provides full rating Single phase operation provides 35 rated current Displ
79. ID Reference and a 5 volt signal 100 PID Reference e A110 Anlg In 0 10V Lo 0 0 e Al1l Anlg In 0 10V Hi 50 0 e A132 PID Ref Sel 2 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 In4 20mA Lo 100 0 e A113 Anlg In4 20mA Hi 0 0 e A132 PID Ref Sel 3 4 20mA Input 24 20 N 4 20mA Input 0 10 20 30 40 50 60 70 80 90 100 PID Reference G 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 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 o
80. 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 10 Above Anlg V e Analog input voltage I O Terminal 13 exceeds the value set 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 Step Logic step with Digit 3 of Command Word A140 A147 set to enable Step Logic 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 Programming and Parameters 3 21 A058 18
81. Ki Speed Loop Kp Speed Loop Positioning Mode Find Home Freq Find Home Dir Encoder Pos Tol Counts Per Unit vuVvV a a Encoder Speed Units Traveled H Units Traveled L Fault 4 Code Fault 5 Code b013 b014 b015 b016 b017 b018 b019 b020 P034 P035 P036 P037 P038 A109 A110 A111 A112 A113 A114 A115 A116 A117 A118 A119 A120 A121 A122 A123 A124 A125 A126 A127 A128 A129 A130 A131 A132 A133 A134 A135 A136 A137 A138 A139 E216 E217 E218 E219 E220 E221 E222 E223 E224 E225 E226 d306 d308 d309 d310 d311 Analog In 4 20mA b021 Output Power Output Powr Fetr Drive Temp Counter Status Timer Status Stp Logic Status Torque Current Accel Time 1 Decel Time 1 Reset To Defalts Voltage Class Motor OL Ret MMADNNNNNANDNNNNNNDNDD Vos Step Uni Step Uni Step Uni Step Uni Step Uni Step Uni Step Uni Step Uni Pos Reg Pos Reg Enh Con Cmd Stai 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 M Brk Off Delay M Brk On Delay OP Reset Sel B Threshold D Invert Error s 0 s 1 s 2 s3 S 4 s5 s 6 S 7 Filter Gain rol Word Select Fault 6 Code Fault 7 Code Fault 8 Code Fault 9 Code Fault 10 Code b022 b023 b024 b025 b026 b028 b029 P039 P040 P041 P042 P043 A140 A141 A142 A
82. N EAD GA SEA E KAE a AA e o s o Analog I O amp PTC 8760 9460 0 750 mm 18AWG twisted 300V pair 100 shield with drain 75 90 C Remote Pot 8770 0 750 mm 18AWG 3 167 194 F cond shielded a a a Encoder Pulse I O 89730 0 196 mm 24 AWG individually shielded pairs Stranded or solid wire 9728 or 9730 are equivalent and may be used but may not fit in the drive wire channel S If the wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Table 1 G Recommended Control Wire for Digital I O Minimum Type Wire Type s Description Insulation Rating Unshielded Per US NEC or applicable 300V national or local code 60 degrees C Shielded Multi conductor shielded 0 750 mm 18AWG 3 140 degrees F cable such as Belden conductor shielded 8770 or equiv 1 0 Terminal Block Table 1 H I O Terminal Block Specifications Frame Maximum Wire Size Minimum Wire Size Torque B amp C 1 3mm 16 AWG 10 2 mm 24 AWG 10 5 0 8 N m 4 4 7 Ib in 1 Maximum minimum sizes that the terminal block will accept these are not recommendations Maximum Control Wire Recommendations Do not exceed control wiring length of 30 meters 100 feet Control signal cable length is highly dependent on electrical environment and installation practices To improve noise immunity the I O terminal block Comm
83. PowerUp Reverse Disable Flying Start En Compensation SW Current Trip Process Factor Fault Clear Program Lock Testpoint Sel Comm Data Rate Comm Node Addr Comm Loss Action Comm Loss Time Comm Format Language Comm Write Mode Power Loss Mode Half Bus Enable Max Traverse Traverse Inc Traverse Dec P Jump Sync Time Speed Ratio Drive Status 2 Fibers Status Slip Hz Meter Speed Feedback b004 b005 b006 b007 b008 b009 b010 b012 P031 P032 P033 A078 A079 A080 A081 A082 A083 A084 A085 A086 A087 A088 A089 A090 A091 A092 A093 A094 A095 A096 A097 A098 A099 A100 A101 A102 A103 A104 A105 A106 A107 A108 E207 E208 E209 E210 E211 E212 E213 E214 E215 d301 d302 d303 d304 Contrl In Status Dig In Status Comm Status Control SW Ver Drive Type Elapsed Run Time Testpoint Data Analog In 0 10V Minimum Freq Maximum Freq Start Source Stop Mode Speed Reference 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 ux Current Ref D 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 Motor Fdbk Type Motor NP Poles Encoder PPR Pulse In Scale
84. Program Step Units F 6 E243 Enhanced Program Step Units F 7 E245 Enhanced Program Stop Mode P037 Basic Program Stp Logic Status b028 Display Stp Logic Time x A150 A157 Advanced Program Stp Logic x A140 A147 Advanced Program SW Current Trip A098 Advanced Program Sync Time E214 Enhanced Program Testpoint Data b019 Display Testpoint Sel A102 Advanced Program Timer Status b026 Display Torque Current b029 Display Torque Perf Mode A125 Advanced Program Traverse Dec E212 Enhanced Program Traverse Inc E211 Enhanced Program Programming and Parameters 3 67 Parameter Name No Group Units Traveled H d308 Advanced Display Units Traveled L d309 Advanced Display Var PWM Disable A124 Advanced Program Voltage Class P042 Basic Program 3 68 Programming and Parameters Notes Chapter 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 40P drive Included is a listing and description of drive faults with possible solutions when applicable For information on See page For information on Drive Status 4 1 Fault Descriptions 4 3 Faults 4 1 Common Symptoms and 4 6 Corrective Actions not contain user serviceable components Do not disassemble drive ATTENTION Risk of injury or equipment damage exists Drive does chassis Drive Status The condition or state of your drive is constantly monitored Any changes will be indicated through the integral LED
85. Supply SNK O Stop Run Forward O O Stop Run Reverse 01 02 03 04 1 24 Input Output 3 Wire SRC Control Non Reversing Installation Wiring Connection Example Internal Supply SRC External Supply SRC P036 Start Source 1 So nlo fi A momentary input will _L 02 Pale 02 start the drive A stop Ostar star input to I O Terminal 01 i 04 will stop the drive as specified by P037 WN c Stop Mode t i o JE 8 Each digital input draws 6 mA 3 Wire SNK Control Internal Supply SNK Non Reversing 01 02 S 04 3 Wire SRC Control Internal Supply SRC External Supply SRC Reversing P036 Start Source 1 Ot Stop 01 A momentary i i 02 y input will 02 is 7 start the drive A stop 03 03 input to I O Terminal 01 04 will stop the drive as recti specified by P037 O B aie V0 Ps 24V Common S determines direction Each digital input draws 6 mA 3 Wire SNK Control Internal Supply SNK Reversing Stop 01 02 03 Direction i 8 0000 04 Input Output Opto Output 1 amp 2 A058 Opto Out Sel determines Opto Output 1 I O Terminal 17 oper
86. a ol e Jlo mo l A 119 3 4 70 Frame B 117 8 2 300 5 8 105 8 138 2 e 11 81 417 4 5 44 d f a e ei semo e 20A DG01 Bis fl 325 le o 12 8 l d 22D CCC OU UW i Go 1 a Oo 7 q Y m 130 3 5 13 D d Frame C Accessories and Dimensions Figure B 4 PowerFlex 40P Flange Mount Cutout Dimensions Dimensions are in millimeters and inches 145 SSj j 6 71 235 ya A Cos AA x 197 7 76 a 225 8 27 8 86 7 te 98 5 3 88 253 0 21 is E 141 31 49 t 7 5 0 55 1 22 1 93 Sg J 0 30 le ne 160 A 6 30 Frame B eee 164 253 0 31 6 46 Fa 0 21 go 307 5 12 11 74 o 230 6 9 08 291 5 _ 11 48 K t 153 8 6 06 T 76 9 T k 9 t 8 N 3 54 180 0 31 7 09 Frame C Accessories and Dimensions B 11 Figure B 5 PowerFlex 40P Plate Drive Dimensions Dimensions are in millimeters and inches 7 125 100 3 94 5 x 3 46 0 37
87. a fault is issued Options 0 60 Seconds Default 1 120 Seconds 240 Seconds 360 Seconds 2 3 4 480 Seconds 5 Fit Disabled Programming and Parameters 3 39 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 Ensure that the Voltage Range Select DIP Switch is set to 10V Options 0 Disabled Default 1 Fault F29 F29 Analog Input Loss 2 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 Ensure that the Voltage Range Select DIP Switch setting matches the selected control scheme Refer to Figure 1 5 on page 1 15 Options 0 Uni Polar In Default 0 to 10V only 1 Bi Polar In 10V A124 Var PWM
88. able frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as 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 driv
89. acement Power Factor 0 98 across entire speed range Maximum Short Circuit Rating 100 000 Amps Symmetrical Actual Short Circuit Rating Determined by AIC Rating of installed fuse circuit breaker Transistor Type Isolated Gate Bipolar IGBT Control Method Sinusoidal PWM Volts Hertz and Sensorless Vector Carrier Frequency 2 16 kHz Drive rating based on 4 kHz Frequency Accuracy Digital Input Within 0 05 of set output frequency Analog Input Within 0 5 of maximum output frequency 10 Bit resolution Analog Output 2 of full scale 10 Bit resolution Speed Regulation Open Loop with Slip Compensation 1 of base speed across a 80 1 speed range With Encoder 0 3 of base speed across a 80 1 speed range 0 05 of base speed across a 20 1 speed range Output Frequency 0 500 Hz programmable Efficiency 97 5 typical Stop Modes Multiple programmable stop modes including Ramp Coast DC Brake and Ramp to Stop Accel Decel Four independently programmable accel and decel times Each time may be programmed from 0 600 seconds in 0 1 second increments Intermittent Overload 150 Overload capability for up to 1 minute 200 Overload capability for up to 3 seconds Electronic Motor Overload Protection Provides class 10 motor overload protection according to NEC article 430 and motor over temperature protection according to NEC article 430 126 A 2 UL 508C File 29572
90. alog Input Loss 33 Auto Restart Tries 38 Phase U to Ground Short 39 Phase V to Ground Short 8449 40 Phase W to Ground Short 41 Phase UV Short 42 Phase UW Short 43 Phase VW Short 48 Parameters Defaulted 63 Software Overcurrent 64 Drive Overload 70 Power Unit Fail 71 Network Loss Fault 80 AutoTune Fail 81 Communication Loss 94 Encoder Loss Fault 100 Parameter Checksum Error 111 Hardware Enable Fault 122 1 0 Board Fail RS485 DSI Protocol Reading 03 and Writing 06 Drive Parameters To access drive parameters the Modbus register address equals the parameter number For example a decimal 1 is used to address Parameter d001 Output Freq and decimal 39 is used to address Parameter P039 Accel Time 1 Additional Information Refer to http Awww ab com drives for additional information Appendix D RJ45 DSI Splitter Cable The PowerFlex 40P 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 c
91. and Logic In2 is not active logically false TIMED OR F Use logic programmed in Digit 1 IGNORE Appendix F Encoder Usage and Position StepLogic Application Encoder Usage The PowerFlex 40P includes a pulse train encoder input When E216 Motor Fdbk Type is set to a value other than zero the drive is set to use an encoder The drive will use the encoder in several ways depending on the settings of other parameters The drive will use the encoder as shown below listed in order of priority 1 If enabled by P038 Speed Reference the encoder will be used directly as a commanded speed normally used with a pulse train or as a position reference normally used with a quadrature encoder 2 If not enabled by P038 Speed Reference when the PID Feedback or PID Reference are set to use an encoder than the PID function will use the encoder or pulse train input 3 If not enabled by P038 Speed Reference or the PID parameters then if E216 Motor Fdbk Type is set the encoder is used for direct feedback and trim of the speed command The normal slip compensation is not used in this case Instead the drive will use the encoder to determine actual output frequency and adjust the output frequency to match the command Parameters E220 Ki Speed Loop and E221 Kp Speed Loop are used in this control loop The primary benefit of this mode is increased speed accuracy when compared to open loop slip compensation It does not provide
92. and level surface Frame ScrewSize 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 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 __ 4 7 in wo D eion Closest object that le ame may restrict air flow p through the drive heat sink and chassis lt a 120 mm 120 mm 4 7 in ET 4 7 in v v 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 IP 20 Open Type Use Mounting Option A 40 C 104 F eae i gp 10 C 14 F IP 30 NEMA 1 UL Type 1 Use Mounting Option B 50 C 122 F IP 20 Open Type Use Mounting Option B Rating requires installation of the PowerFlex 40P IP 30 NEMA 1 UL Type 1 option kit Installation Wiring 1 3 Debris Protection A plastic top panel is included with the drive Install the panel to prevent debris from falling through the vents of the drive housing during installation Remove the panel for IP 20 Open Type applications Storage e Store within an ambi
93. ate Heatsink Dimensions for One Drive without Heatsink Fan Dimensions are in millimeters and inches rap C o lol e a he B o o ese E a A ea Drive Frame Size A B C B 214 8 43 250 9 84 63 1 2 48 c 300 11 81 325 12 8 138 2 5 44 Plate Drive Installation Instructions H 3 Heatsink Surface and Flatness Requirements The drive comes with a thermal pad designed to provide a good interface between the drive and heatsink However in order for this to function properly the mounting surface for the plate drive must be clean and free of dirt oil and debris It must be very flat and smooth and should have no scratches nicks or gouges All mounting holes must be clean and deburred Table H C Surface Requirements Attribute Description Surface Finish 1 6 uM Ra Method Smoothness Overall surface texture free from imperfections scratches nicks or gouges Surface Flatness 1 5 mil Trueness Free from warps twists and concavity depressions Figure H 2 Smoothness Tolerance and Surface Pad Thickness 0 5 mil ANANA 0 5 mil Plate Drive Installation Instructions Mounting Dimensions and Requirements Refer to Figure B 5 on page B 11 for plate drive dimensions and mounting hole locations Use the pattern illustrated in Step 3 below to gradually tighten all m
94. ation A061 Opto Out2 Sel determines Opto Output 2 I O Terminal 18 operation When using 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 Connection Example Opto Output 1 Installation Wiring 1 25 O0O000000 CR 24V Common Each Opto Output is rated 09 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 P Switch must be set to match the analog output alog Out Sel I The Analog Output Select D signal mode set in A065 An S Common gt 49 Tel 6 eoo 1 26 Installation Wiring Typical Multiple Drive Connection Examples Input Output Multiple Digital Input Connections Customer Inputs can be wired per External Supply SRC Connection Example o2 4 o2 04 o2 04 220 GIG 00008 alecloccee O O TTT 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
95. ave been added or updated with Firmware Revision Number FRN 3 xx Parameter Number Description Page Stp Logic Time A150 A157 Max value increased to 6553 5 sec 3 47 PID Invert Error A164 New Parameter 3 48 Fault 4 Code d310 New Parameter 3 64 soc 2 Parameter Number Description Page Fault 5 Code d311 New Parameter 3 64 Fault 6 Code d312 New Parameter 3 64 Fault 7 Code d313 New Parameter 3 64 Fault 8 Code d314 New Parameter 3 65 Fault 9 Code d315 New Parameter 3 65 Fault 10 Code d316 New Parameter 3 65 Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Appendix A Appendix B Overview Installation Wiring Start Up Table of Contents Who Should Use this Manual P 1 Reference Materials P 1 Manual Conventions P 2 Drive Frame Sizes 4 P 2 General Precautions P 3 Catalog Number Explanation P 4 Opening the Cover 1 1 Mounting Considerations 1 2 Plate Drive Installation 1 3 AC Supply Source Considerations 1 4 General Grounding Requirements 1 6 Fuses and Circuit Breakers 1 7 Power Witte 3 2 sissies or tales c eae eater 1 9 Common Bus Precharge Notes 1 13 T O Wiring Recommendations 1 13 Start and Speed Reference Control 1 27 EMC Instructions 1 29 Prepare For Drive Start Up
96. ay 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 0 500 0 Hz Display 0 1 Hz 3 30 Programming and Parameters Advanced Program Group continued A088 Maximum Voltage Related Parameter s b004 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 Zo Max Derate 5 100 5 100 5100 3 5 5 S 80 ise 80 80 S 60 2 60 Z 60 40 40 40 8 3 3 3 20 3 20 8 20 2 10 2 0 20 0 25 50 75 100 125 150 175200 0 25 50 75 100 125 150 175200 0 25 50 75 100 125 150 175 200 of P032 Motor NP Hertz of P032 Motor NP Hertz of P032 Motor NP Hertz Programming a
97. ay 0 1 Hz 3 44 Programming and Parameters 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 a ore A142 Stp Logic 2 m A143 Stp Logic 3 A144 Stp Logic 4 Stop drive before changing this parameter A145 Stp Logic 5 A146 Stp Logic 6 A147 Stp Logic 7 Values Default 00F1 Min Max 0001 FAFF Display 4 Digits For detailed information on applying Step Logic and Position StepLogic refer to Appendix E and Appendix F Parameters A140 A147 are only active if P038 Speed Reference is set to 6 Stp Logic or 9 Positioning 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 or by using Bits 6 and 7 of E248 Enh Control Word 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
98. bit will have two parameter numbers when using RS485 communications and programming software 3 2 Programming and Parameters Parameter Organization Refer to page 3 66 for an alphabetical listing of parameters Basic Display Group Output Freq b001 Commanded Freq b002 Output Current b003 Basic Program Group Advanced Program Group Digital In1 Sel Digital In2 Sel Digital In3 Sel Digital In4 Sel Relay Out Sel Relay Out Level Opto Out Sel Opto Out1 Level Opto Out2 Sel Opto Out2 Level Opto Out Logic Analog Out Sel Analog Out High Accel Time 2 Decel Time 2 Internal Freq Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Preset Freq 4 Preset Freq 5 Preset Freq 6 Preset Freq 7 Enhanced Program Group A051 A052 A053 A054 A055 A056 A058 A059 A061 A062 A064 A065 A066 A067 A068 A069 A070 A071 A072 A073 A074 A075 A076 A077 LED Display Opt E201 Digital Term 3 E202 Accel Time 3 E203 Decel Time 3 E204 Accel Time 4 E205 Decel Time 4 E206 Advanced Display Group Output Voltage DC Bus Voltage Drive Status Fault 1 Code Fault 2 Code Fault 3 Code Process Display Control Source Motor NP Volts Motor NP Hertz Motor OL Current Jog Frequency Jog Accel Decel DC Brake Time DC Brake Level DB Resistor Sel S Curve Boost Select Start Boost Break Voltage Break Frequency Maximum Voltage Current Limit 1 Motor OL Select PWM Frequency Auto Rstrt Tries Auto Rstrt Delay Start At
99. cations Options 0 Ready idle Default 1 Reset Fault 2 Clear Buffer Parameters b007 b009 and d310 d316 Fault x Code A101 Program Lock Protects parameters against change by unauthorized personnel with a 4 digit password Options 0 Unlocked Default 1 Locked A102 Testpoint Sel Related Parameter s b019 Used by Rockwell Automation field service personnel Values Default 400 Min Max 400 FFFF Display 1 Hex 3 34 Programming and Parameters Advanced Program Group continued A103 Comm Data Rate Related Parameter s 0015 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 b015 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 A105 Comm Loss Action Related Parameter s b015 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 coa
100. changing this parameter Selects the encoder type For additional information refer to Appendix F Encoder None Pulse Train Single Chan Single Check Quadrature Quad Check E216 Option APUUN unintended speed or motion Take appropriate precautions to guard against possible ATTENTION The loss of analog input encoder or other feedback may cause A unintended speed or motion Values Default 0 Min Max 0 5 Display 1 E217 Motor NP Poles Defines the number of poles in the motor Values Default 4 Min Max 2 40 Display 1 E218 Encoder PPR Specifies the encoder pulses per revolution when an encoder is used For additional information refer to Appendix F Values Default 1024 Min Max 1 20000 Display 1 E219 Pulse In Scale Sets the scale factor gain for the Pulse Input when E216 Motor Fdbk Type is set to 1 Pulse Train For additional information refer to Appendix F Input Pulse Rate Desired Command Speed Command Values Default 64 Min Max 1 20000 Display 1 3 56 Programming and Parameters Enhanced Program Group continued E220 Ki Speed Loop Sets the Gain used in the PI calculation of the speed loop Values Default 2 0 Min Max 0 0 400 0 Display 0 1 E221 Kp Speed Loop Sets the P Gain used in the PI calculation of the speed loop Values Default 0 5 Min Max 0 0 200 0 Display 0 1 E222 Positioning M
101. city Control Settings Digit 3 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 Output 3 Accel Decel 1 On FWD 4 Accel Decel 1 On REV 5 Accel Decel 1 On No Output 6 Accel Decel 2 Off FWD T Accel Decel 2 Off REV 8 Accel Decel 2 off No Output 9 Accel Decel 2 On FWD A Accel Decel 2 On REV b Accel Decel 2 On No Output Positioning Settings Digit 3 Required Accel Decel StepLogic Direction Type Of Setting Param Used Output State From Home Command 0 Accel Decel 1 Off FWD Absolute 1 Accel Decel 1 Off FWD Incremental 2 Accel Decel 1 Off REV Absolute 3 Accel Decel 1 Off REV Incremental 4 Accel Decel 1 On FWD Absolute 5 Accel Decel 1 On FWD Incremental 6 Accel Decel 1 On REV Absolute 7 Accel Decel 1 On REV Incremental 8 Accel Decel 2 0 FWD Absolute 9 Accel Decel 2 Off FWD Incremental A Accel Decel 2 Off REV Absolute b Accel Decel 2 Off REV Incremental Cc Accel Decel 2 On FWD Absolute d Accel Decel 2 On FWD Incremental E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incremental Settings Digit 2 Settings Digit 1 and Digit 0 0 Jump to Step 0 1 Jump to Step 1 2 Jump to Step 2 3 Jump to Step 3 4 Jump to Step 4 5 Jump to Step 5 6 Jump to Step 6 7 Jump to Step 7 8 End Program Normal Stop 9 End Program Coast to Stop A End Program and Fault F2 0 Skip St
102. d Default 1 Enabled Programming and Parameters 3 15 Advanced Program Group A051 Digital Ini 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 Selects the function for the digital inputs I O Terminal 03 is fully programmable via E202 Digital Term 3 Refer to the flowchart on page 1 27 for more information on speed reference control priority Related Parameter s b012 b014 P038 P039 P040 A067 A068 A070 A077 A078 A079 A118 A140 A147 Stop drive before changing this parameter Options 0 Not Used Terminal has no function but can be read over network communications via b014 Dig In Status 1 Acc Dec Sel1 If active can determine which Accel Decel time will be used for all ramp rates except jog Can be applied to one input only Refer to A067 Accel Time 2 for details Can be used with option 28 Acc Dec Sel2 for additional Accel Decel times 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 Aux Fault When enabled an F2 Auxiliary Inout fault will occur when the input is removed
103. d local industrial safety regulations and or electrical codes may determine additional requirements for these installations Fusing The ratings in the table that follows are the 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 1 8 Installation Wiring Table 1 C Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Min Enclosure Rating kW HP Amps Protectors 3 MCS Contactors Volume Catalog No Catalog No Inches 240V AC 0 4 0 5 6 140M C2E B40 100 C07 1655 3 Phase 0 75 1 0 10 140M C2E C10 100 C09 1655 1 5 2 0 15 140M C2E C16 100 C12 1655 2 2 3 0 25 140M C2E C16 100 C23 1655 3 7 5 0 30 140M F8E C25 100 C23 1655 5 5 7 5 40 140M F8E C32 100 C37 2069 7 5 10 0 60 140M G8E C45 100 C60 2069 480V AC 0 4 0 5 3 140M C2E B25 100 C07 1655 3 Phase 0 75 1 0 6 140M C2E B40 100 C07 1655 1 5 2 0 10 140M C2E B63 100 C09 1655 2 2 3 0 15 140M C2E C10 100 C09 1655 4 0 5 0 20 140M
104. d write any desired position to step 0 and then toggle the input 1 bit of E248 Enh Control Word to cause the drive to move to the new position This allows almost unlimited flexibility and can be used with absolute or incremental moves Setup Notes The RA computer tools DriveExplorer and DriveTools SP can make setup of the positioning functions much easier Please refer to the latest versions for additional tools or wizards which can aid in the setup F 12 Encoder Usage and Position StepLogic Application Notes Appendix G PID Set Up PID Loop The PowerFlex 40P 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 the 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 G 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 4 or 5 This configuration does not require a mast
105. d308 Units Traveled H and d309 Units Traveled L indicate the current position of the system in terms of units away from Home Parameter d308 is the number value to the left of the decimal whole number and d309 is the number to the right of the decimal the portion less than 1 d301 Drive Status 2 Parameter d301 Drive Status 2 indicates the status of the positioning functions The indication bits are Bit 0 Dir Positive indicates the current direction the drive has moved from Home Bit 1 At Position indicates whether the drive is at its commanded position If the drive is within E225 Encoder Pos Tol of the commanded position this bit will be active Bit 2 At Home indicates whether the drive is at Home If the drive is within E225 Encoder Pos Tol of Home this bit will be active Bit 3 Drive Homed indicates whether the drive has been homed since power up This bit will be active once the drive has been homed either manually or automatically It will remain active until the next power down Use Over Communications If 8 steps are not adequate for the application or if dynamic program changes are required many of the positioning functions can be controlled via an active communication network The following parameters will allow this control E207 Comm Write Mode Repeated writes to parameters over a communication network can cause damage to the drive EEPROM This parameter allows the drive t
106. 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 power 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 A Senna re 1 14 Installation Wiring Signal and Control Wire Types Table 1 F Recommended Signal Wire Signal Type Belden Wire Type s J Min Insulation Where Used or equivalent Description Rating TA T APIA OSEAIG
107. ddr 8193 14 13 12 100 A070 Preset Freq 0 101 A071 Preset Freq 1 110 A072 Preset Freq 2 111 A073 Preset Freq 3 15 Not Used RS485 DSI Protocol C 5 Position Bit Definitions Logic Command E249 1 Position 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 54 01 Forward Command 10 Reverse Command 11 No Command 6 1 Logic In 1 7 1 Logic In 2 000 A070 Freq Source E230 Position Source 8192 001 A071 Freq Source E232 Position Source 010 A072 Freq Source E234 Position Source 1098 011 A073 Freq Source E236 Position Source a 100 A074 Freq Source E238 Position Source 101 A075 Freq Source E240 Position Sourcec 110 A076 Freq Source E242 Position Source 111 A077 Freq Source E244 Position Source 11 1 Find Home 12 1 Hold Step 13 1 Pos Redefine 14 1 Sync Enable 15 1 Traverse Disable Writing 06 Reference The Speed Reference to a PowerFlex 40P 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 Comm Port in order to accept the Speed Reference Reference Address Decimal Description A decimal value entered as xxx xx where
108. des will appear in these parameters in the order they occur 007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will be moved to Fault 9 Code and this parameter will be overwritten by Fault 7 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d315 Fault 9 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the ninth most recent drive fault The codes will appear in these parameters in the order they occur 007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will be moved to Fault 10 Code and this parameter will be overwritten by Fault 8 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d316 Fault 10 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the tenth most recent drive fault The codes will appear in these parameters in the order they occur 007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will overwritten by Fault 9 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 3 66 Programming and Parameters Param
109. display LED Indications See page 2 3 for information on drive status indicators and controls Faults A fault is a condition that stops the drive There are two fault types Table 4 4 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 The integral LED display provides visual Pe yo vy ae of a fault condition by displaying the ed i L J A e Flashing fault number e Flashing fault indicator Press the Up Arrow key to regain control of the display Manually Clearing Faults Step Key s 1 Address the condition that caused the fault The cause must be corrected before the fault can be cleared See Table 4 B After corrective action has been taken clear the fault by one of these methods e Press and hold the Up Arrow key for three seconds A e Cycle d
110. e 3 15 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 Inductor not connected Inductor 4 10 Troubleshooting Notes Appendix A Supplemental Drive Information For information on Drive Fuse amp Circuit Breaker Ratings A 1 Specifications A 2 Drive Fuse amp Circuit Breaker Ratings The tables on the following pages provide recommended AC line input fuse and circuit breaker information See Fusing and Circuit Breakers below for UL and IEC requirements Sizes listed are the recommended sizes based on 40 C 104 F and the U S N E C Other country state or local codes may require different ratings Fusing The recommended fuse types are listed below If available current ratings do not match those listed in the tables provided choose the next higher fuse rating e IEC BS88 British Standard Parts 1 amp 2 EN60269 1 Parts 1 amp 2 type gG or equivalent should be us
111. e Step Logic 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 Relay 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 Programming and Parameters 3 19 A055 19 Anlg In Loss Analog input loss has occurred Program A122 Analog In Options Loss for desired action when input loss occurs Cont 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 Cntr EM brake is energized Program A160 EM Brk Off Delay and A161 EM Brk On Delay for desired action 23 At Position The drive is in Positioning mode and has reached the commanded position Tolerance is adjusted with E225 Encoder Pos Tol 24 At Home The drive is in Positioning mode and has reached the home position Tolerance is adjusted with E225 Encoder Pos Tol 25 Safe Off The DriveGuard Safe Off option is installed and both safe off inputs are active A056 Relay Out Level Related Parameter s A055 A058 A061 7 32 bit parameter Set
112. e Table 1 1 The drive will always coast to a stop regardless of the settings of P036 Start Source and P037 Stop Mode 4 If I O Terminal 01 is used as hardware enable and 3 wire control is needed program one of the digital inputs for the desired stop mode MUA Installation Wiring 1 21 The DriveGuard Safe Off Option Series B board when used with suitable safety components provides protection according to EN ISO 13849 1 2008 AC 2009 Performance Level d Safety Category 3 for safe off and protection against restart The PowerFlex safe off option is just one safety control system All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding Refer to the DriveGuard Safe Off Option Series B User Manual publication PFLEX UM003 for detailed installation information install a Series B or greater DriveGuard Safe Off Option in a PowerFlex i ATTENTION Hazard of injury exists due to electric shock Only 40P Drive Important When using the DriveGuard Safe Off Option Series B with the drive in an IP30 NEMA 1 UL Type 1 installation only use low voltage Class 2 circuits Table 1 K_Safe Off Option Terminal Description No Signal Description 4 24V Common f 3 424V DC Connections for user supplied power to energize coil 2 Commo
113. e cooling for the drive power components as well as a flat and clean surface for a proper thermal interface General Requirements The drive is designed to operate with the drive enclosed and the heatsink exposed for improved cooling Therefore it is expected that the drive control section will experience a higher ambient temperature than the heatsink Table H A Maximum Surrounding Air Temperature Heatsink 40 C 104 F Drive 50 C 122 F Note that the standard 480V 11 kW 15 HP drive includes an internal inductor This inductor cannot be included in the plate drive Therefore this rating requires the use of an external DC inductor or an AC input reactor as described in Table B E on page B 3 Plate Drive Installation Instructions Heatsink Thermal Capacity The heatsink provided must have the thermal capacity to cool the drive under worst case loading conditions as well as for short duration overload conditions in the application Refer to Table A C on page A 5 for estimated watts loss data Table H B Required Heatsink Degrees C W Capabilities Plate Drive Input Voltage kW HP Heatsink C W Needed 230V AC 0 4 0 5 1 59 0 75 1 0 0 88 1 5 2 0 0 56 2 2 3 0 0 35 3 7 6 0 0 23 5 5 7 5 0 18 7 5 10 0 13 460V AC 0 4 0 5 2 06 0 75 1 0 1 17 1 5 2 0 0 73 2 2 3 0 0 47 3 7 5 0 0 26 5 5 7 5 0 25 7 5 10 0 20 11 15 0 13 Figure H 1 Approxim
114. e 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 cases ATTENTION Risk of injury or equipment damage exists Drive does not contain user serviceable components Do not disassemble drive chassis P 4 Overview Catalog Number Explanation 1 3 4 5 6 8 9 10 11 12 13 14 22D AA Optional Code ode Version 22D PowerFlex 40P 4 Standard Code EMC Filter Code Voltage Ph 0 Not Filter B 240V AC 3 D 480VAC 3 E 600VAC 3 Code HIM Version 1 Display Fault Reset Only 2 Display Fault Reset Only Plate Drive Code Purpose AA Reserved for thru custom firmware ZZ Code Enclosure N Panel Mount IP 20 NEMA Type Open F Flange Mount IP 20 NEMA Type Open H Plate Drive IP 20 NEMA Type Open Output Current 200 240V Input Output Current 380 480V Input Output Current 460 600V Input Code Amps kW HP Code Amps kW HP Code Amps kW HP 2P3 23 0 4 0 5 1P4 14 0 4 0 5 1P7 17 0 75 10 5PO 5 0 0 75 1 0 2P3 23 0 75 1 0 3PO 30 15 2 0 8PO 8 0 1 5 2 0 4PO 40 15 2 0 4P2 42 22 3 0 02 12 22 3 0 6PO 6 0 22 3 0 6P6 6 6 4 0 5 0 017 175 37 5 0 010 10 5 4 0 5 0 9P9 9 9 5 5 7 5 024 24 55 7 5 012 12 5 5 75 012 12 75 10 033 33 7 5 10 07 17 75 10 09 19 11 15 024 24 11 15 Additional accesso
115. e will Start and Run at Jog Speed Direction comes from 1 O Terminal 03 Dir Run REV or Jog Forward Jog Reverse command Comm Select Input Enabled and Active Digital Inx Sel 6 Start Speed and Direction commands come from RS485 DSI port 0 10V Override Enabled and Active Digital Inx Sel 13 Speed commands come from 0 10V or 10 10V Start and Direction follows P036 Start Source or Bi Polar input when enabled 4 20mA Override Enabled and Active Digital Inx Sel 14 Speed commands come from 4 20mA Start and Direction follows P036 Start Source P038 Speed Reference 4o0r5 Run as specified by P038 Speed Reference Start and Direction commands come from P036 Start Source All Results A051 A052 A053 Preset Inputs Active Run as specified by A071 A077 Preset Freq 1 7 Start and Direction commands come from P036 Start Source Encoder Enabled P038 8 or A132 9 PID Enabled A132 PID Ref Sel 0 Yes Run as specified by A132 PID Ref Sel Start and Direction commands come from P036 Start Source Encoder Type Selected A216 Motor Fdbk Type Yes 1 27 No change in control Run according to Priority Checklist Speed Commands as defined Encoder provides trim No change in direction control Run as specified by P038 Speed Refere
116. e 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 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 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
117. ea Fle aoe tycoon cays H 4 Preface Overview The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex 40P 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 p2 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 Application Installation and F Maintenance of Solid State www rockwellautomation com Control literature A Global Reference Guide for 100 2 10 Reading Schematic Diagrams Guarding Against Electrostatic 8000 4 5 2 Damage DriveGuard Safe Off Option PFLEX UMO003 Series B for PowerFlex AC Drives P 2 Overview Manual Conventions e In this manual we refer to the PowerFlex 40P Adjustable Fre
118. ed e UL UL Class CC T or J must be used Circuit Breakers The non fuse listings in the following tables include inverse time circuit breakers instantaneous trip circuit breakers motor circuit protectors and 140M self protected combination motor controllers If one of these is chosen as the desired protection method the following requirements apply e IEC Both types of circuit breakers and 140M self protected combination motor controllers are acceptable for IEC installations e UL Only inverse time circuit breakers and the specified 140M self protected combination motor controllers are acceptable for UL installations 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 2 Typical designations include Type CC KTK R FNQ R Type J JKS LPJ Type T JJS JUN A 2 Supplemental Drive Information Specifications Table A A Drive Ratings Catalog Output Ratings Input Ratings Branch Circuit Protection Number Voltage 140M Motos Min Engjpsurg kW HP Amps Range kVA Amps Fuses Protectors 9 Contactors Volume in 200 240V AC 10 3 Phase Input 0 230V 3 Phase Output 22D B2P3 0 4 0 5 2 3 180 264 1 15 2 5 6 140M C2E B40 100 C07 1655 22D B5P0 0 75 1 0 5 0 180 264 2 45 5 7 10 140M C2E C10 100 C09 1655 22D B8P0 1 5 2 0 8 0 180 264 4 0 9 5 15 140M C2E C16
119. ed properly Check the control input signals 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 Verify that I O Terminal 01 is active Verify that P036 Start Source matches your configuration Verify that A095 Reverse Disable is not prohibiting movement If using the DriveGuard Safe Off Option Series B board verify that inputs are active o Improper boost setting at initial start up None Set A084 Boost Select to option 2 35 0 VT Drive is Faulted Flashing red status light Clear fault Press and hold Up Arrow key for 3 seconds Cycle power Set A100 Fault Clear to option 1 Clear Faults Cycle digital input if A051 A054 Digital Inx Sel is set to option 7 Clear Fault Troubleshooting 4 7 Drive does not Start from Start or Run Inputs wired to the terminal block Cause s Indication Corrective Action Drive is Faulted Flashing red status light Clear fault e Press and hold Up Arrow key for 3 seconds 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 None Check parameter settings e P036 Start Source is set to option 5 Comm Port Incorrect input wiring None Wire inputs correctly
120. el Time 2 Decel Time 2 1 1 0 A073 E236 Accel Time 2 Decel Time 2 0 0 1 A074 E238 Accel Time 1 Decel Time 1 1 0 1 A075 E240 Accel Time 1 Decel Time 1 0 1 1 A076 E242 Accel Time 2 Decel Time 2 1 1 1 A077 E244 Accel Time 2 Decel Time 2 aay 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 00 Hz Min Max 0 00 Maximum Freq Display 0 01 Hz 3 26 Programming and Parameters 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 A051 A054 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 A051 A054 Defines the maximum DC brake current in amps applied to the motor when P037 Stop Mode is set to either option 4 Ramp or 6 DC Brake Values Default Drive Rated Amps x 0 05 Min Max 0 0 Drive
121. elerating 0 Not Accelerating 5 1 Decelerating 0 Not Decelerating 6 1 Forward Travel Position 0 Reverse Travel Position 8448 7 1 Faulted 0 Not Faulted 8 1 At Speed 0 Not At Speed 9 1 At Position 0 Not At Position 10 1 At Home 0 Not At Home 11 1 Drive Homed 0 Not Drive Homed 12 1 Sync Hold 0 Not Syc Hold 13 1 Sync Ramp 0 Not Syc Ramp 14 1 Traverse On 0 Traverse Off 15 1 Traverse Decel 0 Not Trav Decel RS485 DSI Protocol C 7 Reading 03 Feedback The Feedback Output Frequency from the PowerFlex 40P 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 Reading 03 Drive Error Codes The PowerFlex 40P Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 Drive Error Codes Logic Status Address Decimal Value Decimal Description 0 No Fault 2 Auxiliary Input 3 Power Loss 4 Undervoltage 5 Overvoltage 6 Motor Stalled 7 Motor Overload 8 Heatsink Overtemperature 12 HW Overcurrent 300 13 Ground Fault 29 An
122. energized the pre charge relay will open and the drive will coast to a stop 30 Inertia Dcel Forces drive into Inertia Ride Through state The drive will attempt to regulate the DC bus at the current level 31 Sync Enable Must be used in order to hold the existing frequency when Sync Time is set to enable speed synchronization When this input is released the drive will accelerate to the commanded frequency in E214 Sync Time 32 Traverse Dis When an input is programmed the traverse function will be disabled while this input is active Refer to E210 Max Traverse 33 Home Limit In Positioning mode this indicates the drive is at the home position Refer to Appendix F for detailed information on positioning 34 Find Home In Positioning mode this causes the drive to return to the Home position when a start is issued It does this by using the Find Home Freq and Find Home Direction until the Home Limit input is activated If it passes this point it then runs in the reverse direction at 1 10th the frequency of Find Home Freq until the Home Limit is activated again As long as this input is active any start command will cause the drive to enter the homing routing Only functions if in Positioning mode Once the Find Home routine has finished the drive will stop Refer to Appendix F for detailed information on positioning 35 Hold Step In Positioning
123. ent 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 Plate Drive Installation For Plate drive installation instructions refer to Appendix H 1 4 Installation Wiring AC Supply Source Considerations Ungrounded Distribution Systems are referenced to ground These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system ATTENTION PowerFlex 40P drives contain protective MOVs that 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 ae Tighten screw after jumper removal oo we i Figure 1 2 Phase to Ground MOV Removal Three Phase AC Input S L2 T L3 h Jumper 1 2 3 4 Installation Wiring 1 5 Input Power Conditioning The drive is suitable for direct connection to
124. ep Jump Immediately 1 Step Based on Stp Logic Time x 2 Step if Logic In1 is Active 3 Step if Logic In2 is Active 4 Step if Logic In1 is Not Active 5 Step if Logic In2 is Not Active 6 Step if either Logic In1 or Logic In2 is Active 7 Step if both Logic In1 and Logic In2 is Active 8 Step if neither Logic In1 or Logic In2 is Active 9 Step if Logic In1 is Active and Logic In2 is Not Active 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 47 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 E222 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 or if using E222 Positioning Mode set to 0 Values Default 30 0 Secs Min Max 0 0 6553 5 Secs Display 0 1 Secs A160 EM Br
125. er reference only a desired set point such as a flow rate for a pump PID Loop 1 PID Ref gt PID Prop Gain PID 4 4 PID _ Error Output PID Fdbk PID Integ Time gt a ee a b gt Come I t _ gt PID Diff Rate pid Enabiad Example In a pumping application the PID Reference equals the Desired System Pressure set point 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 The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow When the PID Control Loop is disabled the Commanded Speed is the Ramped Speed Reference PID Feedback Pressure Transducer Signal PID Reference Desired System Pressure PIDSetUp G3 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 6 7 8 9 or 10 P038 Speed Reference PID Loop l Accel Decel Ramp l I 1 _PID Ref gt PID Prop Gain i Po O PID i I l l I
126. ers 328 feet 5 meters 16 feet 1 Refer to Appendix B for details on optional external filters 2 Equivalent to EN55011 Class A 8 Equivalent to EN55011 Class B To meet radiated emissions requirements for EN61800 3 2004 A1 2012 First Environment Unrestricted Distribution when communications is used ferrite cores need to be added to the communication lines The recommended core is Fair Rite part number 0446176451 or Erocore part number FH29 7x13x25 9 FH1300 or an equivalent core The communication line must be wrapped a total of three times around the core Two cores may be needed depending on the thickness of the wire and the core chosen Both recommended cores are split type and can be added to an existing installation Figure 1 8 Connections and Grounding r i Shielded Enclosurel l IP 30 NEMA 1 UL Type 1 l Option Kit l l PowerFex a y EMI Fittings and Metal Conduit EMI Filter l m a 2 Lo BB 3o g 3 y E ve o mst Enclosure Ground Connection Shielded Motor Cable Building Structure Steel 1 First Environment Unrestricted Distribution installations require a shielded enclosure Keep wire length as short as possible between the enclosure entry point and the EMI filter Installation Wir
127. es Default 10 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs P035 Maximum Freq 0 P039 A067 i P040 A068 E203 or E205 a mme E204 or E206 a Accel Time x Decel Time x 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 0 600 0 Secs Display 0 1 Secs P035 Maximum Freq o P039 A067 7 P040 A068 E203 or E205 a mme E204 or E206 ka Accel Time x Decel Time x 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 3 14 Programming and Parameters Basic Program Group continued 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 Disable
128. eset frequency parameter defines the maximum frequency the drive will run at during the corresponding step For example if Preset Freq 2 is set to 40Hz the drive will accelerate to 40Hz maximum when moving to Position 2 Frequency Source Step Source Position Source A070 Preset Freq 0 A140 Step Logic 0 E230 Step Units 0 A071 Preset Freq 1 A141 Step Logic 1 E232 Step Units 1 A072 Preset Freq 2 A142 Step Logic 2 E234 Step Units 2 A073 Preset Freq 3 A143 Step Logic 3 E236 Step Units 3 A074 Preset Freq 4 A144 Step Logic 4 E238 Step Units 4 A075 Preset Freq 5 A145 Step Logic 5 E240 Step Units 5 A076 Preset Freq 6 A146 Step Logic 6 E242 Step Units 6 A077 Preset Freq 7 A147 Step Logic 7 E244 Step Units 7 Important The default value for A070 Preset Freq 0 is 0 00 Hz This value needs to be changed or the drive will not be able to move during Step 0 A150 A157 Stp Logic Time x In Positioning mode each Step Logic Time parameter defines the time the drive will remain in each corresponding step if that step is time based For example if A152 Stp Logic Time 2 is set to 5 0 seconds and that step is time based the drive will remain in Step 2 for 5 0 seconds Note that this is the total time in that step not the time at that position Therefore it will include the time needed to accelerate run and decelerate to that position Encoder Usage and Positio
129. eter Cross Reference by Name Parameter Name No Group 10V Bipolar Enbl A123 Advanced Program Accel Time 1 P039 Basic Program Accel Time 2 A067 Advanced Program Accel Time 3 E203 Enhanced Program Accel Time 4 E205 Enhanced Program Analog In 0 10V b020 Display Analog In 4 20mA b021 Display Analog In Loss A122 Advanced Program Analog Out High A066 Advanced Program Analog Out Sel A065 Advanced Program Anlg In 0 10V Hi A111 Advanced Program Anlg In 0 10V Lo A110 Advanced Program Anlg In4 20mA Hi A113 Advanced Program Anlg In4 20mA Lo A112 Advanced Program Anlg Out Setpt A109 Advanced Program Auto Rstrt Delay A093 Advanced Program Auto Rstrt Tries A092 Advanced Program Autotune A127 Advanced Program Boost Select A084 Advanced Program Break Frequency A087 Advanced Program Break Voltage A086 Advanced Program Bus Reg Mode A117 Advanced Program Cmd Stat Select E249 Enhanced Program Comm Data Rate A103 Advanced Program Comm Format A107 Advanced Program Comm Loss Action A105 Advanced Program Comm Loss Time A106 Advanced Program Comm Node Addr A104 Advanced Program Comm Status b015 Display Comm Write Mode E207 Enhanced Program Commanded Freq b002 Display Compensation A097 Advanced Program Contrl In Status b013 Display Control Source b012 Display Control SW Ver b016 Display Counter Status b025 Display Counts Per Unit E226 Enhanced Program Current Limit x A089 A118 Advanced Program DB Resistor Sel A082 Advanced Program DB Threshold
130. 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 Countr A055 Relay Out Sel set to 17 to select Counter Out A0560 Relay Out Level set to 5 0 Counts Velocity StepLogic Basic Logic and Timer Counter Functions E 7 Velocity StepLogic Parameters 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
131. g for the resistor selected E217 Motor NP Poles must be set to match the number of motor poles on the motor driven by the PowerFlex 40P drive E218 Encoder PPR must be set to match the number of pulses per revolution of the encoder used i e 1024 PPR Encoder E226 Counts Per Unit sets the number of encoder counts that will be used to define one position unit This allows the encoder positions to be defined in terms of units important to the application For example if 1cm of travel on a conveyor belt requires 0 75 turns of the motor the motor encoder is 1024 PPR and the Motor Feedback type is set to Quadrature then this parameter would need to be set to 4 x 1024 x 0 75 3072 counts for 1cm of travel Then all other positions could be setup in units of cm E225 Encoder Pos Tol indicates the desired position tolerance for the system This will determine how close the drive must be to the commanded position before the drive will indicate At Home or At Position in units of raw encoder pulses This has no effect on the actual positioning control of the motor Encoder Usage and Position StepLogic Application F 5 Positioning Operation Parameter E222 Positioning Mode must be set to properly match the desired operation of the positioning function E222 Positioning Mode Options 0 Time Steps uses Step Logic times This mode ignores the Step Logic settings and moves through the steps Step 0 to Step
132. ge at I O Terminal 13 100 0 10 volts Values Default Read Only Min Max 0 0 100 0 Display 0 1 b021 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 b022 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 b023 Output Powr Fctr The angle in electrical degrees between motor voltage and motor current Values Default Read Only Min Max 0 0 180 0 deg Display 0 1 deg 3 8 Programming and Parameters Basic Display Group continued b024 Drive Temp Present operating temperature of the drive power section Values Default Read Only Min Max 0 120 degC Display 1 degC b025 Counter Status The current value of the counter when counter is enabled Values Default Read only Min Max 0 9999 Display 1 b026 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 b028 Stp Logic Status When P038 Speed Reference is set to 6 Stp Logic or 9 Positioning this parameter will display the current step of the Step Logic profile as defined by parameters A140 A147 Stp Logic x Values Default Read Only Min
133. gh the Step Logic functions speed or position via comms control without requiring actual digital input transitions 7 Logic In 2 This provides and identical function as the Logic In2 Digital Input option This bit is logically ORed with a digital input A051 A054 set to option 24 Logic In2 It can be used to move through the Step Logic functions speed or position via comms control without requiring actual digital input transitions Programming and Parameters 3 61 Enhanced Program Group continued E249 Cmd Stat Select Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network For additional information refer to Appendix C Options 0 Velocity Default 1 Position 3 62 Programming and Parameters Advanced Display Group d301 Drive Status 2 Present operating condition of the drive When in Positioning mode Bit 10 indicates positive or negative position in relation to Home OGG l 1 Condition True 0 Condition False Dir Positive Bit 0 At Position Bit 1 At Home Bit 2 Drive Homed Bit 3 Values Default Read Only Min Max 0 1 Display 1 d302 Fibers Status Present status of the Fibers features MINI LI LIIL L l 1 Condition True 0 Condition False Sync Hold Digit 1 Sync Ramp Digit 2 Traverse On Digit
134. gic Int gt Logic In2 gt Time Velocity 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 Level are used to set the desired time in seconds Parameters A055 Relay Out Sel A058 Opto Out1 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
135. gramming and Parameters 3 41 Advanced Program Group continued 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 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 Hz Min Max 0 0 500 0 Hz Display 0 1 Hz 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 Hz Min Max 0 0 500 0 Hz Display 0 1 Hz 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 Encoder Encoder or Pulse Train Setpnt Trim 0 10V Trim 4 20mA Trim Oo oo NI DD oy A O N Comm Trim 10 Encoder Trim Encoder or Pulse Train 3 42 Programming and Parameters Advanced Program Group continued A133 PID Feedback Sel Select the source of the PID feedback Refer to Appendix F for details unintended speed or motion Take appropriate precautions to guard against possible ATTENTION The loss of analog input
136. gt I 40 6 1 60 7 J pp U e Hay 22 2 i boo O S 3 44 z O E EH E 6 61 J l T 1 Lee eat OC OO Sos o O Chum e Frame B 22 JBAB k 192 0 7 56 lt 130 0 5 1 lt 180 0 7 1 gt pa e Aa ee lt 107 0 4 21 285 HHI pe 66 0 2 60 1 12 ai _ 24 0 0 94 22 2 12 6 ie Can 260 10 2 246 9 7 JUUUVUU UUL 152 2 5 99 be m 111 2 4 cE 4 38 U 4 y Frame C 22 JBAC B 8 Accessories and Dimensions Figure B 2 IP 30 NEMA 1 UL Type 1 Option Kit with Communication Option Dimensions are in mi lt 77 5 3 05 50 0 1 97 Jee ie 22 5 0 89 lt 100 0 3 94 lt 87 0 3 43 llimeters and inches 161 0 6 34 lt _ 136 0 5 35 _ o P Jx
137. hanced Program Power Loss Mode E208 Enhanced Program Preset Freq x A070 A077 Advanced Program Process Display b010 Display Process Factor A099 Advanced Program Process Time Hi A116 Advanced Program Process Time Lo A115 Advanced Program Program Lock A101 Advanced Program Pulse In Scale E219 Enhanced Program PWM Frequency A091 Advanced Program Relay Out Level A056 Advanced Program Relay Out Sel A055 Advanced Program Reset To Defalts P041 Basic Program Reverse Disable A095 Advanced Program S Curve A083 Advanced Program Skip Freq Band A120 Advanced Program Skip Frequency A119 Advanced Program Slip Hertz FLA A114 Advanced Program Slip Hertz Meter d303 Advanced Display Speed Feedback d304 Advanced Display Speed Feedback F d305 Advanced Display Speed Ratio E215 Enhanced Program Speed Reference P038 Basic Program Stall Fault Time A121 Advanced Program Start At PowerUp A094 Advanced Program Start Boost A085 Advanced Program Start Source P036 Basic Program Step Units 0 E230 Enhanced Program Step Units 1 E232 Enhanced Program Step Units 2 E234 Enhanced Program Step Units 3 E236 Enhanced Program Step Units 4 E238 Enhanced Program Step Units 5 E240 Enhanced Program Step Units 6 E242 Enhanced Program Step Units 7 E244 Enhanced Program Step Units F 0 E231 Enhanced Program Step Units F 1 E233 Enhanced Program Step Units F 2 E235 Enhanced Program Step Units F 3 E237 Enhanced Program Step Units F 4 E239 Enhanced Program Step Units F 5 E241 Enhanced
138. he 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 the output level the output will change state The counter can be reset via a digital input programmed as Reset Counter E 2 Velocity StepLogic Basic Logic and Timer Counter Functions Velocity 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 Step 6 Step7 a Forward Ob Reverse v Time Velocity 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
139. in power etc for other Rockwell Automation peripheral devices Wiring terminations on the master controller will vary depending on the master controller used and TxRxD and TxRxD are shown for illustration purposes only Refer to the master controller s user manual for network terminations Note that there is no standard for the and wires and consequently Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wires at the master controller Standard RS485 wiring practices apply e Termination resistors need to be applied at each end of the network cable e RS485 repeaters may need to be used for long cable runs or if greater than 32 nodes are needed on the network e Network wiring should be separated from power wires by at least 0 3 meters 1 foot e Network wiring should only cross power wires at a right angle T O Terminal 19 DSI Shield on the PowerFlex 40P must also be connected to PE ground there are two PE terminals on the drive See Table 1 I for more information Network Common is internally tied to I O Terminal 04 Digital Common Tying I O Terminal 04 to PE ground may improve noise immunity in some applications RS485 DSI Protocol Parameter Configuration The following PowerFlex 40P parameters are used to configure the drive to operate on a network Parameter
140. inating Resistor end of network i or i U or Customer supplied RJ45 male to RJ45 male cables with wires connected at pins 4 and 5 only Both the Master M and Slave S ports on the RJ45 Splitter Cable operate as standard RS 485 ports in this configuration Appendix E Velocity StepLogic Basic Logic and Timer Counter Functions Four PowerFlex 40P logic functions provide the capability to program simple logic functions without a separate controller Velocity 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 t
141. ing 1 31 EN61000 3 2 0 75 kW 1 HP 240V 3 Phase drives are suitable for installation on a private low voltage 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 32 Installation Wiring Notes Chapter 2 Start Up This chapter describes how to start up the PowerFlex 40P 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
142. ions Output Disconnect The drive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used If it is necessary to disconnect power to the motor with the drive outputting power an auxiliary contact should be used to simultaneously disable drive control run commands 1 12 Installation Wiring Power Terminal Block The power terminal block is covered by a finger guard To remove 1 Press in and hold the locking tab 2 Slide finger guard down and out Replace the finger guard when wiring is complete Figure 1 4 Power Terminal Block Typical ail B Frame C Frame R Li S L2 T L3 U M1 V T2 W T3 R L1 S L2 T L3 UMi V T2 WT3 P2 Pt SOS falas SSIS DC DC BR BR 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 Switch any two motor V T2 To Motor V T2 D leads to change GG forward direction W T3 To Motor W T3 DC Bus Inductor Connection C F ra Frame drives only The C Frame drive is shipped with a jumper between U U P
143. itional Information C 8 Connectivity Guidelines D 1 DSI Cable Accessories D 2 Connecting One Temporary Peripheral D 3 Connecting One Temporary Peripheral and One Permanent Peripheral D 3 Connecting Two Permanent Peripherals D 4 Connecting an RS 485 Network D 4 Velocity StepLogic Basic Logic and Timer Counter Functions Velocity StepLogic Using Timed Steps E 2 Velocity StepLogic Using Basic Logic Functions 0 00000 ce eee eee E 3 Timer Function 0 0005 E 4 Counter Function 00 E 6 Encoder Usage and Position StepLogic Application PID Set Up Plate Drive Installation Instructions Encoder Usage 0 00005 F 1 Wiring Notes 0 000000005 F 2 Positioning Overview F 2 Common Guidelines for All Applications F 3 Positioning Operation F 5 Homing Routine F 8 Encoder and Position Feedback F 9 Use Over Communications F 10 Setup Notes 00000 F 11 PID LO0p cn ci wie caine Waa es G 1 PID Reference and Feedback G 4 Analog PID Reference Signals G 5 Introduction 0 00 000005 H 1 General Requirements H 1 Heatsink Thermal Capacity H 2 Heatsink Surface and Flatness Requirements H 3 Mounting Dimensions and Requirements H 4 VerifiCation n ppr a
144. k Off Delay 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 Cntrl to control brake operation Values Default 2 00 Secs Min Max 0 01 10 00 Secs Display 0 01 Secs Frequency Minimum Freq gt a M Time A M A Start EM Brk Stop EM Brk Drive Stops Commanded Energized Off Commanded De Energized On 3 48 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 Cntrl 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
145. king properly remove power to the drive and swap the A and A NOT encoder channels or swap any two motor leads Drives using FRN 2 xx and greater will fault when an encoder is incorrectly wired and E216 Motor Fdbk Type is set to option 5 Quad Check Installation Wiring 1 19 Figure 1 6 Sample Encoder Wiring 1 0 Connection Example 1 0 Connection Example Encoder 12V DC Encoder Power w jopa Power Internal Drive S amei External Power B HOT odole Power Internal drive H Source 12V DC us 250mA Encoder Encoder Signal Signal Single Ended 44 S Differential amp Dual Channel 2 16 Dual B B HO Channel 8 A NO A a Ne A to SHLD Figure 1 7 Encoder Wire Routing Options IP20 Open Type 1 20 Installation Wiring Hardware Enable Circuitry T O Terminal 01 is always a stop input The status of this input is interpreted by drive software If the application requires the drive to be disabled without software interpretation a hardware enable configuration can be utilized This is done by removing the ENBL enable jumper and wiring the enable input to I O Terminal 1 see below 1 Remove drive cover as described on page 1 1 2 Locate and remove the Enable Jumper on the Main Control Board see diagram 3 Wire Enable to I O Terminal 1 se
146. le 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 A 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 Manual Updates The information below summarizes the changes to the PowerFlex 40P User Manual since the June 2013 release Description of New or Updated Information Replaced ISO 13849
147. lication 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 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 Rating Type 600V 90 C 194 F XHHW2 RHW 2 Anixter B209500 B209507 Description e Four tinned copper conductors with XLPE insulation e Copper braid aluminum foil combination shield and tinned copper drain wire Belden 29501
148. log 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 37 Advanced Program Group continued A113 Anlg In4 20mA Hi Related Parameter s b021 P035 P038 Stop drive before changing this parameter 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 E216 Compensates for the inherent slip in an induction motor This frequency is added to the commanded output frequency Values Default 2 0 Hz Min Max 0 0 10 0 Hz Display 0 1 Hz A115 Process Time Lo Related Parameter s b010 P034 Scales the time value when the drive is running at P034 Minimum Freq When set to a value other than zero b010 Process Display indicates the duration of the process Values Default 0 00 Min Max 0 00 99 99 Display 0 01 A116 Process Time Hil Related Parameter s b010 P035 Scales the time value when the drive is running at P035 Maximum Freq When set to a value other than zero b010 Process Display indicates the duration of the process Values Default 0 00 Min Max 0 00 99 99 Display
149. m P039 Accel Time 1 or A067 Accel Time 2 Excess load or short None Compare b003 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 b002 Commanded Freq value is not as expected Check b012 Control Source for the proper Speed Command Programming is preventing the None Check P035 Maximum Freq to drive output from exceeding insure that speed is not limited by limiting values programming Verify programming of E215 Speed Ratio 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 Motor operation is unstable Troubleshooting 4 9 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 pag
150. meters A055 A058 A061 Options 11 14 May be used in conjunction with Step Logic parameters A140 A147 Stp Logic x Logically ORed with 248 Enh Control Word bit 7 Logic In 2 25 Current Lmt2 When active A118 Current 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 Hi 27 EM Brk Rise If EM brake function is enabled this input releases the brake Refer to A160 EM Brk Off Delay for additional information material exists an auxiliary mechanical braking device must be used ATTENTION Ifa hazard of injury due to movement of equipment or 28 Acc Dec Sel2 If active can determine which Accel Decel time will be used for Option all ramp rates except jog Canbe 9g Description applied to one input only Used with option 1 Acc Dec Sel1 for 9 10 Acc Dec 1 the Accel Decel times listed in O 1 Acc Dec 2 this table 1 0 Acc Dec 3 1 1 Acc Dec 4 A051 A054 Options Cont 29 Precharge En Programming and Parameters 3 17 Forces drive into precharge state Typically controlled by auxiliary contact on the disconnect at the DC input to the drive If this input is assigned it must be energized for the pre charge relay to close and for the drive to run If itis de
151. mode this input over rides other inputs and causes the drive to remain at its current step running at zero speed once it reaches its position until released While in Hold the drive will ignore any input command which would normally result in a move to a new step Timers continue to run Therefore when the Hold is removed the drive must see any required digital inputs transition even if they already transitioned during the hold but it does not reset any timer Refer to Appendix F for detailed information on positioning 36 Pos Redefine In Positioning mode this input resets the home position to the current position of the machine Refer to Appendix F for detailed information on positioning 3 18 Programming and Parameters Advanced Program Group continued 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 Relay changes state when power is applied This indicates Default that the drive is ready for operation Relay returns drive to shelf state when power is removed or a fault occurs 1 At Frequency Drive reaches commanded frequency 2 MotorRunning Motor is receiving power from the drive 3 Reverse Drive is commanded to run in reverse direction 4 Motor Overld Motor overload condition exis
152. motor speed Values Default Read Only Min Max 0 0 0 9 Display 0 1 d308 Units Traveled H Related Parameter s d309 E226 7 32 bit parameter Displays the number of user defined units whole number portion traveled from the home position Values Default Read Only Min Max 0 64000 Display 1 d309 Units Traveled L Related Parameter s d308 E226 Displays the number of user defined units fractional portion traveled from the home position Values Default Read Only Min Max 0 00 0 99 Display 0 01 3 64 Programming and Parameters d310 Fault 4 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the fourth most recent drive fault The codes will appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will be moved to Fault 5 Code and this parameter will be overwritten by Fault 3 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d311 Fault 5 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the fifth most recent drive fault The codes will appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this paramete
153. n N C Normally closed contacts for monitoring relay status 1 Monitor N C Maximum Resistive Load 250V AC 30V DC 50 VA 60 Watts Maximum Inductive Load 250V AC 30V DC 25 VA 30 Watts 1 22 Installation Wiring 1 0 Wiring Examples Input Output Connection Example Potentiometer P038 Speed Reference 2 0 10V Input 1 10k Ohm Pot S Recommended 45 2 Watt minimum TE 8 A 14 Analog Input Bipolar Unipolar Voltage Unipolar Current O 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 ole 10v ho JEO taai Common title Common tte Common oe o E ts L be Analog Input PTC Wire the PTC and External Resistor typically matched to the PTC Hot For Drive Fault 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 R2 Re Retc Vip Rete hot Rete hot Re x 100 05
154. n StepLogic Application F 7 A140 A147 Stp Logic x When a positioning mode is selected that utilizes the Step Logic functions these parameters allow additional flexibility and control various aspects of each step Note that in Positioning mode these parameters have a different function than when used for normal velocity Step Logic Each of the 4 digits controls one aspect of the each position step The following is a listing of the available settings for each digit co Giga Po 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 Settings For Positioning Digit 3 Required Accel Decel StepLogic Direction Type Of Setting Param Used Output State From Home Command 0 Accel Decel 1 O FWD Absolute 1 Accel Decel 1 O FWD Incremental 2 Accel Decel 1 O REV Absolute 3 Accel Decel 1 O REV Incremental 4 Accel Decel 1 On FWD Absolute 5 Accel Decel 1 On FWD Incremental 6 Accel Decel 1 On REV Absolute i Accel Decel 1 On REV Incremental 8 Accel Decel 2 O FWD Absolute 9 Accel Decel 2 O FWD Incremental A Accel Decel 2 O REV Absolute b Accel Decel 2 O REV Incremental 0 Accel Decel 2 On FWD Absolute d Accel Decel 2 On FWD Incremental E Accel Decel 2 On REV Absolute F Accel Decel 2 On REV Incremental Settings Digit 2 Settings Digit 1 and Digit 0 0 Jump to Step 0 0 Skip Step Jump Immediately 1 Jump
155. nce Start and Direction commands come from P036 Start Source No change in control 1 28 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 Drive will Start and Run at Jog Speed Drive will use A079 Jog Accel Decel Direction comes from W O Terminal 03 Dir Run REV Jog Input Enabled and Active A051 A052 A053 or A054 2 11 12 Drive Stopped Not Running Yes 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 P039 Accel Time 1 P040 Decel Time 1 Input is programmed as Accel 2 amp Decel 2 or 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 by Stp Logic or Pos Logic or A067 Accel Time 2 A068
156. nce EMC RFI 1 29 Internal Precharge 1 13 L LEDs 2 3 M Minimum Clearances 1 2 Motor Cable Length 1 11 Motor Overload 4 3 Motor Overload Fault 4 3 Motor Stalled Fault 4 3 motor starter 1 7 noun Options and Clearances MOVs 1 4 0 Opening the Cover 1 1 Operating Temperatures 1 2 Operator Interface 2 3 OverVoltage Fault 4 3 P Parameter Descriptions 3 1 Types 3 1 Parameter Checksum Fault 4 5 Parameter Cross Reference by Name 3 66 Parameters Advanced Display Group 3 62 Advanced Program Group 3 15 Basic Display Group 3 3 Basic Program Group 3 9 Enhanced Program Group 3 49 PE Ground 1 6 Phase Short Fault 4 4 Phase to Ground Fault 4 4 Potentiometer Wiring 1 22 Power Cables Wiring 1 9 Power Conditioning Input 1 5 Power Loss Fault 4 3 Power Unit Fault 4 4 Powering Up the Drive 2 1 2 2 Precautions General P 3 Product Selection B 1 Programming 3 1 PTC Analog Input Wiring 1 22 R Ratings A 1 Reflective Wave Protection 1 11 Removing Cover 1 1 Repeated Start Stop 1 13 Index 3 Repeated Start Stop Precautions 1 13 RFI see EMC RFI RWR Reflective Wave Reducer 1 11 S Safe Off Operation 1 21 Safety Ground 1 6 Shielded Power Cables 1 9 Short Circuit Protection 1 7 Software 3 1 Start and Speed Reference Selection and Control 1 27 1 28 Start Stop Repeated 1 13 Start Up Checklist 2 1 2 2 Static Discharge ESD P 3 Status LEDs 2 3 Supply Source
157. nd Parameters 3 31 Advanced Program Group continued 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 80 76 72 O 68 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Carrier Frequency kHz 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 For information on faults and fault codes refer to Chapter 4 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 Rsirt Delay Related Parameter s A092
158. ng 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 Cable 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
159. nly 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 G 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 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 0 di
160. note that this is not intended to replace high end servo controllers or any application that needs high bandwidth or very high torque at low speeds Encoder Usage and Position StepLogic Application F 3 Common Guidelines for All Applications The position regulator can be configured for operation appropriate for a variety of applications Certain parameters will need to be adjusted in all cases P038 Speed Reference must be set to option 9 Positioning E216 Motor Fdbk Type must be set to the match the feedback device Positioning mode must use E216 Motor Fdbk Type option 4 E216 Motor Fdbk Type Options 0 None indicates no encoder is used This can not be used for positioning 1 Pulse Train is a single channel input no direction speed feedback only This should not be used for positioning The Single Channel selection is similar to a Pulse Train but uses the standard encoder scaling parameters 2 Single Chan is a single channel input no direction speed feedback only This should not be used for positioning Single channel uses the standard encoder scaling parameters 3 Single Check is a single channel input with encoder signal loss detection The drive will fault if it detects that the input pulses do not match the expected motor speed This should not be used for positioning 4 Quadrature is a dual channel encoder input with direction and speed from the encoder This may be used for
161. nput 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 b015 Comm Status Related Parameter s A103 A107 Status of the communications ports AAAI a 1 Condition True 0 Condition False Receiving Data Bit 0 Transmitting Data Bit 1 RS485 DSI Based Option Connected Bit 2 Allen Bradley devices only Communication Error Occurred Bit 3 Values Default Read Only Min Max 0 1 Display 1 b016 Control SW Ver Main Control Board software version Values Default Read Only Min Max 1 00 99 99 Display 0 01 b017 Drive Type Used by Rockwell Automation field service personnel Values Default Read Only Min Max 1001 9999 Display 1 Programming and Parameters 3 7 Basic Display Group continued b018 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 b019 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 b020 Analog In 0 10V Related Parameter s A110 A111 The present value of the volta
162. nu Description Basic Display Group View Only Commonly viewed drive operating b conditions 4 T Advanced Display Group View Only RUN n Consists of advanced drive operating Awb OD A N LI conditions o 27 Fault Designator E Consists of list of codes for specific fault 5 conditions Displayed only when fault is L J present No LED LED State Description Run Status Steady Red Indicates drive is running Flashing Red Drive has been commanded to change direction Direction Status Steady Red Indicates drive is running in reverse direction Flashing Red Drive has been commanded to change direction and motor is decelerating to zero Fault Status Flashing Red Indicates drive is faulted No Key Name Description 2 Up Arrow Scroll A Press and release to scroll through user selectable display parameters Refer to E201 LED Display Opt for options Reset Press and hold for three seconds to clear active fault Drive Programming Tools For additional drive programming and control a DSI remote HIM or PC programming tools DriveExplorer or DriveTools SP should be used Description Catalog Number Serial Converter Module 22 SCM 232 USB Converter Module 1203 USB DriveExplorer Software 9306 4EXPO2ENE DriveTools SP Software 9303 4DTS01 ENE Remote Panel Mount LCD Display 22 HIM C2S Remo
163. o accept parameter changes without writing to the EEPROM Important Parameter values set prior to setting option 1 RAM only will be saved in drive non volatile memory EEPROM E249 Cmd Stat Select Selects velocity specific or position fibers specific Command and Status Word bit definitions for use over a communication network Encoder Usage and Position StepLogic Application F 11 E248 Enh Control Word This parameter allows many of the positioning functions to be completed via parameter control using an explicit message This allows the operation over communications instead of with hardware inputs The bits have the same functions as the digital input options of the same name Options relating to positioning are Bit 0 Home Limit Bit 1 Find Home Bit 2 Hold Step Bit 3 Pos Redefine E230 E244 Step Units x All of the position steps can be written to while the drive is running The changes will take place at the next move For example if step 0 is over written while the drive is moving to step 0 the drive will move to the previous commanded position at step 0 The next time the drive is commanded to return to step 0 it will proceed to the new position One possible use of this capability is when an application requires full control of the movement by a controller external to the drive The Step Logic program might be written to jump from step 0 back to step 0 when Input 1 is active The controller coul
164. ode Stop drive before changing this parameter Defines the positioning transition mode used for the position steps For additional information refer to Appendix F E222 Option Transition Mode Description 0 Time Steps Steps based on time 1 Preset Input Preset inputs directly command a given step 2 Step Logic Use Step Logic commands Always start from Step 0 3 Preset StpL Use Preset inputs to determine starting step then Step Logic commands 4 StpLogic Lst Use Step Logic commands from last StepLogic step at last drive stop Values Default 0 Min Max 0 4 Display 1 E223 Find Home Freq Sets the maximum frequency the drive uses when Find Home is issued For additional information refer to Appendix F Values Default 10 0 Hz Min Max 0 1 500 0 Hz Display 0 1 Hz Programming and Parameters 3 57 Enhanced Program Group continued E224 Find Home Dir Stop drive before changing this parameter Sets the direction the drive commands when Find Home is issued For additional information refer to Appendix F Options 0 Forward Default 1 Reverse E225 Encoder Pos Tol Sets the At Position and the At Home tolerance around the encoder count The value is added to and subtracted from the target encoder unit value to create the tolerance range For additional information refer to Appendix F Values Default 100 Min Max 1
165. on may be connected to ground terminal protective earth If using the RS485 DSI port I O Terminal 19 should also be connected to ground terminal protective earth Installation Wiring 1 15 Figure 1 5 Control Wiring Block Diagram Enable Jumper Stop 16 sat Wing snk Wiring wm m La 2 ate alg rae 02 Start Run FWD ee re oe 03 Direction Run REV 8 66 SNK o Xp SRC pg Disital Common 05 Digital Input 1 yod 06 Digital Input 2 ene a a Digital Input 3 ot oe om 08 Digital Input 4 ae e Opto Common 09 2AN q 2A DC fo 10V 10V DC E 12 ny i 0 10V or 10V Input i l 13 ii i u Analog Common i Pot must be Relay N O 15 4 20mA Input 4 10k ohm Rt i 0 10V 2 Watt Min a t Analog Output Relay Common R2 LFO o 14 20mA 16 commands Relay N C R3 f 7 17 Opto Output 1 C oay oes Opto Output 2 30V DC vy 18 EUR RS485 Shield Non inductive 19 0 10V lt Analog Output Select We gt 2 4 4 0 20mA HAOV W 10V lt Voltage Range Select vy v ee Enable 6 Ri R2 R3 sik NY ENBL lumper OOO A 01 02
166. on that allows the drive to reconnect to a spinning motor at actual RPM Important Do not use this feature with permanent magnet motors 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 attempts 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 Programming and Parameters 3 33 Advanced Program Group continued A098 SW Current Trip Related Parameter s P033 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 b010 Scales the output frequency value displayed by b010 Process Display Output Process _ Process Freq X Factor Display Values Default 30 0 Min Max 0 1 999 9 Display 0 1 A100 Fault Clear O Stop drive before changing this parameter Resets a fault and clears the fault queue Used primarily to clear a fault over network communi
167. onfigured 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 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 D 2 RJ45 DSI Splitter Cable DSI Cable Accessories RJ45 Splitter Cable Catalog Number AK U0 RJ45 SC1 n Fl Slave Port m Luu a ARAR I lt Master Port h PIN 1 PIN 8 RJ45 Two Position Terminal Block Adapter Catalog Number AK U0 RJ45 TB2P TB2 PIN 5 PIN 8 ce TBI we PIN 4 PIN 1 RJ45 Adapter with Integrated Termination Resistor Catalog Number AK U0 RJ45 TR1 ID PIN 8
168. or 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 additional characteristics of each step 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 Parameter E222 Positioning Mode is set to 2 3 or 4 remove power to the drive and ATTENTION If the StepLogic sequence continues running and never stops while A swap the A and A NOT encoder channels 3 46 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 GIG Se 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 Velo
169. ounting bolts to the recommend torque of 2 0 N m 18 lb in Isopropyl Alcohol Verification Once the drive is mounted a worst case test should be run to verify the design The drive should run at its maximum load conditions at the highest expected surrounding air temperature After four hours in this condition the temperature of the drive plate should be measured It should not exceed 75 C 167 F at its hottest point Also parameter b024 Drive Temp should be monitored and should not exceed 80 C 176 F A AC Supply Ground 1 6 Source 1 4 Ungrounded 1 4 Advanced Display Group Parameters Advanced Program Group Parameters 3 15 Ambient Temperatures 1 2 Armored Cable 1 9 Auto Rstrt Tries Fault 4 4 Auxiliary Input Fault 4 3 Basic Display Group Parameters 3 3 Basic Program Group Parameters 9 Before Applying Power 2 1 2 2 Bus Capacitors Discharging P 3 C Cable Power 1 9 Capacitors Discharging P 3 CE Conformity 1 29 Checklist Start Up 2 1 2 2 Circuit Breakers Input 1 7 Comm Loss Fault 4 4 Command Sources for Start and Speed 1 27 Common Bus 1 13 Common Symptoms and Corrective Action 4 6 Contactors Input 1 13 Control Wire 1 14 Control 2 and 3 Wire 1 22 1 26 Conventions Manual P 2 Cover Opening 1 1 Cross Reference Parameter by Name 3 66 D
170. overy 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 Table 1 1 Control I O Terminal Designations 1 17 No Signal Default Description Param R1 Relay N O Fault Normally open contact for output relay A055 R2 Relay Common 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 o Coast The factory installed jumper or a normally closed P036 l y input must be present for the drive to start 02 Start Run FWD Not Active 1 0 Terminal 03 is fully programmable Program with P036 P037 03 Digital Term 3 Not Active E202 Digital Term 3 To disable reverse operation 5936 P037 see A095 Reverse Disable A095 E202 04 Digital Common 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 F
171. positioning control 5 Quad Check is a dual channel encoder with encoder signal loss detection The drive will fault if it detects that the encoder speed does not match the expected motor speed FRN 2 xx or greater supports Option 5 Quad Check in Positioning mode Important Drives using FRN 1 xx must use option 4 Quadrature for Positioning mode FRN 1 xx does not support option 5 Quad Check A095 Reverse Disable should be set to option 0 Rev Enabled to allow bidirectional movement necessary for position control A125 Torque Perf Mode default setting of 1 Sensrls Vect is recommended for most applications to improve the low speed torque for positioning applications The autotune routine can be completed to further improve the drive motor performance Encoder Usage and Position StepLogic Application A117 Bus Reg Mode default setting is option 1 Enabled If the deceleration time is too short the drive may overshoot the desired position For best results a longer deceleration time may be necessary A117 Bus Reg Mode can be disabled to provide precise stopping movements but the deceleration time will need to be manually tuned so that it is long enough to avoid F5 OverVoltage faults A082 DB Resistor Sel default setting is 0 Disabled If improved deceleration performance is required a Dynamic Brake resistor can be used If used this parameter should be set to the appropriate settin
172. put Current 90 8 OutPowr 0 20 18mA for 200 Drive Rated Power Values Default 100 Min Max 0 800 Display 1 A067 Accel Time 2 Related Parameter s P039 A051 A054 A070 A077 A140 A147 E203 E206 When active sets the rate of acceleration for all speed increases except jog Maximum Freq Accel Time DOSER Values Default 20 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs P035 Maximum Freq Option 28 1 Description Speed 0 0 Acc Dec 1 0 1 Acc Dec2 F 1 10 Acc Dec 3 PaE e mme O a fe 1 1 AceiDec4 0 Accel Time x Decel Time x A068 Decel Time 2 Related Parameter s P040 A051 A054 A067 A070 A077 A140 A147 E203 E206 When active sets the rate of deceleration for all speed decreases except jog Refer to graphic at A067 Accel Time 2 Maximum Freq Decel Time peel Rate Values Default 20 0 Secs Min Max 0 0 600 0 Secs Display 0 1 Secs 3 24 Programming and Parameters Advanced Program Group continued A069 Internal Freq Related Parameter s P038 A162 Provides the frequency command to the drive when P038 Speed Reference is set to 1 InternalFreq When enabled this parameter will change the frequency command in real time 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 00 Hz Min Max 0 00 500 0 Hz Display 0 01 Hz
173. quency AC Drive as drive PowerFlex 40P or PowerFlex 40P Drive e Parameter numbers and names are shown in this format P031 Motor NP Volts Name Number Group b Basic Display Group P Basic Program Group A Advanced Program Group E Enhanced Program Group d Advanced Display 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 40P 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 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 adjust
174. r load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current Verify A084 Boost Select setting Check for blocked or dirty heat sink fins Verity that ambient temperature has not exceeded 40 C 104 F for IP 30 NEMA 1 UL Type 1 installations or 50 C 122 F for IP20 Open type installations 2 Check fan Check programming Check for excess load improper A084 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 1 Check parameters 2 Check for broken loose connections at inputs 4 4 No F33 F38 F39 F40 F41 F42 F43 F48 F63 F64 F70 F71 F80 F81 Troubleshooting E Fault Z 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 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 was commanded to write default values to EEPROM Programmed A
175. r second Default for A069 is 60 Hz 17 MOP Down Decreases the value of A069 Internal Freq at a rate of 2 Hz per second 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 Logically ORed with 248 Enh Control Word bit 6 Logic In 1 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 Logically ORed with 248 Enh Control Word bit 7 Logic In 2 25 Current Lmt2 When active A118 Current 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
176. r will be moved to Fault 6 Code and this parameter will be overwritten by Fault 4 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d312 Fault 6 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the sixth most recent drive fault The codes will appear in these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will be moved to Fault 7 Code and this parameter will be overwritten by Fault 5 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 d313 Fault 7 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the seventh most recent drive fault The codes will appear in these parameters in the order they occur 007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur the value of this parameter will be moved to Fault 8 Code and this parameter will be overwritten by Fault 6 Code Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 122 Display 1 Programming and Parameters 3 65 d314 Fault 8 Code Related Parameter s A100 With FRN 3 xx and later A code that represents the eighth most recent drive fault The co
177. ram Jog Frequency A078 Advanced Program Ki Speed Loop E220 Enhanced Program Kp Speed Loop E221 Enhanced Program Language A108 Advanced Program LED Display Opt E201 Enhanced Program Max Traverse E210 Enhanced Program Maximum Freq P035 Basic Program Maximum Voltage A088 Advanced Program Minimum Freq P034 Basic Program MOP Reset Sel A162 Advanced Program Motor Fdbk Type E216 Enhanced Program Motor NP FLA A126 Advanced Program Motor NP Hertz P032 Basic Program Motor NP Poles E217 Enhanced Program Motor NP Volts P031 Basic Program Motor OL Current P033 Basic Program Motor OL Ret P043 Basic Program Motor OL Select A090 Advanced Program Opto Out Logic A064 Advanced Program Opto Outx Level A059 A062 Advanced Program Opto Outx Sel A058 A061 Advanced Program Output Current b003 Display Output Freq b001 Display Output Power b022 Display Output Powr Fetr b023 Display Output Voltage b004 Display P Jump E213 Enhanced Program PID Deadband A138 Advanced Program PID Diff Rate A136 Advanced Program PID Feedback Sel A133 Advanced Program PID Integ Time A135 Advanced Program PID Invert Error A164 Advanced Program PID Preload A139 Advanced Program PID Prop Gain A134 Advanced Program PID Ref Sel A132 Advanced Program PID Setpoint A137 Advanced Program Parameter Name No Group PID Trim Hi A130 Advanced Program PID Trim Lo A131 Advanced Program Pos Reg Filter E246 Enhanced Program Pos Reg Gain E247 Enhanced Program Positioning Mode E222 En
178. re G 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 G 3 increase A135 PID Integ Time 3 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 PIDSetUp G9 The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains Figure G 1 Unstable PID Reference PID Feedback Time Figure G 2 Slow Response Over Damped PID Reference l aes PID Feedback Time Figure G 3 Oscillation Under Damped PID Reference PID Feedback Time Figure G 4 Good Response Critically Damped PID Reference PID Feedback Time G 10 PID Set Up Notes Appendix H Plate Drive Installation Instructions Introduction The PowerFlex 40P is available in a plate drive version without heatsink This is designed to allow mounting to a customer supplied heatsink This may be a large heatsink to be shared by multiple drives a large thermal mass that is part of a system or some other heat sinking system Care must be taken to insure the heatsink used provides adequat
179. re information on speed reference control priority Reserved Comm Port e When active sets communications device as default start speed command source e Can only be tied to one input 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 DCInjStop CF Causes drive to immediately begin a DC Injection stop regardless of how P037 Stop Mode is set 3 50 E202 Options Cont Programming and Parameters 11 Jog Forward 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 13 10V In Ctrl Selects 0 10V or 10V control as the frequency reference Start source is not changed 14 20mA In Ctrl Selects 4 20mA control as the frequency reference Start 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 a rate of 2 Hz pe
180. req Program with A052 Digital In2 Sel A052 07 Digital Input 3 Local Program with A053 Digital In3 Sel A05 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 Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100mA 12 10VDC Referenced to Analog Common P038 Drive supplied power for 0 10V external potentiometer Maximum output current is 15mA 13 10VIn 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 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
181. ries options and adapters are available See Appendix B for details Chapter 1 Installation Wiring This chapter provides information on mounting and wiring the PowerFlex 40P Drive For information on See page For information on See page Opening the Cover 1 1 Fuses and Circuit Breakers 1 7 Mounting Considerations 1 2 Power Wiring 1 9 AC Supply Source Considerations 1 4 VO Wiring 1 13 Recommendations General Grounding Requirements 1 6 EMC Instructions 1 29 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 1 Press and hold in the tabs on each side of the cover 2 Pull the cover out and up to release Installation Wiring Mounting Considerations e Mount the drive upright on a flat vertical
182. rive 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 ine Automatically Clearing Faults Option Step 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 Fault types are listed in Table 4 A Refer to Table 4 B for fault descriptions Caution should be used when enabling this feature since the drive will attempt to issue its own start command based on user selected programming Troubleshooting No F2 F3 F4 F5 F6 F7 F8 F12 F13 F29 1 Fault Descriptions Table 4 B Fault Types Descriptions and Actions Fault Auxiliary Input Power Loss UnderVoltage OverVoltage Motor Stalled Motor Overload Heat
183. rs 22 RFOP8 BL 22 RF012 BS BL Series B 22 RF021 BS BL oy 3 94 A 281 l 3 07 Se etelelelelor KO fe 217 229 8 54 9 02 16 50 A gt k 5 5 0 22 Iil Accessories and Dimensions B 15 Figure B 10 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 g Biy 130 x a T 238 99 612 1 26 3 54 o OeleleleO amp o 297 309 11 69 12 17 297 11 69 2 F AT A ey a L m gt 5 5 0 22 B 16 Accessories and Dimensions Figure B 11 Remote Panel Mount HIM Dimensions are in millimeters and inches Catalog Number 22 HIM C2S gt 25 0 98 HE 93 3 66 Accessories and Dimensions B 17 Figure B 12 NEMA Type 1 Bezel Dimensions are in millimeters and inches Catalog Number 22 HIM B1 25 2 uy 0 99 lt 2m gt AARAA 93 3 66 1141 0 44 OOO0O OOCOO CQOCOCO OOOC gt OOOC 180 7 09 B 18 Accessories and Dimensions Notes Appendix C RS485 DSI Protocol Po
184. rth 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 1 6 Installation Wiring General Grounding Requirements The drive Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes The integrity of all ground connections should be periodically checked Figure 1 3 Typical Grounding 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
185. s 120 Drive Rated Output Volts 0 20mA 004 8 OutPowr 0 20 0 20mA OmA 0kW 200 Drive Rated Power 0 20mA b022 9 TstData 0 20 0 20mA 0mA 0000 65535 Hex FFFF 0 20mA b019 10 OutFreq 4 20 4 20mA 4mA 0Hz P035 Maximum Freq 0 20mA b001 11 OutCurr 4 20 4 20mA 4mA 0 Amps 200 Drive Rated Output Current 0 20mA b00 12 OutVolt 4 20 4 20mA 4mA 0Volts 120 Drive Rated Output Volts 0 20mA b004 13 OutPowr 4 20 4 20mA 4mA 0kW 200 Drive Rated Power 0 20mA b022 14 TstData 4 20 4 20mA 4mA 0000 65535 Hex FFFF 0 20mA b019 15 OutTorg 0 10 0 10V OV 0 Amps 200 Drive Rated FLA 0 10V b029 16 OutTorg 0 20 0 20mA OmA 0Amps 200 Drive Rated FLA 0 20mA b029 17 OutTorg 4 20 4 20mA 4mA 0Amps_ 200 Drive Rated FLA 0 20mA b029 18 Setpnt 0 10 0 10V OV 0 100 0 Setpoint Setting 0 10V A109 19 Setpnt 0 20 0 20mA 0 mA 0 100 0 Setpoint Setting 0 20mA A109 20 Setpnt 4 20 4 20mA 4mA 0 100 0 Setpoint Setting 0 20 mA A109 Values Default 0 Min Max 0 20 Display 1 Programming and Parameters 3 23 Advanced Program Group continued 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 Setting A065 Max Output Value 50 1 OutCurr 0 10 5V for 200 Drive Rated Out
186. s 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 0 500 Hz 7 0 180 8 0 815 Volts 10 0 100 16 0 1 9999 Secs 1 9999 Counts 1 180 degs 0 1 Values Default 0 0 Min Max 0 0 9999 Display 0 1 3 20 Programming and Parameters Advanced Program Group continued A058 Opto Out Sel Related Parameter s P033 A056 A092 A140 A147 A150 A157 A061 Opto Out2 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 Motor Overld Motor overload condition exists 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
187. sables 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 G 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 If the response is too slow increase A134 PID Prop Gain If the response is too quick and or unstable see Figure G 1 decrease A134 PID Prop Gain Typically A134 PID Prop Gain is set to some value below the point where the PID begins to go unstable 2 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 Figu
188. se the current status of the Preset Inputs to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if setting 2 was selected 4 StpLogic Lst is identical to option 2 Step Logic except the drive will use the step prior to its last stop command to determine which Step Logic step to begin This only affects the initial step After start the drive will move through the steps in the same manner as if option 2 was selected This allows a process to be stopped and then restarted at the position where it stopped Encoder Usage and Position StepLogic Application In all position modes the following parameters will control the characteristics at each step E230 E244 Step Units x These are the number value to the left of the decimal whole number of the 8 positions desired for an application beginning with Step 0 E230 and continuing with each step until Step 7 E244 For example enter 2 into this parameter if you would like a commanded position of 2 77 E231 E245 Step Units F x These are the number value to the right of the decimal the portion less than 1 of the 8 positions desired for an application beginning with Step 0 E231 and continuing with each step until Step 7 E245 For example enter 0 77 into this parameter if you would like a commanded position of 2 77 A070 A077 Preset Freq x In Positioning mode each pr
189. sink OvrTmp HW OverCurrent Ground Fault Analog Input Loss Description Auxiliary input interlock is open DC bus voltage remained below 85 of nominal or single phase operation detected 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 See page 4 1 for a description of fault types 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 moto
190. sions 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 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 B 14 Accessories and Dimensions Figure B 9 Frame B EMC Line Filters Dimensions are in millimeters and inches Catalog Numbe
191. st 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 b015 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 Programming and Parameters 3 35 Advanced Program Group continued A107 Comm Format Related Parameter s 0015 Selects the protocol RTU only data bits 8 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 A109 Anlg Out Setpt Related Parameter s A065 When A065 Analog Out Sel is set to option 18 19 or
192. t 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 b001 b002 b012 b020 b021 P039 P040 A051 A054 A069 A070 A077 A110 A111 A112 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 27 for more information on speed reference control priority Options 1 InternalFreq Internal frequency command from A069 Internal Freq Must be set when using MOP function 2 0 10V Input External frequency command from the 0 10V or 10V analog input or remote
193. tarting 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 Writing 06 Logic Command Data The PowerFlex 40P 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 Comm Port in order to accept the commands Parameter E249 Cmd Stat Select is used to select Velocity or Position Bit definitions Velocity Bit Definitions Logic Command E249 0 Velocity 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 1 Logic In 1 7 1 Logic In 2 00 No Command 01 Accel Rate 1 9 8 10 Accel Rate 2 8192 11 Hold Accel Rate Selected 00 No Command 01 Decel Rate 1 11 1 10 10 Decel Rate 2 11 Hold Decel Rate Selected 000 No Command 001 Freq Source P036 Start Source 010 Freq Source A069 Internal Freq 011 Freq Source Comms A
194. te Handheld LCD Display 22 HIM A3 1 Requires a Serial or USB Converter Module 2 4 Start Up Notes Chapter 3 Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 40P parameters Parameters are programmed viewed edited using either a DSI Remote HIM or PC programming tools DriveExplorer or DriveTools SP 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 Display Group 3 3 Basic Program Group 3 9 Advanced Program Group 3 15 Enhanced Program Group 3 49 Advanced Display Group 3 62 Parameter Cross Reference by Name 3 66 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 7 32 bit parameter Parameters marked 32
195. tely the Find Home Freq and or Home Limit bits in E248 Enh Control Word can be activated instead of utilizing a digital input The inputs or bits should be returned to inactive after the routine is complete Important After the position is reached the drive will stop If the Find Home is removed before the homing is complete the drive will begin running the position routine without the proper home In this case Home will not be reset and the position will be in relation to the power up position Encoder and Position Feedback Parameter d304 Speed Feedback and d305 Speed Feedback F indicate the measured speed feedback or the calculated speed feedback when no feedback device is selected Parameter d304 Speed Feedback is the number value to the left of the decimal whole number and d305 Speed Feedback F is the value to the right of the decimal the portion less than 1 d306 Encoder Speed Parameter d306 Encoder Speed and d307 Encoder Speed F indicate the measured speed of the feedback device This is useful if the encoder is not used for motor speed control However the encoder must be used for some purpose in order for Encoder Speed to indicate a value Parameter d306 is the number value to the left of the decimal whole number and d307 is the number to the right of the decimal the portion less than 1 F 10 Encoder Usage and Position StepLogic Application d308 Units Traveled Parameter
196. 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 the source end only not at the drive end Installation Wiring 1 7 RFI Filter Grounding Using 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 40P does not provide branch short circuit protection This product should be installed with either input fuses or an input circuit breaker National an
197. 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 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 Note Incremental move commands will cause the drive to move the amount specified based on the current position Absolute commands are always with reference to Home E246 Pos Reg Filter provides a low pass filter at the input of the position regulator Encoder Usage and Position StepLogic Application E247 Pos Reg Gain is a single adjustment for increasing or decreasing the responsiveness of the
198. top drive before changing this parameter Sets the highest frequency the drive will output Values Default 60 00 Hz Min Max 0 00 500 0 Hz Display 0 01 Hz 3 10 Programming and Parameters Basic Program Group continued P036 Start Source Related Parameter s b012 P037 Stop drive before changing this parameter Sets the control scheme used to start the drive and controls the behavior of I O Terminals 01 02 and 03 However I O Terminal 03 is fully programmable via E202 Digital Term 3 Refer to Start and Speed Reference Control on page 1 27 for details about how other drive settings can override the setting of this parameter Important For all settings except option 3 the drive must receive a leading edge from the start input for the drive to start after a stop input loss of power or fault condition Important I O Terminal 01 is always a stop and must be active for the drive to run regardless of stop source Options 1 3 Wire 1 O Terminal 01 Stop stop according to the value set in P037 Stop Mode 1 0 Terminal 03 Direction 2 2 Wire 1 O Terminal 01 Stop coast to stop 1 0 Terminal 03 Run REV 3 2 W Lvl Sens 1 0 Terminal 01 Stop coast to stop Drive will restart after a Stop command when e Stop is removed and e Start is held active I O Terminal 03 Run REV ATTENTION Hazard of injury exists due to unintended operation When
199. top when input becomes inactive A valid start will override this command 13 10V In Ctrl Selects 0 10V or 10V control as the frequency reference Start source is not changed 14 20mA In Ctrl Selects 4 20mA control as the frequency reference Start 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 a rate of 2 Hz per second Default for A069 is 60 Hz 17 MOP Down Decreases the value of A069 Internal Freq at a rate of 2 Hz per second 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 Step Logic parameters A140 A147 Stp Logic x Logically ORed with 248 Enh Control Word bit 6 Logic In 1 24 Logic In2 Logic function input number 2 May be used to control the relay or opto outputs see para
200. ts 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 A056 Relay Out Level e Use A056 to set threshold 7 Above 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 A05 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 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 Step Logic step with Digit 3 of Command Word A140 A147 set to enabl
201. ts 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 Encoder Selects Exclusive Control Encoder or Pulse train will be used as an input for the PID Reference 6 Setpnt Trim Selects Trim Control A137 PID Setpoint will be used to set the value of the PID Reference 7 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 8 4 20mA Trim Selects Trim Control Selects the 4 20mA Input 9 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 1
202. werFlex 40P 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 40P drives can be multi dropped on an RS485 network using Modbus protocol in RTU mode Controller For information regarding DeviceNet or other communication protocols refer to the appropriate user manual Network Wiring Network wiring consists of a shielded 2 conductor cable that is daisy chained from node to node Figure C 1 Network Wiring Diagram PowerFlex 40P PowerFlex 40P PowerFlex 40P Node 1 Node 2 Node n Master TxRxD TxRxD TxRxD 5 120 ohm resistor 120 ohm resistor PINS PIN1 TxRxD TxRxD 4 TxRxD 4 _t Shield Shield Shield a X FRONT NOTE The shield is connected at ONLY ONE end of each cable segment 01 02 03 04 05 06 07 08 09 01 02 03 04 05 06 07 08 09 QOOCODOOD GOODOOODOD LEAORRoRe Fis RAO RE EES ras UL ak oo Ru4s TB2P U R L1 S L2 T L3 UT AV T2W T3 rA R L1 S L2 T L3 UTAVIT2WITS AR DC DC BR BR DC DC BR BR RS485 DSI Protocol Only pins 4 and 5 on the RJ45 plug should be wired The other pins on the PowerFlex 40P RJ45 socket must not be connected because they conta
203. with EN ISO 13849 1 2008 AC 2009 1 21 3 11 and A 3 Certification for Australian C Tick CE Directives and TUV updated The information below summarizes the changes to the PowerFlex 40P User Manual since the May 2007 release Description of New or Updated Information See Page s Link to Rockwell Automation Literature Library under Reference Preface 1 Materials has been fixed Minimum Enclosure Volume column and new footnotes added 1 8 A 2 Information on swapping encoder channels updated 1 18 and F 2 Certification standard for DriveGuard Safe Off Option updated to ISO 1 21 3 11 and 13849 1 Performance Level d Safety Category 3 A 3 USB Converter Module added to Drive Programming Tools 2 3 Parameters A164 and d310 d316 added to Parameter Organzation 3 2 Max value for Parameter A069 Internal Freq updated to 500 0 Hz 3 24 Cross reference to parameters d310 d316 added to description for 3 3 Parameter A100 Fault Clear Attention added to Parameters A140 A147 Stp Logic x 3 45 Max vaule for A150 A157 Stp Logic Time x increased to 6553 5 sec 3 47 Parameters A164 and d310 d316 added to Parameter 3 66 Cross Reference by Name Drive Fuse amp Circuit Breaker Ratings topic updated A 1 Electronic Motor Overload Protection description updated A 3 A 4 Description of Option 1 for Parameter E222 Positioning Mode updated F Parameter Updates The following parameters h
204. y Group continued b006 Drive Status Related Parameter s A09 Present operating condition of the drive MIIA LILL 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 b007 Fault 1 Code b008 Fault 2 Code b009 Fault 3 Code A code that represents a drive fault The codes will appear in these parameters in the order they occur b007 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 b010 Process Display Related Parameter s b001 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 Basic Display Group continued b012 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 27 and 1 28 for details AANA I EE ES Es Start Command Digit 1 1 Terminal Block 2

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