Adjustable Frequency AC Drive FRN 6.xx User Manual www.abpowerflex.
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.
Summary of Changes The information below summarizes changes made for the June 2013 PowerFlex 4 User Manual, Publication 22A-UM001J-EN-E. Description of New or Updated Information Minimum Enclosure Volume column and new footnotes added. Drive, Fuse & Circuit Breaker Ratings topic updated. Electronic Motor Overload Protection description updated. See Page(s) 1-7, A-2 A-1 A-3 The information below summarizes changes made for the September 2010 PowerFlex 4 User Manual, Publication 22A-UM001I-EN-E.
soc-2 Description of New or Updated Information Attention statement added to parameter A082 [DB Resistor Sel]. External Comm Options, Compact I/O added to Table B.G. Modbus function code 16 added.
Table of Contents Preface Overview Who Should Use this Manual? . . . . . . . . . Reference Materials . . . . . . . . . . . . . . . . . Manual Conventions . . . . . . . . . . . . . . . . . Drive Frame Sizes . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . Catalog Number Explanation . . . . . . . . . . Chapter 1 P-1 P-1 P-2 P-2 P-3 P-4 Installation/Wiring Opening the Cover . . . . . . . . . . . . . . . . . . 1-1 Mounting Considerations . . . . . . . . . . . . .
ii Appendix C RS485 (DSI) Protocol Network Wiring . . . . . . . . . . . . . . . . . . . . . Parameter Configuration . . . . . . . . . . . . . . Supported Modbus Function Codes . . . . . Writing (06) Logic Command Data. . . . . . Writing (06) Reference . . . . . . . . . . . . . . . Reading (03) Logic Status Data. . . . . . . . . Reading (03) Feedback . . . . . . . . . . . . . . . Reading (03) Drive Error Codes . . . . . . . . Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . .
Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 4 Adjustable Frequency AC Drive. For information on… Who Should Use this Manual? Reference Materials Manual Conventions Drive Frame Sizes General Precautions Catalog Number Explanation See page… P-1 P-1 P-2 P-2 P-3 P-4 Who Should Use this Manual? This manual is intended for qualified personnel.
P-P-2 Overview Manual Conventions • • In this manual we refer to the PowerFlex 4 Adjustable Frequency AC Drive as: drive, PowerFlex 4 or PowerFlex 4 Drive.
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.
P-P-4 Overview Catalog Number Explanation 1-3 4 5 6-8 22A - A 1P5 Drive Dash Voltage Rating Rating 9 10 11 12 (1) N 1 1 4 Enclosure HIM Emission Class Type Code 22A PowerFlex 4 Code V A B D Voltage 120V AC 240V AC 240V AC 480V AC Code Rating 0 Not Filtered 1 Filtered Ph. 1 1 3 3 Output Current @ 100-120V Input Amps 1.5 2.3 4.5 6.0 Code Interface Module 1 Fixed Keypad kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.
Chapter 1 Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 4 Drive. For information on… Opening the Cover Mounting Considerations AC Supply Source Considerations See page 1-1 1-2 1-3 General Grounding Requirements 1-4 For information on… Fuses and Circuit Breakers Power Wiring I/O Wiring Recommendations EMC Instructions See page 1-6 1-8 1-11 1-20 Most start-up difficulties are the result of incorrect wiring.
1-2 Installation/Wiring Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. – Install on 35 mm DIN Rail. or – Install with screws. Table 1.A Screw Mounting Recommendations • • • Minimum Panel Thickness Screw Size Mounting Torque 1.9 mm (0.0747 in.) 1.56-1.96 N-m (14-17 lb.-in.) M4 (#8-32) Protect the cooling fan by avoiding dust or metallic particles. Do not expose to a corrosive atmosphere. Protect from moisture and direct sunlight.
Installation/Wiring 1-3 Storage • • • Store within an ambient temperature range of -40° to +85°C. Store within a relative humidity range of 0% to 95%, non-condensing. Do not expose to a corrosive atmosphere. AC Supply Source Considerations Ungrounded Distribution Systems ! ATTENTION: PowerFlex 4 drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system.
1-4 Installation/Wiring Input Power Conditioning The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix A). Listed in Table 1.C are certain input power conditions which may cause component damage or reduction in product life. If any of the conditions exist, as described in Table 1.C, install one of the devices listed under the heading Corrective Action on the line side of the drive. Important: Only one device per branch circuit is required.
Installation/Wiring 1-5 Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Safety Ground - (PE) This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.
1-6 Installation/Wiring Fuses and Circuit Breakers The PowerFlex 4 does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.
Installation/Wiring 1-7 Table 1.D Minimum Recommended Branch Circuit Protective Devices Voltage Rating Drive Rating kW (HP) Fuse Rating(1) 140M(2) (3) Amps Catalog No. 120V AC – 1-Phase 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 10 15 30 40 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-F8E-C32 100-C09 100-C12 100-C23 100-C37 1655 1655 1655 1655 240V AC – 0.2 (0.25) 1-Phase 0.4 (0.5) NO BRAKE 0.75 (1.0) 1.5 (2.0) 2.2 (3.
1-8 Installation/Wiring Power Wiring ! ! ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
Installation/Wiring 1-9 Reflected Wave Protection The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor (reflected wave phenomena). See Table 1.E for recommendations. The reflected wave data applies to all frequencies 2 to 16 kHz. For 240V ratings, reflected wave effects do not need to be considered. Table 1.
1-10 Installation/Wiring Power Terminal Block The drive utilizes a finger guard over the power wiring terminals. To remove: 1. Press in and hold the locking tab. 2. Slide finger guard down and out. Replace the finger guard when wiring is complete. Figure 1.
Installation/Wiring 1-11 I/O Wiring Recommendations Motor Start/Stop Precautions ! ! ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur.
1-12 Installation/Wiring Control Wire Types Table 1.G Recommended Control and Signal Wire(1) Wire Type(s) Description Minimum Insulation Rating Belden 8760/9460 (or equiv.) 0.8 mm2 (18AWG), twisted pair, 100% shield with drain. (1) Belden 8770 (or equiv.) 0.8 mm2 (18AWG), 3 conductor, shielded for remote pot only.
Installation/Wiring 1-13 Figure 1.5 Control Wiring Block Diagram (1) Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set to “3-Wire” 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]. 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.
1-14 Installation/Wiring I/O Wiring Examples Input Potentiometer 1-10k Ohm Pot.
Installation/Wiring Input Connection Example Internal Supply (SRC) 2 Wire SRC Control Non-Reversing P036 [Start Source] = 2, 3 11 or 4 Input must be active for Stop-Run the drive to run. When input is opened, the drive will stop as specified by P037 [Stop Mode]. If desired, a User Supplied 24V DC power source can be used. Refer to the “External Supply (SRC)” example.
1-16 Installation/Wiring Input 3 Wire SRC Control Non-Reversing P036 [Start Source] = 1 A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by P037 [Stop Mode]. Connection Example Internal Supply (SRC) Stop 11 External Supply (SRC) Stop 01 02 01 02 Start Start +24V 04 Common Each digital input draws 6 mA.
Installation/Wiring 1-17 Typical Multiple Drive Connection Examples Input Connection Example Multiple Digital 02 04 02 04 02 04 02 04 Input Connections Customer Inputs can be wired per External Supply (SRC) or Internal Supply (SNK) Optional Ground Connection Customer Inputs examples on page 1-15. 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.
1-18 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 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or 6, and the digital input is active, A051 or A052 will override the speed reference commanded by P038 [Speed Reference]. See the chart below for the override priority.
Installation/Wiring 1-19 Accel/Decel Selection The selection of Accel/Decel rates can be made through digital inputs, RS485 (DSI) communications and/or parameters. Jog Input Enabled and Active: A051 or A052 = 2 Yes A079 [Jog Accel/Decel] used. Yes Active when A067 [Accel Time 2]/A068 [Decel Time 2] is selected by RS485 (DSI) port.
1-20 Installation/Wiring 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.
Installation/Wiring 1-21 Essential Requirements for CE Compliance Conditions 1-3 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3. 1. Grounding as described in Figure 1.6. Refer to page 1-5 for additional grounding recommendations. 2. Output power, control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation. 3. Allowable cable length in Table 1.I is not exceeded. Table 1.
1-22 Installation/Wiring EN61000-3-2 • • 0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5 HP) 240V 1-Phase drives are suitable for installation on a private low 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.
Chapter 2 Start Up This chapter describes how to start up the PowerFlex 4 Drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group. Important: Read the General Precautions section before proceeding. ! ATTENTION: Power must be applied to the drive to perform the following start-up procedures. Some of the voltages present are at incoming line potential.
2-2 Start Up Applying Power to the Drive ❏ 6. Apply AC power and control voltages to the drive. ❏ 7. Familiarize yourself with the integral keypad features (see page 2-3) before setting any Program Group parameters. Start, Stop, Direction and Speed Control Factory default parameter values allow the drive to be controlled from the integral keypad. No programming is required to start, stop, change direction and control speed directly from the integral keypad.
Start Up 2-3 Integral Keypad ➋ ➊ ➌ RUN FWD REV PROGRAM ➍ ➏ Menu VOLTS AMPS HERTZ FAULT ➎ Basic Program Group Consists of most commonly used programmable functions. ➑ ➐ Description Display Group (View Only) Consists of commonly viewed drive operating conditions. ➒ Advanced Program Group Consists of remaining programmable functions. Fault Designator Consists of list of codes for specific fault conditions. Displayed only when fault is present. No.
2-4 Start Up Viewing and Editing Parameters The last user-selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied. The following is an example of basic integral keypad and display functions. This example provides basic navigation instructions and illustrates how to program the first Program Group parameter. Step Key(s) 1. When power is applied, the last user-selected Display Group parameter number is briefly displayed with flashing characters.
Chapter 3 Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 4 parameters. Parameters are programmed (viewed/edited) using the integral keypad. As an alternative, programming can also be performed using DriveExplorer™ or DriveExecutive™ software, a personal computer and a serial converter module. Refer to Appendix B for catalog numbers.
3-2 Programming and Parameters Parameter Organization Displa roup y Gro See page 3-3 Output Freq Commanded Freq Output Current Output Voltage DC Bus Voltage Drive Status Fault 1 Code Fault 2 Code Fault 3 Code Process Display Control Source Contrl In Status Dig In Status Comm Status Control SW Ver Drive Type Elapsed Run Time Testpoint Data Analog In 0-10V Analog In 4-20mA Drive Temp Ad Progrvanced am G roup B Progr asic am G up d001 d002 d003 d004 d005 d006 d007 d008 d009 d010 d012 d013 d014 d015 d0
Programming and Parameters 3-3 Display Group d001 [Output Freq] Related Parameter(s): d002, d010, P034, P035, P038 Output frequency present at T1, T2 & T3 (U, V & W). Values Default Read Only Min/Max: 0.0/P035 [Maximum Freq] Display: 0.1 Hz d002 [Commanded Freq] Related Parameter(s): d001, d013, P034, P035, P038 Value of the active frequency command. Displays the commanded frequency even if the drive is not running. Important: The frequency command can come from a number of sources.
3-4 Programming and Parameters Display Group (continued) d006 [Drive Status] Related Parameter(s): A095 Present operating condition of the drive. Running Forward Accelerating Decelerating Values Default 1 = Condition True, 0 = Condition False Bit 0 Bit 1 Bit 2 Bit 3 Read Only Min/Max: 0/1 Display: 1 d007 [Fault 1 Code] d008 [Fault 2 Code] d009 [Fault 3 Code] A code that represents a drive fault.
Programming and Parameters 3-5 Display Group (continued) d012 [Control Source] Related Parameter(s): P036, P038, A051, A052 Displays the active source of the Start Command and Speed Command which are normally defined by the settings of P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital inputs. Refer to the flowcharts on pages 1-18 and 1-19 for details.
3-6 Programming and Parameters Display Group (continued) d014 [Dig In Status] Related Parameter(s): A051, A052 Status of the control terminal block digital inputs. 1 = Input Present, 0 = Input Not Present Digital In1 Sel (I/O Terminal 05) Bit 0 Digital In2 Sel (I/O Terminal 06) Bit 1 Reserved Bit 2 Reserved Bit 3 Values Default Read Only Min/Max: 0/1 Display: 1 d015 [Comm Status] Related Parameter(s): A103 - A107 Status of the communications ports.
Programming and Parameters 3-7 Display Group (continued) d018 [Elapsed Run Time] Accumulated time drive is outputting power. Time is displayed in 10 hour increments. Values Default Read Only Min/Max: 0/9999 Hrs Display: 1 = 10 Hrs d019 [Testpoint Data] Related Parameter(s): A102 The present value of the function selected in A102 [Testpoint Sel].
3-8 Programming and Parameters Basic Program Group P031 [Motor NP Volts] Related Parameter(s): d004, A084 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, A090 Stop drive before changing this parameter. Set to the motor nameplate rated frequency.
Programming and Parameters 3-9 Basic Program Group (continued) P036 [Start Source] Related Parameter(s): d012, P037 Stop drive before changing this parameter. Sets the control scheme used to start the drive. Refer to Start and Speed Reference Control on page 1-18 for details about how other drive settings can override the setting of this parameter.
3-10 Programming and Parameters Basic Program Group (continued) P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082, A105 Active stop mode for all stop sources [e.g. keypad, run forward (I/O Terminal 02), run reverse (I/O Terminal 03), RS485 port] except as noted below. Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set for “3-Wire” control. When in three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode].
Programming and Parameters 3-11 Basic Program Group (continued) P038 [Speed Reference] Related Parameter(s): d001, d002, d012, P039, P040, A051, A052, A069, A070-A073, A110, A111, A112, A113 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].
3-12 Programming and Parameters Basic Program Group (continued) P040 [Decel Time 1] Related Parameter(s): P038, P039, A051, A052, A068, A070-A073 Sets the rate of deceleration for all speed decreases. Maximum Freq = Decel Rate Decel Time Values Default 10.0 Secs Min/Max: 0.1/600.0 Secs Display: 0.
Programming and Parameters 3-13 Advanced Program Group A051 [Digital In1 Sel] (I/O Terminal 5) A052 [Digital In2 Sel] Related Parameter(s): d012, d014, P038, P039, P040, A067, A068, A070-A073, A078, A079 Stop drive before changing this parameter. (I/O Terminal 6) Selects the function for the digital inputs. Refer to the flowchart on page 1-18 for more information on speed reference control priority.
3-14 Programming and Parameters A051 & 13 “10V In Ctrl” A052 Options 14 “20mA In Ctrl” (Cont.) Selects 0-10V or ±10V control as the frequency reference. Start source is not changed. Selects 4-20mA control as the frequency reference. Start source is not changed. 15 - 25 Reserved 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].
Programming and Parameters 3-15 Advanced Program Group (continued) A056 [Relay Out Level] 32 Related Parameter(s): A055 32 bit parameter. Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7, 8, 10 or 20. A055 Setting 6 7 8 10 20 Values A056 Min/Max 0/240 Hz 0/180% 0/815 Volts 0/100% 0/1 Default 0.0 Min/Max: 0.0/9999 Display: 0.
3-16 Programming and Parameters Advanced Program Group (continued) A069 [Internal Freq] Related Parameter(s): P038 Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal Freq”. When enabled, this parameter will change the frequency command in “real time” using the integral keypad Up Arrow or Down Arrow when in program mode. Important: Once the desired command frequency is reached, the Enter key must be pressed to store this value to EEPROM memory.
Programming and Parameters 3-17 Advanced Program Group (continued) A079 [Jog Accel/Decel] Related Parameter(s): A051, A052, A078 Sets the acceleration and deceleration time when a jog command is issued. Values Default 10.0 Secs Min/Max: 0.1/600.0 Secs Display: 0.1 Secs A080 [DC Brake Time] Related Parameter(s): P037, A081 Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter A081 [DC Brake Level]. Values Default 0.0 Secs Min/Max: 0.0/90.
3-18 Programming and Parameters Advanced Program Group (continued) A082 [DB Resistor Sel] Stop drive before changing this parameter. Enables/disables external dynamic braking. Setting 0 1 2 3-99 Min/Max “Disabled” “Normal RA Res” (5% Duty Cycle) - Refer to Table B.C on page B-2 “No Protection” (100% Duty Cycle) “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.
Programming and Parameters 3-19 Advanced Program Group (continued) A084 [Boost Select] Related Parameter(s): d004, P031, P032 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.(1) (1) Drive may add additional voltage unless option 5 is selected. Options 1 “30.0, VT” 2 “35.0, VT” Variable Torque 3 “40.0, VT” 4 “45.0, VT” 5 “0.0 no IR” 6 “0.0” 7 “2.5, CT” [Default for 3.7kW (5HP) Drives] 8 “5.0, CT” (Default) Constant Torque 9 “7.5, CT” 10 “10.0, CT” 11 “12.
3-20 Programming and Parameters Advanced Program Group (continued) A089 [Current Limit] Maximum output current allowed before current limiting occurs. Values Default Drive Rated Amps × 1.5 Min/Max: 0.1/(Drive Rated Amps × 1.8) Display: 0.1 Amps A090 [Motor OL Select] Related Parameter(s): P032 Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I2t overload function.
Programming and Parameters 3-21 Advanced Program Group (continued) A092 [Auto Rstrt Tries] Sets the maximum number of times the drive attempts to reset a fault and restart. Clear a Type 1 fault and restart the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than “0”. 2. Set A093 [Auto Rstrt Delay] to a value other than “0”. Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than “0”. 2.
3-22 Programming and Parameters Advanced Program Group (continued) A095 [Reverse Disable] Related Parameter(s): d006 Stop drive before changing this parameter. Enables/disables the function that allows the direction of motor rotation to be changed. The reverse command may come from a digital command, the keypad or a serial command. All reverse inputs including two-wire Run Reverse will be ignored with reverse disabled.
Programming and Parameters 3-23 Advanced Program Group (continued) A100 [Fault Clear] Stop drive before changing this parameter. Resets a fault and clears the fault queue. Used primarily to clear a fault over network communications. Options 0 “Ready/Idle” (Default) 1 “Reset Fault” 2 “Clear Buffer” (Parameters d007-d009 [Fault x Code]) A101 [Program Lock] Protects parameters against change by unauthorized personnel.
3-24 Programming and Parameters Advanced Program Group (continued) A105 [Comm Loss Action] Related Parameter(s): d015, P037, A106 Selects the drive’s response to a loss of the communication connection or excessive communication errors. Options 0 “Fault” (Default) Drive will fault on an F81 Comm Loss and coast to stop. 1 “Coast to Stop” Stops drive via coast to stop. 2 “Stop” Stops drive via P037 [Stop Mode] setting.
Programming and Parameters A110 [Anlg In 0-10V Lo] 3-25 Related Parameter(s): d020, P034, P038, A051, A052 Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038 [Speed Reference]. Analog inversion can be accomplished by setting this value larger than A111 [Anlg In 0-10V Hi] or by setting A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert” Values Default 0.0% Min/Max: 0.0/100.0% Display: 0.
3-26 Programming and Parameters A114 [Slip Hertz @ FLA] Related Parameter(s): P033 Compensates for the inherent slip in an induction motor. This frequency is added to the commanded output frequency based on motor current. Values Default 2.0 Hz Min/Max: 0.0/10.0 Hz Display: 0.1 Hz A115 [Process Time Lo] Related Parameter(s): d010, P034 Scales the time value when the drive is running at P034 [Minimum Freq].
Programming and Parameters 3-27 Parameter Cross Reference – by Name Parameter Name No. Group Parameter Name No.
3-28 Notes: Programming and Parameters
Chapter 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 4 drive. Included is a listing and description of drive faults (with possible solutions, when applicable). For information on… Drive Status Faults See page… For information on… 4-1 Fault Descriptions 4-1 Common Symptoms and Corrective Actions See page… 4-3 4-5 Drive Status The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral keypad.
4-2 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. The integral keypad provides visual notification of a fault condition by displaying the following. • Flashing fault number • Flashing fault indicator Press the Escape key to regain control of the integral keypad. VOLTS AMPS HERTZ RUN FWD REV PRGOGRAM FAULT Manually Clearing Faults Step Key(s) 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the integral keypad.
Troubleshooting 4-3 Fault Descriptions Type(1) Table 4.A Fault Types, Descriptions and Actions No. F2 Fault Auxiliary Input F3 Power Loss ➁ F4 UnderVoltage ➀ F5 OverVoltage ➀ F6 Motor Stalled ➀ F7 Motor Overload ➀ F8 Heatsink OvrTmp ➀ F12 HW OverCurrent ➁ F13 Ground Fault ➁ (1) ➀ Description Auxiliary input interlock is open. Action 1. Check remote wiring. 2. Verify communications programming for intentional fault. DC bus voltage remained below 1.
Troubleshooting Type(1) 4-4 No. F33 Fault Auto Rstrt Tries F38 F39 F40 Phase U to Gnd Phase V to Gnd Phase W to Gnd ➁ F41 F42 F43 Phase UV Short Phase UW Short Phase VW Short ➁ F48 Params Defaulted F63 SW OverCurrent ➀ F64 Drive Overload ➁ F70 Power Unit ➁ F71 Net Loss F81 Comm Loss ➁ ➁ F100 Parameter Checksum ➁ F122 I/O Board Fail ➁ (1) Description Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A092 [Auto Rstrt Tries].
Troubleshooting 4-5 Common Symptoms and Corrective Actions Motor does not Start. Cause(s) No output voltage to the motor. Indication None Improper boost setting at initial start-up. None Corrective Action Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Check the motor. • Verify that the motor is connected properly. Check the control input signals. • Verify that a Start signal is present.
4-6 Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block. Cause(s) Drive is Faulted Indication Flashing red status light Incorrect programming. None • P036 [Start Source] is set to option 0 “Keypad” or option 5 “RS485 (DSI) Port”. • A051 - A052 [Digital Inx Select] is set to option 5 “Local” and the input is active. None Incorrect input wiring. See 1-14 for wiring examples. • 2 wire control requires Run Forward, Run Reverse or Jog input.
Troubleshooting 4-7 Motor and/or drive will not accelerate to commanded speed. Cause(s) Indication Acceleration time is excessive. None None Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration. Speed command source or value is not as expected. None Programming is preventing the None drive output from exceeding limiting values. Corrective Action Reprogram P039 [Accel Time 1] or A067 [Accel Time 2].
4-8 Notes: Troubleshooting
Appendix A Supplemental Drive Information For information on… Drive, Fuse & Circuit Breaker Ratings Specifications See page… A-1 A-2 Drive, Fuse & 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.
A-2 Supplemental Drive Information Specifications Drive Ratings Input Ratings Branch Circuit Protection Min. Enclosure Voltage 140M Motor kW (HP) Amps Range kVA Amps Fuses Protectors(2) (3) Contactors Volume(4) (in.3) 100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output Catalog Number 22A-V1P5N104 22A-V2P3N104 22A-V4P5N104 22A-V6P0N104 Output Ratings 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 1.5 2.3 4.5 6.0 90-126 90-126 90-126 90-126 0.75 1.15 2.25 3.0 6.0 9.0 18.0 24.
Supplemental Drive Information (3) (4) A-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. 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.
A-4 Supplemental Drive Information PowerFlex 4 Estimated Watts Loss (Rated Load, Speed & PWM) Voltage 100–120V 200–240V 380–480V kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.
Appendix B Accessories and Dimensions For information on… Product Selection Product Dimensions See page B-1 B-5 Product Selection Table B.A Catalog Number Description 22A Drive A 1P5 N 1 1 4 Voltage Rating Rating Enclosure HIM Emission Class Type Table B.B PowerFlex 4 Drives Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase No Filter kW 0.2 0.4 0.75 1.1 240V 50/60 Hz 0.2 1-Phase 0.4 NO BRAKE 0.75 With Integral “S Type” 1.5 EMC Filter 2.2 240V 50/60 Hz 0.2 1-Phase 0.4 NO BRAKE 0.
B-2 Accessories and Dimensions Table B.C Dynamic Brake Modules Drive Ratings Minimum Resistance Ω kW 120V 50/60 Hz 1-Phase 0.2 0.25 60 AK-R2-091P500 0.4 0.5 60 AK-R2-091P500 240V 50/60 Hz 1-Phase 240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase (1) (2) HP Catalog Number (1) (2) Input Voltage 0.75 1.0 60 AK-R2-091P500 1.1 1.5 60 AK-R2-091P500 0.2 0.25 60 AK-R2-091P500 0.4 0.5 60 AK-R2-091P500 0.75 1.0 60 AK-R2-091P500 1.5 2.0 60 AK-R2-091P500 0.2 0.
Accessories and Dimensions B-3 Table B.E EMC Line Filters Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase 240V 50/60 Hz 1-Phase 240V 50/60 Hz 1-Phase NO BRAKE 240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase (1) (2) (3) (4) kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 3.7 0.4 0.75 1.5 2.2 3.7 HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 0.5 1.0 2.0 3.0 5.
B-4 Accessories and Dimensions Table B.G Communication Option Kits Item Description Catalog Number (2) External DSI™ Communications Kit External mounting kit for 22-COMM-C, -D, -E, -P. 22-XCOMM-DC-BASE External Comms Power Supply Optional 100-240V AC Power Supply for External 20-XCOMM-AC-PS1 DSI Communications Kit. Compact I/O Module Three channel.
Accessories and Dimensions B-5 Product Dimensions Frame Table B.I PowerFlex 4 Panel Mount Drives – Ratings are in kW and (HP) 240V AC – 1-Phase 240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase No Brake 120V AC – 1-Phase A 0.2 (0.25) 0.37(0.5) 0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) B 0.75(1.0) 1.1 (1.5) 1.5 (2.0) 2.2 (3.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 2.2 (3.0) 3.7 (5.0) Figure B.
B-6 Accessories and Dimensions Figure B.3 PowerFlex 4 Flange Mount Drives – Dimensions are in millimeters and (inches) Frame A 175 (6.89) 92.8 (3.65) 145 (5.71) 54.7 (2.15) 210 (8.27) Frame B 244 (9.61) 94.3 (3.71) 214 (8.43) 250 (9.84) 63.1 (2.
Accessories and Dimensions Figure B.4 PowerFlex 4 Cutout Dimensions – Dimensions are in millimeters and (inches) Frame A 8 (0.31) 114 (4.49) 5.3 (0.21) 195 (7.68) 179 (7.05) 97.5 (3.84) 16 (0.63) 49 (1.93) 98 (3.86) 130 (5.12) 8 (0.31) Frame B 145 (5.71) 6.5 (0.26) 23.5 (0.93) 197 (7.76) 210 (8.27) 225 (8.86) 98.5 (3.88) 5.3 (0.21) 14 (0.55) 31 (1.22) 49 (1.93) 98 (3.86) 7.5 (0.30) 160 (6.
B-8 Accessories and Dimensions Figure B.5 PowerFlex 4 Replacement Plate Drive Dimensions – Dimensions are in millimeters and (inches) Frame A 104.8 (4.13) 92 (3.62) 50 (1.97) 88 (3.46) 6 (0.24) 163 (6.42) 152 (5.98) 175 (6.89) 81.5 (3.21) 5.3 (0.21) 80 (3.15) Frame B 112 (4.41) 125 (4.92) 80 (3.15) 88 (3.46) 192 (7.56) 204 (8.03) 96 (3.78) 100 (3.94) 5.3 (0.21) 180 (7.09) 9.5 (0.
Accessories and Dimensions Figure B.6 Dynamic Brake Modules – Dimensions are in millimeters and (inches) Frame A Frame B 30.0 (1.18) 60.0 (2.36) 31.0 (1.22) 59.0 (2.32) C US C US 17.0 (0.67) 61.0 (2.40) 335.0 (13.19) 386.0 (15.20) AUTOMATION ROCKWELL 316.0 (12.44) ROCKWELL AUTOMATION SURFACES MAY BE 13.0 (0.51) Frame Catalog Number A AK-R2-091P500, AK-R2-047P500, AK-R2-360P500 B AK-R2-030P1K2, AK-R2-120P1K2 Figure B.
B-10 Accessories and Dimensions Figure B.8 Bulletin 1321-3R Series Line Reactors – Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). a b e d c Catalog Number a b c d e Weight 1321-3R2-A 112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 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-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.
Accessories and Dimensions B-11 Figure B.9 Frame A EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL 29.8 (1.17) 80 60 (3.15) (2.36) 50 (1.97) 208 (8.19) 220 (8.66) 208 (8.19) 17.8 (0.70) 5.5 (0.22) 24 (0.94) Figure B.10 Frame B EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF012-BS, -BL (Series B); 22-RF018-BS; 22-RF021-BS, -BL 29.8 (1.17) 50 (1.97) 100 78 (3.94) (3.07) 217 (8.
B-12 Accessories and Dimensions Figure B.11 Frame C EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Number: 22-RF025-CL 32 (1.26) 60 (2.36) 130 90 (5.12) (3.54) 297 (11.69) 309 (12.17) 297 (11.69) 17 (0.67) 30 (1.18) 5.5 (0.22) Important: The piggyback mounting option cannot be used with Frame B PowerFlex 4 drives and Frame C EMC Line Filters.
Accessories and Dimensions B-13 Figure B.12 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2 17.6 (0.69) 104 (4.09) 220 (8.66) 2.9m 78 (3.07) 66 (2.60) 194 (7.64) 125 (4.92) 60.5 (2.38) 19.1 (0.75) 4.8 (0.19) 38 (1.
B-14 Accessories and Dimensions Figure B.13 Remote (Panel Mount) Small HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2S 25 (0.98) 93 (3.66) 180 (7.09) 2m 67 (2.64) 60 (2.36) 154 (6.06) 19.1 (0.75) 77 (3.03) 4.8 (0.19) 23.5 (0.93) Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement.
Accessories and Dimensions Figure B.14 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-B1 11.1 (0.44) 93 (3.66) 25.2 (0.99) 180 (7.09) 2m 67 (2.64) 60 (2.36) 154 (6.06) 19.1 (0.75) 77 (3.03) 4.8 (0.19) 23.5 (0.
B-16 Notes: Accessories and Dimensions
Appendix C RS485 (DSI) Protocol PowerFlex 4 drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some Modbus functions are supported to allow simple networking. PowerFlex 4 drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode. Controller For information regarding DeviceNet or other communication protocols, refer to the appropriate usr manual.
C-2 RS485 (DSI) Protocol Standard RS485 wiring practices apply. Termination resistors need to be applied at each end of the network cable. RS485 repeaters may need to be used for long cable runs, or if greater than 32 nodes are needed on the network. Control Terminal 16 on the PowerFlex 4 must also be connected to PE ground (there are two PE terminals on the drive). See Figure 1.5 for more information.
RS485 (DSI) Protocol C-3 Writing (06) Logic Command Data The PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8192 (Logic Command). P036 [Start Source] must be set to 5 “RS485 (DSI) Port” in order to accept the commands. In addition to being written, register address 8192 can be read using Function Code 03.
C-4 RS485 (DSI) Protocol Writing (06) Reference The Speed Reference to a PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8193 (Reference). P038 [Speed Reference] must be set to 5 “RS485 (DSI) Port” in order to accept the Speed Reference. In addition to being written, register address 8193 can be read using Function Code 03. Reference Address (Decimal) 8193 Description A decimal value entered as xxx.x where the decimal point is fixed.
RS485 (DSI) Protocol C-5 Reading (03) Drive Error Codes The PowerFlex 4 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error Codes).
C-6 Notes: RS485 (DSI) Protocol
Appendix D RJ45 DSI Splitter Cable The PowerFlex 4 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 ! ATTENTION: Risk of injury or equipment damage exists. The peripherals may not perform as intended if these Connectivity Guidelines are not followed. Precautions should be taken to follow these Connectivity Guidelines.
RJ45 DSI Splitter Cable DSI Cable Accessories PIN 1 S RJ45 Splitter Cable – Catalog Number: AK-U0-RJ45-SC1 Slave Port M D-2 Master Port PIN 8 RJ45 Two-Position Terminal Block Adapter – Catalog Number: AK-U0-RJ45-TB2P TB2 (PIN 5) PIN 8 TB1 (PIN 4) PIN 1 RJ45 Adapter with Integrated Termination Resistor – Catalog Number: AK-U0-RJ45-TR1 PIN 8 PIN 1
RJ45 DSI Splitter Cable Connecting an RS-485 Network DSI / MDI Drives AK-U0-RJ45-TB2P Two-position Terminal Block AK-U0-RJ45-TR1 Terminating Resistor (end of network) or 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.
D-4 Notes: RJ45 DSI Splitter Cable
Index A AC Supply Ground, 1-4 Source, 1-3 Ungrounded, 1-3 Advanced Program Group Parameters, 3-13 Ambient Temperatures, 1-2 Armored Cable, 1-8 Auto Rstrt Tries Fault, 4-4 Auxiliary Input Fault, 4-3 B Before Applying Power, 2-1, 2-2 Bus Capacitors, Discharging, P-3 C Cable Length, 1-12 Cable, Power, 1-8 Capacitors, Discharging, P-3 Catalog Number Explanation, P-4 CE Conformity, 1-20 Checklist, Start-Up, 2-1, 2-2 Circuit Breakers Input, 1-6 Comm Loss Fault, 4-4 Command Sources for Start and Speed, 1-18 Cont
Index-2 G General Precautions, P-3 Ground Fault, 4-3 Grounding Filter, 1-5 General, 1-4 H Heatsink OvrTmp Fault, 4-3 HW OverCurrent Fault, 4-3 I I/O Wiring, 1-11 Wiring Examples, 1-14, 1-17 I/O Board Fail Fault, 4-4 Input Contactor, 1-11 Input Fusing, 1-6 Input Potentiometer, 1-14 Input Power Conditioning, 1-4 Installation, 1-1 Integral Keypad, 2-3 Interference, EMC/RFI, 1-20 K Keypad, 2-3 L LEDs, 2-3 M Minimum Clearances, 1-2 Motor Cable Length, 1-9 Motor Overload Fault, 4-3 Motor Stalled Fault, 4-3
Index-3 Start/Stop, Repeated, 1-11 Start-Up Checklist, 2-1, 2-2 Static Discharge, ESD, P-3 Status LEDs, 2-3 Supply Source, AC, 1-3 SW OverCurrent Fault, 4-4 System Grounding, 1-4 T Terminal Block I/O, 1-12 Power, 1-10 Three Wire Control, 1-14, 1-17 Two Wire Control, 1-14, 1-17 U UnderVoltage Fault, 4-3 Ungrounded Supply, 1-3 Unshielded Power Cables, 1-8 W Watts Loss, A-4 Wiring, 1-1 Block Diagram, 1-13 I/O, 1-11 I/O Examples, 1-14, 1-17 Potentiometer, 1-14 Power, 1-8 PTC Example, 1-14
Index-4 Notes:
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