Adjustable Frequency AC Drive

Adjustable Frequency AC Drive
Adjustable
Frequency AC
Drive
User Manual
www.abpowerflex.com
Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. “Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls” (Publication SGI-1.1 available from
your local Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi)
describes some important differences between solid state equipment and
hard-wired electromechanical devices. Because of this difference, and also
because of the wide variety of uses for solid state equipment, all persons
responsible for applying this equipment must satisfy themselves that each intended
application of this equipment is acceptable.
In no event will the Allen-Bradley Company be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, the Allen-Bradley Company cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
!
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss.
Attentions help you:
•
•
•
identify a hazard
avoid the hazard
recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
Shock Hazard labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the drive to alert
people that surfaces may be at dangerous temperatures.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
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 . . . . . . . . . . . . . 1-2
AC Supply Source Considerations . . . . . . 1-3
General Grounding Requirements. . . . . . . 1-4
Fuses and Circuit Breakers . . . . . . . . . . . . 1-6
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . 1-8
I/O Wiring Recommendations. . . . . . . . . 1-11
Start and Speed Reference Control . . . . . 1-16
EMC Instructions . . . . . . . . . . . . . . . . . . 1-18
Chapter 2
Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters . . . . . . . . 2-4
Chapter 3
Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization . . . . . . . . . . . . . . . 3-2
Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-8
Advanced Program Group. . . . . . . . . . . . 3-13
Parameter Cross Reference – by Name . . 3-25
Chapter 4
Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . .
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Descriptions . . . . . . . . . . . . . . . . . . .
Common Symptoms and
Corrective Actions . . . . . . . . . . . . . . . . . . .
Appendix A
4-1
4-1
4-3
4-5
Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Specifications . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B
Accessories and Dimensions
Product Selection. . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions . . . . . . . . . . . . . . . . . B-5
Appendix C
Index
RS485 Protocol
ii
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. 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
Industrial Automation Wiring
and Grounding Guidelines
Preventive Maintenance of
Industrial Control and Drive
System Equipment
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
A Global Reference Guide for
Reading Schematic Diagrams
Guarding Against Electrostatic
Damage
(1)
Publication
1770-4.1
Available Online at …
(1)
DRIVES-SB001A-EN-E www.ab.com/manuals/dr
SGI-1.1
www.ab.com/manuals/gi
0100-2.10
(1)
8000-4.5.2
www.ab.com/manuals/gi
Not available online, contact your local Allen-Bradley Sales Office.
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.
Parameter numbers and names are shown in this format:
P031 [Motor NP Volts]
Name
Number
Group
d = Display Group
P = Basic Program Group
A = Advanced Program Group
•
The following words are used throughout the manual to describe an
action:
Word
Can
Cannot
May
Shall
Should
Should Not
Meaning
Possible, able to do something
Not possible, not able to do something
Permitted, allowed
Required and necessary
Recommended
Not Recommended
Drive Frame Sizes
Similar PowerFlex 4 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference 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 adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
P-4
Overview
Catalog Number Explanation
22A
Drive
-
A
Dash
1P5
Voltage Rating Rating
N
1
Enclosure
HIM
1
Code
22A PowerFlex 4
Code
V
A
B
D
4
Emission Class
Comm Slot
Code Version
4
RS485
Voltage
120V AC
240V AC
240V AC
480V AC
Code Rating
0
No Filter
1
Integral EMI Filter
Ph.
1
1
3
3
Code Interface Module
1
Fixed Keypad
Code Enclosure
N
Panel Mount - IP 20 (NEMA Type Open)
Output Current @ 380-480V Input
Output Current @ 100-120 Input or 200-240V Input
Code
1P4
2P3
4P0
6P0
8P7
Code
1P5
2P3
4P5
8P0
012
017
Amps
1.4
2.3
4.0
6.0
8.7
kW (HP)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
Amps
1.5
2.3
4.5
8.0
12
17.5
kW (HP)
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
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
1-18
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. The Allen-Bradley Company cannot assume responsibility
for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.
Opening the Cover
1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
1-2
Installation/Wiring
Mounting Considerations
•
Mount the drive upright on a flat, vertical and level surface.
– Install on 35 mm DIN Rail.
or
– Install with screws.
Table 1.A Screw Mounting Recommendations
•
•
•
Minimum Panel Thickness Screw Size
Mounting Torque
1.9 mm (0.0747 in.)
1.56-1.96 Nm (14-17 lb.-in.)
m4 x 0.7 (#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.
Minimum Mounting Clearances
Refer to Appendix B for mounting dimensions.
25 mm
(1.0 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Mounting Option A
No clearance required
between drives.
Mounting Option B
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Ambient Operating Temperatures
Table 1.B Enclosure and Clearance Requirements
Ambient Temperature
Minimum
-10°C (14°F)
Enclosure Rating
Minimum Mounting
Clearances
IP 20/Open Type
Use Mounting Option A
Maximum
40°C (104°F)
IP 30/NEMA 1/UL Type 1(1) Use Mounting Option B
50°C (122°F) IP 20/Open Type
(1)
Use Mounting Option B
Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.
Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP 20/Open Type applications.
Storage
•
•
•
Store within an ambient temperature range of -40° to +85°C.
Store within a relative humidity range of 0% to 95%,
non-condensing.
Do not expose to a corrosive atmosphere.
Installation/Wiring
1-3
AC Supply Source Considerations
Ungrounded Distribution Systems
!
ATTENTION: PowerFlex 4 drives contain protective MOVs that are
referenced to ground. These devices should be disconnected if the drive
is installed on an ungrounded distribution system.
Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.
1. Turn the screw counterclockwise to loosen.
2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Figure 1.1 Jumper Location (A Frame Shown)
Important:
Tighten screw after
jumper removal.
Figure 1.2 Phase to Ground MOV Removal
R/L1
Three-Phase
AC Input S/L2
T/L3
Jumper
1
2
3
4
1-4
Installation/Wiring
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.C are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.C, install one of the devices listed under the heading Corrective
Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be
mounted closest to the branch and sized to handle the total
current of the branch circuit.
Table 1.C Input Power Conditions
Input Power Condition
Corrective Action
Low Line Impedance (less than 1% line reactance) • Install Line Reactor(1)
• or Isolation Transformer
Greater than 120 kVA supply transformer
Line has power factor correction capacitors
Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of normal
line to line voltage
Ungrounded distribution system
(1)
• Remove MOV jumper to ground.
• and Install Isolation Transformer
with grounded secondary if
necessary.
Refer to Appendix B for accessory ordering information.
General Grounding Requirements
The drive Safety Ground (PE) must be connected to system ground.
Ground impedance must conform to the requirements of national and
local industrial safety regulations and/or electrical codes. The integrity
of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding
R/L1
S/L2
T/L3
U/T1
V/T2
W/T3
SHLD
Installation/Wiring
1-5
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Safety Ground -
(PE)
This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the 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.
RFI Filter Grounding
Using single phase drives with integral filter, or an external filter with
any drive rating, may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded
AC supply systems and be permanently installed and solidly
grounded (bonded) to the building power distribution ground. Ensure
that the incoming supply neutral is solidly connected (bonded) to the
same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should
be periodically checked.
1-6
Installation/Wiring
Fuses and Circuit Breakers
The PowerFlex 4 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in Table 1.D.
Fusing
The PowerFlex 4 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide. Other devices which meet the
requirements of UL508C and UL489 with similar trip characteristics
may be used in order to meet local or national electrical codes.
Bulletin 140 Manual Motor Starters/UL489 Circuit Breakers
When using Bulletin 140 manual motor starters or UL489 rated circuit
breakers, the guidelines listed below must be followed in order to meet
the NEC requirements for branch circuit protection.
•
•
•
•
Bulletin 140 manual motor starters can be used in single and group
motor applications.
In single motor applications, a fuse or UL489 rated circuit breaker is
required ahead of the Bulletin 140 manual motor starter.
In group motor installations, the Bulletin 140 can be used for
protection of an individual motor within the group and “one set” of
fuses or a UL489 rated circuit breaker serves as the Branch Circuit
Protective Device for the entire “Group Installation”.
Bulletin 140M manual motor starters can be used in single and group
motor applications without additional short circuit protection. Refer
to the technical support literature for the 140M for more details.
Installation/Wiring
Table 1.D Minimum Recommended Branch Circuit Protective Devices
Voltage
Rating
Drive Rating
kW (HP)
Fuse Rating(1)
Amps
Other Protective
Devices(2)
Amps
Recommended
MCS Contactors
Catalog No.
120V AC –
1-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
10
15
30
10
15
30
100-C09
100-C12
100-C23
240V AC –
1-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
10
10
15
30
5
10
15
25
100-C07
100-C09
100-C12
100-C23
240V AC –
3-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
3
6
10
15
25
35
5
5
7
15
25
30
100-C07
100-C07
100-C09
100-C12
100-C23
100-C23
480V AC –
3-Phase
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
3
6
10
15
15
3
4
7
10
15
100-C07
100-C07
100-C09
100-C09
100-C12
(1)
(2)
Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
Includes 140-MN-xxx (A-B Bulletin 140 Manual Motor Starter) or HMCP circuit breaker or
equivalent. Refer to Appendix B for detailed catalog numbers.
1-7
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.
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.
Motor Cable Types Acceptable for 200-600 Volt Installations
General
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.).
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of
15 mils and should not have large variations in insulation concentricity.
Shielded
Location
Standard
(Option 1)
Rating/Type
600V, 75°C or 90°C (167°F
or 194°F) RHH/RHW-2
Belden 29501-29507 or
equivalent
Standard
Tray rated 600V, 75°C or
(Option 2)
90°C (167°F or 194°F)
RHH/RHW-2
Shawflex 2ACD/3ACD or
equivalent
Class I & II; Tray rated 600V, 75°C or
Division I & II 90°C (167°F or 194°F)
RHH/RHW-2
Description
• Four tinned copper conductors with XLPE insulation
• Foil shield and tinned copper drain wire with 85% braid
coverage
• PVC jacket
• Three tinned copper conductors with XLPE insulation
• 5 mil single helical copper tape (25% overlap min.)
with three bare copper grounds in contact with shield
• PVC jacket
• Three bare copper conductors with XLPE insulation
with impervious corrugated continuously welded
aluminum armor
• Black sunlight resistant PVC jacket overall
• Three copper grounds on #10 AWG and smaller
Installation/Wiring
1-9
Reflected Wave Protection
The drive should be installed as close to the motor as possible.
Installations with long motor cables may require the addition of external
devices to limit voltage reflections at the motor (reflected wave
phenomena). See Table 1.E for recommendations.
The reflected wave data applies to all frequencies 2 to 16 kHz.
For 240V ratings, reflected wave effects do not need to be considered.
Table 1.E Maximum Cable Length Recommendations
Reflected Wave
380-480V Ratings
(1)
Motor Insulation Rating
Motor Cable Only(1)
1000 Vp-p
15 meters (49 feet)
1200 Vp-p
40 meters (131 feet)
1600 Vp-p
170 meters (558 feet)
Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.
Output Disconnect
The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.
1-10
Installation/Wiring
Power Terminal Block
The drive utilizes a finger guard over the power wiring terminals. To
remove:
1. Press in and hold the locking tab.
2. Slide finger guard down and out.
Replace the finger guard when wiring is complete.
Figure 1.4 Power Terminal Block (A Frame Shown)
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3
BR+ BR-
Terminal
R/L1, S/L2
R/L1, S/L2, T/L3
U/T1
V/T2
W/T3
BR+, BR-
Description
1-Phase Input
3-Phase Input
To Motor U/T1
To Motor V/T2
=
To Motor W/T3
Dynamic Brake Resistor Connection
[0.75 kW (1 HP) ratings and higher]
Safety Ground - PE
Switch any two motor
leads to change
forward direction.
Table 1.F Power Terminal Block Specifications
Frame
Maximum Wire Size (1) Minimum Wire Size (1) Torque
A
3.3 mm2 (12 AWG)
0.8 mm2 (18 AWG)
B
5.3 mm2 (10 AWG)
1.3 mm2 (16 AWG)
(1)
1.7-2.2 N-m (16-19 lb.-in.)
Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
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.
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:
•
•
•
Always use copper wire.
Wire with an insulation rating of 600V or greater is recommended.
Control and signal wires should be separated from power wires by at
least 0.3 meters (1 foot).
Important: I/O terminals labeled “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.
1-12
Installation/Wiring
Control Wire Types
Table 1.G Recommended Control and Signal Wire(1)
Wire Type(s)
Description
Belden 8760/9460
(or equiv.)
0.8 mm2 (18AWG), twisted pair, 100%
shield with drain. (1)
Belden 8770
(or equiv.)
(1)
Minimum
Insulation Rating
300V
60 degrees C
0.8 mm2 (18AWG), 3 conductor, shielded for (140 degrees F)
remote pot only.
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.
I/O Terminal Block
Table 1.H I/O Terminal Block Specifications
Maximum Wire Size (1)
Minimum Wire Size (1)
Torque
1.3 mm2 (16 AWG)
0.5-0.8 N-m (4.4-7 lb.-in.)
(1)
0.13 mm2 (26 AWG)
Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Maximum Control Wire Recommendations
Do not exceed control wiring length of 30 meters (100 feet). Control
signal cable length is highly dependent on electrical environment and
installation practices. To improve noise immunity, the I/O terminal block
Common must be connected to ground terminal/protective earth. If using
the RS485 (DSI) port, I/O Terminal 16 should also be connected to
ground terminal/protective earth.
Installation/Wiring
1-13
Figure 1.5 Control Wiring Block Diagram
(1) Important: The drive is shipped
with a jumper installed between I/O
Terminals 01 and 11 to enable
keypad control. Remove this
jumper when using I/O Terminal 01
as a stop input.
Important: P037 [Stop Mode] does
not control I/O Terminal 01 except
when P036 [Start Source] is set for
“3-Wire” control. In all other
instances, I/O Terminal 01 is a
“Coast to Stop” input.
01
02
03
SNK
SRC
04
05
06
(2) Two wire control shown. For
+24V
three wire control use a momentary
input.
+10V
11
12
13
Relay N.O.
Relay Common
Relay N.C.
R1
14
R2
15
R3
16
Stop
(1)
Typical
Typical
SRC Wiring SNK Wiring
Start/Run FWD (2)
Dir/Run REV
Digital Common
Digital Input 1
Digital Input 2
+24V DC
+10V DC
0-10V In
Analog Common
4-20mA In
RS485 Shield
Potentiometer
must be
1-10k ohm
2 Watt Min.
01 02 03 04 05 06
R1 R2 R3
30V DC 125V AC 240V AC
Resistive
3.0A
3.0A
3.0A
Inductive
0.5A
0.5A
0.5A
SNK
SRC
11
12 13 14 15 16
(1)
RS485
(DSI)
81
No. Signal
Default
Description
Param.
R1
R2
R3
Fault
–
Fault
Normally open contact for output relay.
Common for output relay.
Normally closed contact for output relay.
A055
Source (SRC)
Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch
setting.
The factory installed jumper or a normally closed input
must be present for the drive to start.
Relay N.O.
Relay Common
Relay N.C.
Sink/Source DIP Switch
A055
01
Stop(1)
Coast
02
03
Start/Run FWD
Dir/Run REV
Command comes from the integral keypad by default. To P036
disable reverse operation, see A095 [Reverse Disable]. P036, A095
For digital inputs. Electronically isolated with digital inputs
–
from analog I/O.
Preset Frequencies Program with A051 [Digital In1 Sel].
A051
Preset Frequencies Program with A052 [Digital In2 Sel].
A052
Drive supplied power for digital inputs.
–
Maximum output current is 100mA.
Drive supplied power for 0-10V external potentiometer.
–
P038
Maximum output current is 15mA.
For external 0-10V input supply
Not Active
P038
(input impedance = 100k ohm) or potentiometer wiper.
04
Digital Common
05
06
Digital Input 1
Digital Input 2
11
+24V DC
12
+10V DC
13
0-10V In(3)
14
Analog Common
–
15
4-20mA In(3)
Not Active
16
RS485 (DSI) Shield
–
(3)
P036, P037
Not Active
Not Active
For 0-10V In or 4-20mA In. Electronically isolated with
analog inputs from digital I/O.
For external 4-20mA input supply
(input impedance = 250 ohm).
Terminal should be connected to safety ground - PE
when using the RS485 (DSI) communications port.
P038
Only one analog frequency source may be connected at a time. If more than one reference is connected at the same
time, an undetermined frequency reference will result.
1-14
Installation/Wiring
I/O Wiring Examples
Input
Potentiometer
1-10k Ohm Pot.
Recommended
(2 Watt minimum)
Connection Example – Source (SRC) Mode(2)
P038 [Speed Reference] = 2
Analog Input
0 to +10V, 100k ohm
impedance
4-20 mA, 100 ohm
impedance
Voltage
P038 [Speed Reference] = 2
12
13
14
+
Common
13
14
Internal Supply (SRC)
2 Wire Control(1) Non-Reversing
11
P036 [Start Source] = 2, 3
or 4
Stop-Run
Input must be active for
the drive to run. When
input is opened, the drive
will stop as specified by
P037 [Stop Mode].
3 Wire Control Internal Supply (SRC)
Non-Reversing
P036 [Start Source] = 1
Stop 11
A momentary input will
start the drive. A stop
Start
input to I/O Terminal 01
will stop the drive as
specified by P037 [Stop
Mode].
(1)
Current
P038 [Speed Reference] = 2
Common
+
14
15
External Supply (SRC)
02
02
Stop-Run
04
+24V
Common
External Supply (SRC)
Stop
01
02
Start
+24V
01
02
04
Common
If desired, a User Supplied 24V DC power source can be used. Refer to the “External Supply
(SRC)” example.
(2) Setup DIP switch also provides a Sink (SNK) selection. Inputs must be tied to Digital Common.
Installation/Wiring
1-15
Typical Multiple Drive Connection Examples
Input
Multiple Digital Input
Connections
Connection Example
02
04
Customer Inputs
02
04
02
04
02
04
Optional Ground Connection
When connecting a single input such as Run, Stop, Reverse or Preset
Speeds to multiple drives, it is important to connect I/O Terminal 04
common together for all drives. If they are to be tied into another common
(such as earth ground or separate apparatus ground) only one point of
the daisy chain of I/O Terminal 04 should be connected.
Multiple Analog
Connections
12 13 14
Remote Potentiometer
13 14
13 14
13 14
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.
1-16
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.
Jog Input
Enabled and Active:
A051 or A052 = 2
Drive will Start and Run at Jog Speed.
Yes
Direction comes from
Terminal 03 Dir/Run REV
No
Local/Remote Input
Enabled and Active:
A051 or A052 = 5
Yes
Start, Speed and Direction commands
come from Integral Keypad.
Yes
Start, Speed and Direction commands
come from RS485 (DSI) port.
No
Comm Select Input
Enabled and Active:
A051 or A052 = 6
No
Yes
P038 [Speed Reference]
= 4 or 5
Run as specified by
P038 [Speed Reference].
Start and Direction commands come
from P036 [Start Source].
No
A051 / A052
Preset Inputs Active
Yes
No
Run as specified by
P038 [Speed Reference].
Start and Direction commands come
from P036 [Start Source].
Run as specified by
A071-A073 [Preset Freq 1-3].
Start and Direction commands come
from P036 [Start Source].
Installation/Wiring
1-17
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.
Yes
A067 [Accel Time 2]/A068 [Decel Time 2]
is active when input is active.
No
RS485 (DSI) Port
Controls Speed
No
Input is programmed
as “Accel 2 & Decel 2”
A051 or A052 = 1
No
Speed is controlled
by [Preset Freq x]
A051 or A052 = 4
Yes
No
P039 [Accel Time 1]/P040 [Decel Time 1]
are used.
P039 [Accel Time 1]/P040 [Decel Time 1];
A067 [Accel Time 2]/A068 [Decel Time 2]
determined by the active
Preset Frequency.
See A070-A073 [Preset Freq 0-3]
on page 3-16.
1-18
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.
Low Voltage Directive (73/23/EEC)
•
EN50178 Electronic equipment for use in power installations
EMC Directive (89/336/EEC)
•
EN61800-3 Adjustable speed electrical power drive systems Part 3:
EMC product standard including specific test methods.
General Notes
•
•
•
•
If the plastic top panel is removed or the optional conduit box is not
installed, the drive must be installed in an enclosure with side
openings less than 12.5 mm (0.5 in.) and top openings less than 1.0
mm (0.04 in.) to maintain compliance with the LV Directive.
The motor cable should be kept as short as possible in order to avoid
electromagnetic emission as well as capacitive currents.
Use of line filters in ungrounded systems is not recommended.
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.
Installation/Wiring
1-19
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.I Allowable Cable Length (1)
Filter Type
EN61800-3 First Environment
Restricted Distribution or
Second Environment (3)
Integral
5 meters (16 feet)
External - S Type(2) 5 meters (16 feet)
External - L Type(2) 100 meters (328 feet)
EN61800-3 First Environment
Unrestricted Distribution (4)
1 meter (3 feet)
1 meter (3 feet)
5 meters (16 feet)
(1) Testing of longer cable lengths is pending.
(2) Refer to Appendix B for details on optional external filters.
(3) Equivalent to EN55011 Class A.
(4) Equivalent to EN55011 Class B.
Figure 1.6 Connections and Grounding
Shielded Enclosure(1)
IP 30/NEMA 1/UL Type 1
Option Kit
(2)
EMI Filter
L1
L2
L3
L1'
L2'
L3'
EMI Fittings and Metal Conduit
R/L1
S/L2
T/L3
Enclosure Ground Connection
U/T1
V/T2
W/T3
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.
(2) Integral EMI filters are available on 240V, 1-Phase drives.
1-20
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. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the procedure
before beginning. If an event does not occur while performing this
procedure, Do Not Proceed. Remove All Power including user
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.
Prepare For Drive Start-Up
Before Applying Power to the Drive
❏ 1. Confirm that all inputs are connected to the correct terminals and are
secure.
❏ 2. Verify that AC line power at the disconnect device is within the rated
value of the drive.
❏ 3. Verify that any digital control power is 24 volts.
❏ 4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See Figure 1.5 on page 1-13 for
location.
Important: The default control scheme is Source (SRC). The Stop
terminal is jumpered (I/O Terminals 01 and 11) to allow
starting from the keypad. If the control scheme is changed
to Sink (SNK), the jumper must be removed from I/O
Terminals 01 and 11 and installed between I/O Terminals
01 and 04.
❏ 5. Verify that the Stop input is present or the drive will not start.
Important: If I/O Terminal 01 is used as a stop input, the jumper
between I/O Terminals 01 and 11 must be removed.
2-2
Start Up
Applying Power to the Drive
❏ 6. Apply AC power and control voltages to the drive.
❏ 7. Familiarize yourself with the integral keypad features (see page 2-3)
before setting any Program Group parameters.
Start, Stop, Direction and Speed Control
Factory default parameter values allow the drive to be controlled from
the integral keypad. No programming is required to start, stop, change
direction and control speed directly from the integral keypad.
Important: To disable reverse operation, see A095 [Reverse Disable].
If a fault appears on power up, refer to Fault Descriptions on page 4-3
for an explanation of the fault code.
Start Up
2-3
Integral Keypad
➋
➊
➌
RUN
FWD
REV
PROGRAM
➍
➏
Menu
VOLTS
AMPS
HERTZ
➎
FAULT
➑
➐
Description
Display Group (View Only)
Consists of commonly viewed drive operating
conditions.
➒
Basic Program Group
Consists of most commonly used
programmable functions.
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. LED
➊ Run/Direction
Status
LED State
Steady Red
Flashing Red
➋
Alphanumeric
Display
Steady Red
Flashing Red
➌
➍
➎
➏
➐
Displayed Units
Steady Red
Description
Indicates drive is running and commanded motor direction.
Drive has been commanded to change direction. Indicates
actual motor direction while decelerating to zero.
Indicates parameter number, parameter value, or fault code.
Single digit flashing indicates that digit can be edited.
All digits flashing indicates a fault condition.
Indicates the units of the parameter value being displayed.
Program Status
Steady Red
Indicates parameter value can be changed.
Fault Status
Flashing Red
Indicates drive is faulted.
Pot Status
Steady Green
Indicates potentiometer on Integral Keypad is active.
Start Key Status Steady Green
No. Key
➑
Name
Escape
Select
Up Arrow
Down Arrow
Enter
➒
Potentiometer
Start
Reverse
Stop
Indicates Start key on Integral Keypad is active.
The Reverse key is also active unless disabled by A095
[Reverse Disable]
Description
Back one step in programming menu.
Cancel a change to a parameter value and exit Program
Mode.
Advance one step in programming menu.
Select a digit when viewing parameter value.
Scroll through groups and parameters.
Increase/decrease the value of a flashing digit.
Advance one step in programming menu.
Save a change to a parameter value.
Used to control speed of drive. Default is active.
Controlled by parameter P038 [Speed Reference].
Used to start the drive. Default is active.
Controlled by parameter P036 [Start Source].
Used to reverse direction of the drive. Default is active.
Controlled by parameters P036 [Start Source] and A095
[Reverse Disable].
Used to stop the drive or clear a fault.
This key is always active.
Controlled by parameter P037 [Stop Mode].
2-4
Start Up
Viewing and Editing Parameters
The last user-selected Display Group parameter is saved when power is removed and is displayed by
default when power is reapplied.
The following is an example of basic integral keypad and display functions. This example provides basic
navigation instructions and illustrates how to program the first Program Group parameter.
Step
Key(s)
Example Displays
1. When power is applied, the last user-selected
VOLTS
AMPS
Display Group parameter number is briefly
HERTZ
displayed with flashing characters. The display
PROGRAM
FAULT
then defaults to that parameter’s current value.
(Example shows the value of d001 [Output
Freq] with the drive stopped.)
2. Press Esc once to display the Display Group
parameter number shown on power-up. The
parameter number will flash.
VOLTS
AMPS
HERTZ
PROGRAM
FAULT
3. Press Esc again to enter the group menu. The
group menu letter will flash.
VOLTS
AMPS
HERTZ
4. Press the Up Arrow or Down Arrow to scroll
through the group menu (d, P and A).
or
5. Press Enter or Sel to enter a group. The right
digit of the last viewed parameter in that group
will flash.
or
6. Press the Up Arrow or Down Arrow to scroll
through the parameters that are in the group.
or
7. Press Enter or Sel to view the value of a
parameter. If you do not want to edit the value,
press Esc to return to the parameter number.
or
8. Press Enter or Sel to enter program mode to
edit the parameter value. The right digit will
flash and the Program LED will illuminate if the
parameter can be edited.
or
9. Press the Up Arrow or Down Arrow to change
the parameter value. If desired, press Sel to
move from digit to digit or bit to bit. The digit or
bit that you can change will flash.
or
PROGRAM
FAULT
VOLTS
AMPS
HERTZ
PROGRAM
FAULT
VOLTS
AMPS
HERTZ
PROGRAM
FAULT
VOLTS
AMPS
HERTZ
PROGRAM
FAULT
10. Press Esc to cancel a change. The digit will
stop flashing, the previous value is restored and
the Program LED will turn off.
Or
Press Enter to save a change. The digit will stop
flashing and the Program LED will turn off.
VOLTS
AMPS
HERTZ
PROGRAM
11. Press Esc to return to the parameter list.
Continue to press Esc to back out of the
programming menu.
If pressing Esc does not change the display,
then d001 [Output Frequency] is displayed.
Press Enter or Sel to enter the group menu.
FAULT
VOLTS
AMPS
HERTZ
PROGRAM
FAULT
The Basic Program Group (page 3-8) contains the most commonly changed parameters.
Chapter 3
Programming and Parameters
Chapter 3 provides a complete listing and description of the PowerFlex
4 parameters. Parameters are programmed (viewed/edited) using the
integral keypad. As an alternative, programming can also be performed
using DriveExplorer™ or DriveExecutive™ software, a personal
computer and a serial converter module. Refer to Appendix B for catalog
numbers.
For information on…
About Parameters
Parameter Organization
Basic Program Group
Advanced Program Group
Parameter Cross Reference – by Name
See page…
3-1
3-2
3-8
3-13
3-25
About Parameters
To configure a drive to operate in a specific way, drive parameters may
have to be set. Three types of parameters exist:
•
ENUM
ENUM parameters allow a selection from 2 or more items. Each
item is represented by a number.
•
Numeric Parameters
These parameters have a single numerical value (i.e. 0.1 Volts).
•
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.
32
= 32 bit parameter. Parameters marked 32 bit will have two
parameter numbers when using RS485 communications and
programming software.
3-2
Programming and Parameters
Parameter Organization
Displa
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
y Gro
B
Progr asic
am G
roup
up
d001
d002
d003
d004
d005
d006
d007
d008
d009
d010
d012
d013
d014
d015
d016
d017
d018
d019
See page 3-8
Motor NP Volts
Motor NP Hertz
Motor OL Current
Minimum Freq
Maximum Freq
Start Source
Stop Mode
Speed Reference
Accel Time 1
Decel Time 1
Reset To Defaults
P031
P032
P033
P034
P035
P036
P037
P038
P039
P040
P041
Ad
Progrvanced
am G
roup
See page 3-13
Digital In1 Sel
Digital In2 Sel
Relay Out Sel
Relay Out Level
Accel Time 2
Decel Time 2
Internal Freq
Preset Freq 0
Preset Freq 1
Preset Freq 2
Preset Freq 3
Jog Frequency
Jog Accel/Decel
DC Brake Time
DC Brake Level
DB Resistor Sel
S Curve %
Start Boost
Maximum Voltage
Current Limit
Motor OL Select
PWM Frequency
Auto Rstrt Tries
Auto Rstrt Delay
Start At 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
A051
A052
A055
A056
A067
A068
A069
A070
A071
A072
A073
A078
A079
A080
A081
A082
A083
A084
A088
A089
A090
A091
A092
A093
A094
A095
A096
A097
A098
A099
A100
A101
A102
A103
A104
A105
A106
A107
Programming and Parameters
3-3
Display Group
d001 [Output Freq]
Related Parameter(s): d002, d010, P034, P035
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, 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 1-16 for details.
Values Default
Read Only
Min/Max:
0.0/P035 [Maximum Freq]
Display:
0.1 Hz
d003 [Output Current]
The output current present at T1, T2 & T3 (U, V & W).
Values Default
Read Only
Min/Max:
0.00/Drive Rated Amps × 2
Display:
0.01 Amps
d004 [Output Voltage]
Related Parameter(s): P031, A084, A088
Output voltage present at terminals T1, T2 & T3 (U, V & W).
Values Default
Read Only
Min/Max:
0/Drive Rated Volts
Display:
1 VAC
d005 [DC Bus Voltage]
Present DC bus voltage level.
Values Default
Read Only
Min/Max:
Based on Drive Rating
Display:
1 VDC
3-4
Programming and Parameters
Display Group (continued)
d006 [Drive Status]
Related Parameter(s): A095
Present operating condition of the drive.
1 = Condition True
Running
Forward
Accelerating
Decelerating
Values
Bit 0
Bit 1
Bit 2
Bit 3
Default
Read Only
Min/Max:
0/1
Display:
1
d007 [Fault 1 Code]
d008 [Fault 2 Code]
d009 [Fault 3 Code]
A code that represents a drive fault. The codes will appear in these parameters in the order they occur
(d007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.
Refer to Chapter 4 for fault code descriptions.
Values Default
Read Only
32
Min/Max:
F2/F122
Display:
F1
32 bit parameter.
d010 [Process Display]
Related Parameter(s): d001, A099
The output frequency scaled by A099 [Process Factor].
Output
Process
Process
Freq x Factor = Display
Values
Default
Read Only
Min/Max:
0.00/9999
Display:
0.01 – 1
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 1-16 and 1-17 for details.
Start Command
Bit 0
0 = Keypad
1 = 3-Wire
2 = 2-Wire
3 = 2-Wire Level Sensitive
4 = 2-Wire High Speed
5 = RS485 (DSI) Port
9 = Jog
Speed Command
Bit 1
0 = Drive Potentiometer
1 = A069 [Internal Freq]
2 = 0-10V Input/Remote Potentiometer
3 = 4-20mA Input
4 = A070-A073 [Preset Freq x]
(A051 - A052 [Digital Inx Sel] must be set to 4)
5 = RS485 (DSI) Port
9 = Jog Freq
Reserved
Bit 2
Reserved
Bit 3
Values
Default
Min/Max:
Display:
Read Only
0/9
1
d013 [Contrl In Status]
Related Parameter(s): d002, P034, P035
Status of the control terminal block control inputs.
Important: Actual control commands may come from a source other than the control terminal block.
1 = Input Present
Start / Run FWD Input (I/O Terminal 02)
Direction / Run REV Input (I/O Terminal 03)
Stop Input(1) (I/O Terminal 01)
Reserved
(1)
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
Bit 0
Bit 1
Bit 2
Bit 3
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
Digital In1 Sel (I/O Terminal 05)
Digital In2 Sel (I/O Terminal 06)
Reserved
Reserved
Values
Default
Read Only
Min/Max:
0/1
Display:
1
d015 [Comm Status]
Bit 0
Bit 1
Bit 2
Bit 3
Related Parameter(s): A103 thru A107
Status of the communications device.
1 = Condition True
Receiving Data
Transmitting Data
RS485 (DSI) Based Option Connected
(Allen-Bradley devices only.)
Communication Error Occurred
Values
Default
Read Only
Min/Max:
0/1
Display:
1
d016 [Control SW Ver]
Main Control Board software version.
Values Default
Read Only
Min/Max:
1.00/99.99
Display:
0.01
d017 [Drive Type]
Used by Rockwell Automation field service personnel.
Values Default
Read Only
Min/Max:
1001/9999
Display:
1
Bit 0
Bit 1
Bit 2
Bit 3
Programming and Parameters
3-7
Display Group (continued)
d018 [Elapsed Run Time]
Accumulated time drive is outputting power. Time is displayed in 10 hour increments.
Values Default
Read Only
Min/Max:
0/9999 Hrs
Display:
1 = 10 Hrs
d019 [Testpoint Data]
Related Parameter(s): A102
The present value of the function selected in A102 [Testpoint Sel].
Values Default
Read Only
Min/Max:
0/FFFF
Display:
1 Hex
3-8
Programming and Parameters
Basic Program Group
Stop drive before changing this parameter.
P031 [Motor NP Volts]
Related Parameter(s): A084
Set to the motor nameplate rated volts.
Values Default
Based on Drive Rating
Min/Max:
20/Drive Rated Volts
Display:
1 VAC
Stop drive before changing this parameter.
P032 [Motor NP Hertz]
Related Parameter(s):A084
Set to the motor nameplate rated frequency.
Values Default
60 Hz
Min/Max:
10/240 Hz
Display:
1 Hz
P033 [Motor OL Current]
Related Parameter(s): A089, A090, A098
Set to the maximum allowable motor current.
The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150% for 60
seconds or 200% for 3 seconds.
Values Default
Based on Drive Rating
Min/Max:
0.0/(Drive Rated Amps × 2)
Display:
0.1 Amps
P034 [Minimum Freq]
Related Parameter(s): P035
Sets the lowest frequency the drive will output continuously.
Values Default
0.0 Hz
Min/Max:
0.0/240.0 Hz
Display:
0.1 Hz
Stop drive before changing this parameter.
P035 [Maximum Freq]
Related Parameter(s): P034
Sets the highest frequency the drive will output.
Values Default
60 Hz
Min/Max:
0/240 Hz
Display:
1 Hz
Programming and Parameters
3-9
Basic Program Group (continued)
Stop drive before changing this parameter.
P036 [Start Source]
Related Parameter(s): d012
Sets the control scheme used to start the drive.
Refer to Start and Speed Reference Control on page 1-16 for details about how other drive settings
can override the setting of this parameter.
Important: For all settings except option 3, the drive must receive a leading edge from the start input
for the drive to start after a stop input, loss of power or fault condition.
Options 0 “Keypad” (Default)
• Integral keypad controls drive operation.
• I/O Terminal 1 “Stop” = coast to stop.
• When active, the Reverse key is also active unless
disabled by A095 [Reverse Disable].
1 “3-Wire”
I/O Terminal 1 “Stop” = stop according to the value set in
P037 [Stop Mode].
2 “2-Wire”
I/O Terminal 1 “Stop” = coast to stop.
3 “2-Wire Level
Sensitive”
Drive will restart after a “Stop” command when:
• Stop is removed
and
• Start is held active
!
ATTENTION: Hazard of injury exists due to unintended operation. When
P036 [Start Source] is set to option 3, and the Run input is maintained, the
Run inputs do not need to be toggled after a Stop input for the drive to run
again. A Stop function is provided only when the Stop input is active (open).
4 “2-Wire High Speed”
Important: There is greater potential voltage on the output
terminals when using this option.
• Outputs are kept in a ready-to-run state. The drive will
respond to a “Start” command within 10 ms.
• I/O Terminal 1 “Stop” = coast to stop.
5 “RS485 (DSI) Port”
• Remote communications.
• I/O Terminal 1 “Stop” = coast to stop.
Important: When commanding Jog via the RS485 communications port on drives with firmware
version 1.02 or earlier, the Jog command will follow the commanded direction from I/O Terminal 03.
On firmware versions 1.03 and later, the commanded direction will be provided via the RS485
communications port.
Important: When sending a continuous start command via the RS485 communications port on drives
with firmware version 1.02 or earlier, a maintained stop input is required to stop the drive. Once the
stop input is inactive, the drive will restart. On firmware versions 1.03 and later, once a stop input is
received, the start command must transition from high to low to high for the drive to start.
3-10
Programming and Parameters
Basic Program Group (continued)
P037 [Stop Mode]
Related Parameter(s): P036, A080, A081, A082
Active stop mode for all stop sources except as noted below.
When this parameter is set to option 0, 1, 2 or 3, the stop input [i.e., keypad stop, I/O Terminal 01 or
RS485 (DSI) port] can be used to clear an active fault. Refer to Chapter 4 for other methods for
clearing fault conditions.
Important: P037 [Stop Mode] does not control I/O Terminal 01 except when P036 [Start Source] is
set for “3-Wire” control. In all other instances, I/O Terminal 01 is a “Coast to Stop” input.
Important: When using options 2, 3, 6 or 7, parameters A080 [DC Brake Time] and A081 [DC Brake
Level] must be set to meet application requirements.
Options 0 “Ramp, Clear Fault”
Ramp to Stop. “Stop” command clears active fault.
(Default)
1 “Coast, Clear Fault”
Coast to Stop. “Stop” command clears active fault.
2 “DC Brake, Clear Fault” DC Injection Braking Stop. “Stop” command clears active
fault.
3 “DC Brake w/Shutoff,
Clear Fault”
DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
• Drive shuts off if the drive detects that the motor is
stopped.
“Stop” command clears active fault.
4 “Ramp”
Ramp to Stop.
5 “Coast”
Coast to Stop.
6 “DC Brake”
DC Injection Braking Stop.
7 “DC Brake w/Shutoff”
DC Injection Braking Stop with Auto Shutoff.
• Standard DC Injection Braking for value set in A080 [DC
Brake Time].
OR
• Drive shuts off if current limit is exceeded.
Programming and Parameters
3-11
Basic Program Group (continued)
P038 [Speed Reference]
Related Parameter(s): d012, A069, A070, A071, A072,
A073
Sets the source of the speed reference to the drive.
Important: When A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or 6, and the digital input is
active, A051 or A052 will override the speed reference commanded by this parameter.
Refer to Start and Speed Reference Control on page 1-16 for details about how other drive settings
can override the setting of this parameter.
Options 0 “Drive Potentiometer” Internal frequency command from the potentiometer on the
(Default)
integral keypad.
1 “Internal Freq”
Internal frequency command from A069 [Internal Freq].
2 “0-10V Input/Remote External frequency command from the 0-10V analog input or
Potentiometer”
remote potentiometer.
3 “4-20mA Input”
External frequency command from the 4-20mA analog input.
4 “Preset Freq 0-3”
External frequency command as defined by A070 - A073
[Preset Freq x] when A051 and A052 [Digital Inx Sel] are
programmed as “Preset Frequencies” and the digital inputs
are active.
5 “RS485 (DSI) Port”
External frequency command from the communications port.
P039 [Accel Time 1]
Related Parameter(s): P038, P040, A051, A052, A067
Sets the rate of acceleration for all speed increases.
Maximum Freq
= Accel Rate
Accel Time
Values
Default
10.0 Secs
Min/Max:
0.0/600.0 Secs
Display:
0.1 Secs
[Maximum Freq]
Acc
tion
ele
ra
ele
ratio
n
Dec
Speed
0
[Accel Time]
0
Time
[Decel Time]
3-12
Programming and Parameters
Basic Program Group (continued)
P040 [Decel Time 1]
Related Parameter(s): P038, P039, A051, A052, A068
Sets the rate of deceleration for all speed decreases.
Maximum Freq
= Decel Rate
Decel Time
Values
Default
Min/Max:
Display:
10.0 Secs
0.1/600.0 Secs
0.1 Secs
[Maximum Freq]
Acc
tion
ele
ra
ele
ratio
n
Dec
Speed
0
[Accel Time]
Time
[Decel Time]
0
Stop drive before changing this parameter.
P041 [Reset To Defaults]
Resets all parameter values to factory defaults.
Options 0 “Idle State” (Default)
1 “Reset Defaults”
• After the reset function is complete, this parameter will set
itself back to “0”.
• Causes an F48 Params Defaulted fault.
Programming and Parameters
3-13
Advanced Program Group
Stop drive before changing this parameter.
A051 [Digital In1 Sel]
Related Parameter(s): A067, A068, A070-A078, A078, A079
(I/O Terminal 5)
A052 [Digital In2 Sel]
(I/O Terminal 6)
Selects the function for the digital inputs. Refer to the flowchart on page 1-16 for more information on
speed reference control priority.
Options 0 “Not Used”
1 “Accel 2 & Decel 2”
2 “Jog”
3 “Auxiliary Fault”
4 “Preset Frequencies”
(Default)
5 “Local”
6 “RS485 (DSI) Port”
7 “Clear Fault”
• Can only be tied to one input.
• When active, A067 [Accel Time 2] and A068 [Decel Time
2] are used for all ramp rates except Jog.
Refer to the flowchart on page 1-17 for more information on
Accel/Decel selection.
• 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].
• When input is removed, drive ramps to a stop according to
the value set in A079 [Jog Accel/Decel].
• A valid “Start” command will override this input.
When enabled, an F2 Auxiliary Input fault will occur when the
input is removed.
Refer to A070 - A073 [Preset Freq x].
Important: Digital Input 1 or 2 has priority for frequency
control when it is programmed as a Preset Speed and is
active.
When active, sets integral keypad as start source and
potentiometer on the integral keypad as speed source.
• Can only be tied to one input.
• When active, sets communications device as default start/
speed command source.
When active, clears an active fault.
3-14
Programming and Parameters
A055 [Relay Out Sel]
Related Parameter(s): P033, A056, A070-A073, A092
Sets the condition that changes the state of the output relay contacts.
Options 0 “Ready” (Not Faulted) Relay changes state when power is applied. This indicates
that the drive is ready for operation. Relay returns drive to
Default
shelf state when power is removed or a fault occurs.
1 “At Frequency”
Drive reaches commanded frequency.
2 “Motor Running”
Motor is receiving power from the drive.
3 “Reverse”
Drive is commanded to run in reverse direction.
4 “Motor Overload”
Motor overload condition exists.
5 “Ramp Regulated”
Ramp regulator is modifying the programmed accel/decel
times to avoid an overcurrent or overvoltage fault from
occurring.
6 “Above Frequency”
Drive exceeds the frequency (Hz) value set in A056 [Relay
Out Level].
7 “Above Current”
Drive exceeds the current (% Amps) value set in A056 [Relay
Out Level].
Important: Value for A056 [Relay Out Level] must be entered
in percent of drive rated output current.
8 “Above DC Bus Volts”
Drive exceeds the DC bus voltage value set in A056 [Relay
Out Level].
9 “Retries Exhausted”
Value set in A092 [Auto Rstrt Tries] is exceeded.
Programming and Parameters
3-15
Advanced Program Group (continued)
32
32 bit parameter.
A056 [Relay Out Level]
Related Parameter(s): A055
Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7 or 8.
A055 Setting
6
7
8
Values
Min/Max
0/240 Hz
0/180%
0/815 Volts
Default
0.0
Min/Max:
0.0/9999
Display:
0.1 – 1
A067 [Accel Time 2]
Related Parameter(s): P039
Sets the rate of acceleration for all speed increases except jog.
Maximum Freq
= Accel Rate
Accel Time
Values
Default
20.0 Secs
Min/Max:
0.0/600.0 Secs
Display:
0.1 Secs
[Maximum Freq]
Acc
tion
ele
ra
ele
ratio
n
Dec
Speed
0
[Accel Time]
Time
[Decel Time]
0
A068 [Decel Time 2]
Related Parameter(s): P040
Sets the rate of deceleration for all speed decreases except jog.
Maximum Freq
= Decel Rate
Decel Time
Values
Default
20.0 Secs
Min/Max:
0.1/600.0 Secs
Display:
0.1 Secs
[Maximum Freq]
Acc
tion
ele
ra
ele
ratio
n
Dec
Speed
0
[Accel Time]
0
Time
[Decel Time]
3-16
Programming and Parameters
Advanced Program Group (continued)
A069 [Internal Freq]
Related Parameter(s): P038
Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal
Freq”. When enabled, this parameter will change the frequency command in “real time” using the
integral keypad Up Arrow or Down Arrow when in program mode.
Important: Once the desired command frequency is reached, the Enter key must be pressed to store
this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return
to the original value following the normal accel/decel curve.
Values Default
60.0 Hz
Min/Max:
0.0/240.0 Hz
Display:
0.1 Hz
A070 [Preset Freq 0](1)
A071 [Preset Freq 1]
A072 [Preset Freq 2]
A073 [Preset Freq 3]
Related Parameter(s): P038, A051, A052
Provides a fixed frequency command value when A051 - A052 [Digital Inx Sel] is set to 4 “Preset
Frequencies”.
(1)
To activate A070 [Preset Freq 0] set P038 [Speed Reference] to option 4 “Preset Freq 0-3”.
Values A070 Default
0.0 Hz
A071 Default
5.0 Hz
A072 Default
10.0 Hz
A073 Default
20.0 Hz
Min/Max:
0.0/240.0 Hz
Display:
0.1 Hz
Input State of Digital In 1
(I/O Terminal 05)
Input State of Digital In 2
(I/O Terminal 06)
Frequency Source
Accel / Decel Parameter Used(2)
0
0
A070 [Preset Freq 0]
[Accel Time 1] / [Decel Time 1]
1
0
A071 [Preset Freq 1]
[Accel Time 1] / [Decel Time 1]
0
1
A072 [Preset Freq 2]
[Accel Time 2] / [Decel Time 2]
1
1
A073 [Preset Freq 3]
[Accel Time 2] / [Decel Time 2]
(2)
When a Digital Input is set to “Accel 2 & Decel 2”, and the input is active, that input overrides the settings in
this table.
A078 [Jog Frequency]
Related Parameter(s): P035, A051, A052
Sets the output frequency when a jog command is issued.
Values
Default
10.0 Hz
Min/Max:
0.0/P035 [Maximum Freq]
Display:
0.1 Hz
Programming and Parameters
3-17
Advanced Program Group (continued)
A079 [Jog Accel/Decel]
Sets the acceleration and deceleration time when a jog command is issued.
Values
Default
10.0 Secs
Min/Max:
0.1/600.0 Secs
Display:
0.1 Secs
A080 [DC Brake Time]
Related Parameter(s): 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:
0.0/90.0 Secs
Display:
0.1 Secs
A081 [DC Brake Level]
Related Parameter(s): P037, A080
Defines the maximum DC brake current, in amps, applied to the motor when P037 [Stop Mode] is set
to either “Ramp” or “DC Brake”.
Values Default
Drive Rated Amps × 0.05
0.0/(Drive Rated Amps × 1.8)
0.1 Amps
Min/Max:
Display:
Ramp-to-Stop Mode
DC Injection Braking Mode
Vo
lta
ge
[DC Brake Time]
Spe
ed
Volts/Speed
Volts/Speed
Voltage
Speed
[DC Brake Time]
[DC Brake Level]
[DC Brake Level]
Time
Stop Command
!
!
Time
Stop Command
ATTENTION: If a 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.
3-18
Programming and Parameters
Advanced Program Group (continued)
Stop drive before changing this parameter.
A082 [DB Resistor Sel]
Enables/disables external dynamic braking.
Setting
0
1
2
3-99
Values
Min/Max
Disabled
AB Resistor (5% Duty Cycle)
No Protection (100% Duty Cycle)
Duty Cycle Limited (3% – 99% of Duty Cycle)
Default
0
Min/Max:
0/99
Display:
1
A083 [S Curve %]
Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve. Time
is added, 1/2 at the beginning and 1/2 at the end of the ramp.
Values Default
0% (Disabled)
Min/Max:
0/100%
Display:
1%
Example:
Accel Time = 10 Seconds
S Curve Setting = 30%
S Curve Time = 10 × 0.3 = 3 Seconds
100% S Curve
Target
S Curve Time = Accel Time
Total Time to Accelerate = Accel Time + S Curve Time
50% S Curve
Target
Target/2
S Curve Time
Total Time to Accelerate = Accel Time + S Curve Time
Programming and Parameters
3-19
Advanced Program Group (continued)
A084 [Start Boost]
Related Parameter(s): P031
Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.(1)
(1)
Drive may add additional voltage unless Option 5 is selected.
Options 1 “30.0”
2 “35.0”
Variable Torque
3 “40.0”
4 “45.0”
5 “0.0 no IR Comp”
6 “0.0”
7 “2.5”
8 “5.0” (Default)
9 “7.5”
Constant Torque
10 “10.0”
11 “12.5”
12 “15.0”
13 “17.5”
14 “20.0”
1/2 [Motor NP Volts]
50
1/2
[Motor NP Hertz]
% [Motor NP Volts]
100
Settings
5-14
0
4
3
2
1
50
% [Motor NP Hertz]
100
A088 [Maximum Voltage]
Sets the highest voltage the drive will output.
Values
Default
Drive Rated Volts
Min/Max:
20/Drive Rated Volts
Display:
1 VAC
3-20
Programming and Parameters
Advanced Program Group (continued)
A089 [Current Limit]
Maximum output current allowed before current limiting occurs.
Values
Default
Drive Rated Amps × 1.5
Min/Max:
Display:
0.1/(Drive Rated Amps × 1.8)
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.
Options 0 “No Derate” (Default)
1 “Minimum Derate”
2 “Maximum Derate”
No Derate
100
80
60
40
20
0
0
175 200
25 50 75 100 125
% of [Motor NP Hertz]
Min Derate
Max Derate
% of [Motor OL Curent]
100
80
60
40
20
0
0
25 50 75 100 125 150 175 200
% of [Motor NP Hertz]
100
80
60
40
20
0
0
25 50 75 100 125 150 175 200
A091 [PWM Frequency]
Sets the carrier frequency for the PWM output waveform. The chart below provides derating
guidelines based on the PWM frequency setting.
Important: Ignoring derating guidelines can cause reduced drive performance.
Values Default
4.0 kHz
100
96
92
88
84
80
76
72
68
64
60
56
52
1
Min/Max:
2.0/16.0 kHz
Display:
0.1 kHz
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16
Programming and Parameters
3-21
Advanced Program Group (continued)
A092 [Auto Rstrt Tries]
Sets the maximum number of times the drive attempts to reset a fault and restart.
Clear a Type 1 fault and restart the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to a value other than “0”.
Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.
1. Set A092 [Auto Rstrt Tries] to a value other than “0”.
2. Set A093 [Auto Rstrt Delay] to “0”.
!
Values
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.
Default
0
Min/Max:
0/9
Display:
1
A093 [Auto Rstrt Delay]
Related Parameter(s): A092
Sets the time between restart attempts when A092 [Auto Rstrt Tries] is set to a value other than zero.
Values Default
1.0 Secs
Min/Max:
0.0/120.0 Secs
Display:
0.1 Secs
Stop drive before changing this parameter.
A094 [Start At PowerUp]
Enables/disables a feature that allows a Start or Run command to automatically cause the drive to
resume running at commanded speed after drive input power is restored. Requires a digital input
configured for Run or Start and a valid start contact.
This parameter will not function if parameter P036 [Start Source] is set to 4 “2-Wire High Speed”.
!
ATTENTION: Equipment damage and/or personal injury may result if this parameter
is used in an inappropriate application. Do not use this function without considering
applicable local, national and international codes, standards, regulations or industry
guidelines.
Options 0 “Disabled” (Default)
1 “Enabled”
3-22
Programming and Parameters
Advanced Program Group (continued)
Stop drive before changing this parameter.
A095 [Reverse Disable]
Enables/disables the function that allows the direction of motor rotation to be changed. The reverse
command may come from a digital command, the keypad or a serial command. All reverse inputs
including two-wire Run Reverse will be ignored with reverse disabled.
Options 0 “Reverse Enabled”
(Default)
1 “Reverse Disabled”
A096 [Flying Start En]
Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.
Options 0 “Disabled” (Default)
1 “Enabled”
A097 [Compensation]
Enables/disables correction options that may improve problems with motor instability.
Options 0 “Disabled”
1 “Electrical” (Default)
2 “Mechanical”
3 “Both”
A098 [SW Current Trip]
Enables/disables a software instantaneous (within 100 ms) current trip.
Values
Default
0.0 (Disabled)
Min/Max:
0.0/(Drive Rated Amps × 2)
Display:
0.1 Amps
A099 [Process Factor]
Related Parameter(s): d010
Scales the value displayed by d010 [Process Display].
Output
Process
Process
Freq x Factor = Display
Values
Default
30.0
Min/Max:
0.1/999.9
Display:
0.1
Programming and Parameters
Advanced Program Group (continued)
Stop drive before changing this parameter.
A100 [Fault Clear]
Resets a fault and clears the fault queue.
Options 0 “Ready” (Default)
1 “Reset Active Fault”
2 “Clear Fault Queue”
(Parameters d007-d009 [Fault x Code])
A101 [Program Lock]
Protects parameters against change by unauthorized personnel.
Options 0 “Unlocked” (Default)
1 “Locked”
A102 [Testpoint Sel]
Used by Rockwell Automation field service personnel.
Values
Default
400
Min/Max:
0/FFFF
Display:
1 Hex
A103 [Comm Data Rate]
Sets the serial port rate for the RS485 (DSI) port.
Important: Cycle drive power for a change to this parameter to take affect.
Options 0 “1200”
1 “2400”
2 “4800”
3 “9600” (Default)
4 “19.2K”
5 “38.4K”
A104 [Comm Node Addr]
Sets the drive node address for the RS485 (DSI) port if using a network connection.
Values
Default
100
Min/Max:
1/247
Display:
1
3-23
3-24
Programming and Parameters
Advanced Program Group (continued)
A105 [Comm Loss Action]
Related Parameter(s): P037, A106
Selects the drive’s response to a loss of the communication connection or excessive communication
errors.
Options 0 “Fault” (Default)
Drive will fault on an F81 Comm Loss and coast to stop.
1 “Coast to Stop”
Stops drive via coast to stop.
2 “Stop”
Stops drive via P037 [Stop Mode] setting.
3 “Continue Last Speed” Drive continues operating at communication commanded
speed saved in RAM.
A106 [Comm Loss Time]
Related Parameter(s): A105
Sets the time that the drive will remain in communication loss before implementing the option selected
in A105 [Comm Loss Action].
Values Default
5.0 Secs
Min/Max:
0.1/60.0 Secs
Display:
0.1 Secs
A107 [Comm Format]
Determines details related to the specific RS485 (DSI) protocol used by the drive.
Refer to Appendix C for details on using the drive communication features.
Options 0 “RTU 8-N-1” (Default)
1 “RTU 8-E-1”
2 “RTU 8-O-1”
Programming and Parameters
3-25
Parameter Cross Reference – by Name
Parameter Name
No.
Group
Parameter Name
No.
Group
Accel Time 1
Accel Time 2
Auto Rstrt Delay
Auto Rstrt Tries
Comm Data Rate
Comm Format
Comm Loss Action
Comm Loss Time
Comm Node Addr
Comm Status
Commanded Freq
Compensation
Contrl In Status
Control Source
Control SW Ver
Current Limit
DB Resistor Sel
DC Brake Level
DC Brake Time
DC Bus Voltage
Decel Time 1
Decel Time 2
Dig In Status
Digital Inx Sel
Drive Status
Drive Type
Elapsed Run Time
Fault x Code
Fault Clear
Flying Start En
Internal Freq
P039
A067
A093
A092
A103
A107
A105
A106
A104
d015
d002
A097
d013
d012
d016
A089
A082
A081
A080
d005
P040
A068
d014
A051, A052
d006
d017
d018
d007-d009
A100
A096
A069
Basic Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Display
Display
Advanced Program
Display
Display
Display
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Display
Basic Program
Advanced Program
Display
Advanced Program
Display
Display
Display
Display
Advanced Program
Advanced Program
Advanced Program
Jog Accel/Decel
Jog Frequency
Maximum Freq
Maximum Voltage
Minimum Freq
Motor NP Hertz
Motor NP Volts
Motor OL Current
Motor OL Select
Output Current
Output Freq
Output Voltage
Preset Freq x
Process Display
Process Factor
Program Lock
PWM Frequency
Relay Out Level
Relay Out Sel
Reset To Defaults
Reverse Disable
S Curve %
Speed Reference
Start At PowerUp
Start Boost
Start Source
Stop Mode
SW Current Trip
Testpoint Data
Testpoint Sel
A079
A078
P035
A088
P034
P032
P031
P033
A090
d003
d001
d004
A070-A073
d010
A099
A101
A091
A056
A055
P041
A095
A083
P038
A094
A084
P036
P037
A098
d019
A102
Advanced Program
Advanced Program
Basic Program
Advanced Program
Basic Program
Basic Program
Basic Program
Basic Program
Advanced Program
Display
Display
Display
Advanced Program
Display
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Advanced Program
Basic Program
Advanced Program
Advanced Program
Basic Program
Advanced Program
Advanced Program
Basic Program
Basic Program
Advanced Program
Display
Advanced Program
3-26
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.
LED Indications
See page 2-3 for information on drive status indicators and controls.
Faults
A fault is a condition that stops the drive. There are two fault types.
Type Fault Description
➀ 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
➁
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 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.
Access d007 [Fault 1 Code] to view the most recent fault information.
2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
See Table 4.A.
3. After corrective action has been taken, clear the fault by one of these
methods.
• Press Stop if P037 [Stop Mode] is set to a value between “0” and “3”.
• Cycle drive power.
• Set A100 [Fault Clear] to “1” or “2”.
• Cycle digital input if A051 - A052 [Digital Inx Sel] is set to option 7
“Clear Fault”.
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.
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
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. Monitor the incoming AC line for
85% of nominal.
low voltage or line power
interruption.
2. Check input fuses.
DC bus voltage fell below the
Monitor the incoming AC line for low
minimum value.
voltage or line power interruption.
DC bus voltage exceeded
Monitor the AC line for high line
maximum value.
voltage or transient conditions. Bus
overvoltage can also be caused by
motor regeneration. Extend the
decel time or install dynamic brake
option.
Drive is unable to accelerate
Increase P039 - A067 [Accel Time x]
motor.
or reduce load so drive output
current does not exceed the current
set by parameter A089 [Current
Limit].
Internal electronic overload trip. 1. An excessive motor load exists.
Reduce load so drive output
current does not exceed the
current set by parameter P033
[Motor OL Current].
2. Verify A084 [Start Boost] setting
Heatsink temperature exceeds a 1. Check for blocked or dirty heat
predefined value.
sink fins. Verify that ambient
temperature has not exceeded
40°C (104°F) for IP 30/NEMA 1/UL
Type 1 installations or 50°C (122°F)
for IP20/Open type installations.
2. Check fan.
The drive output current has
Check programming. Check for
exceeded the hardware current excess load, improper A084 [Start
limit.
Boost] setting, DC brake volts set
too high or other causes of excess
current.
A current path to earth ground
Check the motor and external wiring
has been detected at one or
to the drive output terminals for a
more of the drive output
grounded condition.
terminals.
See page 4-1 for a description of fault types.
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
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].
A phase to ground fault has been
detected between the drive and
motor in this phase.
Action
Correct the cause of the fault and
manually clear.
1. Check the wiring between the
drive and motor.
2. Check motor for grounded
phase.
3. Replace drive if fault cannot be
cleared.
Excessive current has been
1. Check the motor and drive output
detected between these two
terminal wiring for a shorted
output terminals.
condition.
2. Replace drive if fault cannot be
cleared.
The drive was commanded to
1. Clear the fault or cycle power to
write default values to EEPROM.
the drive.
2. Program the drive parameters as
needed.
Programmed A098 [SW Current Check load requirements and A098
Trip] has been exceeded.
[SW Current Trip] setting.
Drive rating of 150% for 1 minute Reduce load or extend Accel Time.
or 200% for 3 seconds has been
exceeded.
Failure has been detected in the 1. Cycle power.
drive power section.
2. Replace drive if fault cannot be
cleared.
RS485 (DSI) port stopped
1. If adapter was not intentionally
communicating.
disconnected, check wiring to the
port. Replace wiring, port
expander, adapters or complete
drive as required.
2. Check connection.
3. An adapter was intentionally
disconnected.
4. Turn off using A105 [Comm Loss
Action].
The checksum read from the
Set P041 [Reset To Defaults] to
board does not match the
option 1 “Reset Defaults”.
checksum calculated.
Failure has been detected in the 1. Cycle power.
drive control and I/O section.
2. Replace drive if fault cannot be
cleared.
See page 4-1 for a description of fault types.
Troubleshooting
4-5
Common Symptoms and Corrective Actions
Motor does not Start.
Cause(s)
No output voltage to the motor.
Indication
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. 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.
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 Sel] is
set to option 5 “Local” and the
input is active.
Incorrect input wiring.
None
See 1-14 for wiring examples.
• 2 wire control requires Run
Forward, Run Reverse or Jog
input.
• 3 wire control requires Start and
Stop inputs
• Stop input is always required.
Corrective Action
Clear fault.
• Press Stop
• Cycle power
• Set A100 [Fault Clear] to option 1
“Clear Faults”.
• Cycle digital input if A051 - A052
[Digital Inx Sel] is set to option 7
“Clear Fault”.
Check parameter settings.
Wire inputs correctly and/or install
jumper.
4-6
Troubleshooting
Drive does not Start from Integral Keypad.
Cause(s)
Indication
Corrective Action
Integral keypad is not enabled. Green LED above Start key is • Set parameter P036 [Start
not illuminated.
Source] to option 0 “Keypad”.
• Set parameter A051 - A052
[Digital Inx Sel] to option 5
“Local” and activate the input.
I/O Terminal 01 “Stop” input is None
Wire inputs correctly and/or install
not present.
jumper.
Drive does not respond to changes in speed command.
Cause(s)
No value is coming from the
source of the command.
Indication
The drive “Run” indicator is lit
and output is 0 Hz.
Incorrect reference source is
being selected via remote
device or digital inputs.
None
Corrective Action
• Check d012 [Control Source] for
correct source.
• If the source is an analog input,
check wiring and use a meter to
check for presence of signal.
• Check d002 [Commanded Freq]
to verify correct command.
• Check d012 [Control Source] for
correct source.
• Check d014 [Dig In Status] to
see if inputs are selecting an
alternate source. Verify settings
for A051 - A052 [Digital Inx Sel].
• Check P038 [Speed Reference]
for the source of the speed
reference. Reprogram as
necessary.
• Review the Speed Reference
Control chart on page 1-16.
Motor and/or drive will not accelerate to commanded speed.
Cause(s)
Indication
Acceleration time is excessive. None
Excess load or short
None
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].
Compare d003 [Output Current] with
A089 [Current Limit].
Remove excess load or reprogram
P039 [Accel Time 1] or A067 [Accel
Time 2].
Check for improper A084 [Start
Boost] setting.
Verify d002 [Commanded Freq].
Check d012 [Control Source] for the
proper Speed Command.
Check P035 [Maximum Freq] to
insure that speed is not limited by
programming.
Troubleshooting
4-7
Motor operation is unstable.
Cause(s)
Motor data was incorrectly
entered.
Indication
None
Corrective Action
1. Correctly enter motor nameplate
data into P031, P032 and P033.
2. Enable A097 [Compensation].
3. Use A084 [Start Boost] to reduce
boost level.
Drive will not reverse motor direction.
Cause(s)
Indication
Digital input is not selected for None
reversing control.
Digital input is incorrectly
wired.
Motor wiring is improperly
phased for reverse.
Reverse is disabled.
None
Corrective Action
Check [Digital Inx Sel] (See
page 3-13). Choose correct input
and program for reversing mode.
Check input wiring. (See page 1-13)
None
Switch two motor leads.
None
Check A095 [Reverse Disable].
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 drive ratings and
recommended AC line input fuse and circuit breaker information. Both
types of short circuit protection are acceptable for UL and IEC
requirements. Sizes listed are the recommended sizes based on 40 degree
C and the U.S. N.E.C. Other country, state or local codes may require
different ratings.
Fusing
If fuses are chosen as the desired protection method, refer to the
recommended types listed below. If available amp ratings do not match
the tables provided, the closest fuse rating that exceeds the drive rating
should be chosen.
• IEC – BS88 (British Standard) Parts 1 & 2 (1), EN60269-1, Parts 1 &
2, type gG or equivalent should be used.
• UL – UL Class CC, T or J must be used. (2)
Circuit Breakers
The “other devices” listings in the following tables include both circuit
breakers (inverse time or instantaneous trip) and 140M Self-Protecting
Motor Starters.
(1)
Typical designations include, but may not be limited to the following; Parts 1 & 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, JJN
A-2
Supplemental Drive Information
Specifications
Drive Ratings
Catalog
Number
Output Ratings
Branch Circuit
Power Dissipation
Protection
Fuse
Other
IP20 Open IP20 Chassis
kVA Amps Rating
Devices Watts
Watts
Input Ratings
Voltage
kW (HP) Amps Range
100 - 120V AC – 1-Phase (4kV Transient Protection, Standard)
22A-V1P5N104 0.2 (0.25)
22A-V2P3N104 0.37 (0.5)
22A-V4P5N104 0.75 (1.0)
1.5
90-126
0.75 6.1
2.3
90-126
1.15 9.4
4.5
90-126
2.25 18.4
200 - 240V AC – 1-Phase(1) (4kV Transient Protection, Standard)
22A-A1P5N104 0.2 (0.25) 1.5
180-265 0.75 3.1
22A-A2P3N104 0.37 (0.5) 2.3
180-265 1.15 4.7
22A-A4P5N104 0.75 (1.0) 4.5
180-265 2.25 9.2
22A-A8P0N104 1.5 (2.0)
8.0
180-265 4.0 16.4
200 - 240V AC – 3-Phase (4kV Transient Protection, Standard)
22A-B1P5N104 0.2 (0.25) 1.5
180-265 0.75 1.8
22A-B2P3N104 0.37 (0.5) 2.3
180-265 1.15 2.7
22A-B4P5N104 0.75 (1.0) 4.5
180-265 2.25 5.3
22A-B8P0N104 1.5 (2.0)
8.0
180-265 4.0 9.5
22A-B012N104 2.2 (3.0)
12.0
180-265 5.5 14.2
22A-B017N104 3.7 (5.0)
17.5
180-265 8.6 20.7
380 - 480V AC – 3-Phase (6kV Transient Protection, Standard)
22A-D1P4N104 0.37 (0.5) 1.4
340-528 1.4 1.7
22A-D2P3N104 0.75 (1.0) 2.3
340-528 2.3 2.7
22A-D4P0N104 1.5 (2.0)
4.0
340-528 4.0 4.7
22A-D6P0N104 2.2 (3.0)
6.0
340-528 5.9 7.1
22A-D8P7N104 3.7 (5.0)
8.7
340-528 8.6 10.3
10
15
30
10
15
30
25
30
50
15
21
38
10
10
15
30
5
10
15
25
25
30
50
80
15
21
38
64
3
6
10
15
25
35
5
5
7
15
25
30
25
30
50
80
115
165
15
21
38
64
99
149
3
6
10
15
15
3
4
7
10
15
30
40
60
90
145
15
27
47
73
131
Approvals
Input/Output Ratings
Digital Control Inputs (Input Current = 6mA)
SRC (Source) Mode:
18-24V = ON
0-6V = OFF
SNK (Sink) Mode:
0-6V = ON
18-24V = OFF
LIST
ED 966X
UL
Output Frequency: 0-240 Hz (Programmable)
Efficiency: 97.5% (Typical)
®
I ND
LIST
UL508C
C
®
I ND
CO N T E Q
ED 966X
UL
CSA 22.2
CO N T E Q
EMC Directive 89/336
LV:
EN 50178, EN 60204
EMC: EN 61800-3, EN 50081-1, EN 50082-2
Analog Control Inputs
4-20mA Analog: 250 ohm input impedance
0-10V DC Analog: 100k ohm input impedance
External Pot: 1-10k ohms, 2 Watt minimum
Control Output
Programmable Output (form C relay)
Resistive Rating: 3.0A at 30V DC, 3.0A at 125V AC, 3.0A at 240V AC
Inductive Rating: 0.5A at 30V DC, 0.5A at 125V AC, 0.5A at 240V AC
Fuses and Circuit Breakers
Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
Other Protective Devices: 140M-xxx (A-B Bulletin 140 Manual Motor Starter) or HMCP circuit breaker or equivalent.
Refer to Appendix B for detailed catalog numbers.
Protective Features
Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)
Overcurrent: 200% hardware limit, 300% instantaneous fault
Over Voltage:
100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)
200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)
380-480V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)
Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)
200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line)
380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)
Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs
Faultless Power Ride Through: 100 milliseconds
Dynamic Braking
Internal brake IGBT included with all ratings 0.75 kW (1 HP) and larger. Refer to page B-2 for external dynamic brake module
options.
(1)
200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N104 to N114.
Supplemental Drive Information
Category
Environment
Control
Specification
Altitude:
Ambient Operating Temperature
IP20:
NEMA 1:
Storage Temperature:
Atmosphere:
Relative Humidity:
Shock (operating):
Vibration (operating):
Carrier Frequency
Frequency Accuracy
Digital Input:
Analog Input:
Speed Regulation - Open Loop
with Slip Compensation:
Stop Modes:
Accel/Decel:
Intermittent Overload:
Electronic Motor Overload
Protection
A-3
1000 m (3300 ft) max. without derating
–10 to 50 degrees C (14 to 122 degrees F)
–10 to 40 degrees C (14 to 104 degrees F)
–40 to 85 degrees C (–40 to 185 degrees F)
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.
0 to 95% non-condensing
15G peak for 11ms duration (±1.0ms)
1G peak, 5 to 2000 Hz
2-16 kHz. Drive rating based on 4 kHz.
Within ±0.05% of set output frequency.
Within 0.5% of maximum output frequency.
±2% of base speed across a 40:1 speed range.
Multiple programmable stop modes including Ramp, Coast, DC-Brake, Ramp-to-Hold and
S Curve.
Two independently programmable accel and
decel times. Each time may be programmed
from 0 - 600 seconds in 0.1 second increments.
150% Overload capability for up to 1 minute
200% Overload capability for up to 3 seconds
Class 10 protection with speed sensitive
response.
A-4
Notes:
Supplemental Drive Information
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
Comm Slot
Table B.B PowerFlex 4 Drives
Drive Ratings
Input Voltage
120V 50/60 Hz
1-Phase
No Filter
240V 50/60 Hz
1-Phase
With Integral “S Type”
EMC Filter
240V 50/60 Hz
1-Phase
No Filter
240V 50/60 Hz
3-Phase
No Filter
480V 50/60 Hz
3-Phase
No Filter
kW
0.2
0.37
0.75
0.2
0.37
0.75
1.5
0.2
0.37
0.75
1.5
0.2
0.37
0.75
1.5
2.2
3.7
0.37
0.75
1.5
2.2
3.7
HP
0.25
0.5
1.0
0.25
0.5
1.0
2.0
0.25
0.5
1.0
2.0
0.25
0.5
1.0
2.0
3.0
5.0
0.5
1.0
2.0
3.0
5.0
Output Current
1.5A
2.3A
4.5A
1.5A
2.3A
4.5A
8.0A
1.5A
2.3A
4.5A
8.0A
1.5A
2.3A
4.5A
8.0A
12.0A
17.5
1.4A
2.3A
4.0A
6.0A
8.7A
Catalog Number
22A-V1P5N104
22A-V2P3N104
22A-V4P5N104
22A-A1P5N114
22A-A2P3N114
22A-A4P5N114
22A-A8P0N114
22A-A1P5N104
22A-A2P3N104
22A-A4P5N104
22A-A8P0N104
22A-B1P5N104
22A-B2P3N104
22A-B4P5N104
22A-B8P0N104
22A-B012N104
22A-B017N104
22A-D1P4N104
22A-D2P3N104
22A-D4P0N104
22A-D6P0N104
22A-D8P7N104
Frame
Size
A
A
B
A
A
A
B
A
A
A
B
A
A
A
A
B
B
A
A
A
B
B
B-2
Accessories and Dimensions
Table B.C Dynamic Brake Modules
Drive Ratings
Input Voltage
120V 50/60 Hz
1-Phase
240V 50/60 Hz
1-Phase
240V 50/60 Hz
3-Phase
480V 50/60 Hz
3-Phase
(1)
(2)
kW
0.2
HP
0.25
Catalog Number
0.37
0.75
0.2
0.37
0.75
1.5
0.2
0.37
0.75
1.5
2.2
3.7
0.5
1.0
0.25
0.5
1.0
2.0
0.25
0.5
1.0
2.0
3.0
5.0
(1)
0.37
0.75
1.5
2.2
3.7
0.5
1.0
2.0
3.0
5.0
(1)
(1)
160-BMA1
(1)
(1)
160-BMA1
160-BMA2
(1)
(1)
160-BMA1
160-BMA2
160-BMA2
160-BMA2 (2)
160-BMB1
160-BMB2
160-BMB2
160-BMB2 (2)
Drive does not support dynamic braking.
Two in parallel required.
Table B.D Bulletin 1321-3R Series Line Reactors
Fundamental
Input Voltage kW HP Amps
240V 50/60 Hz 0.2 0.25 2
3-Phase
0.37 0.5 4
0.75 1.0 4
1.5 2.0 8
2.2 3.0 12
3.7 5.0 18
480V 50/60 Hz 0.37 0.5 2
3-Phase
0.75 1.0 2
1.5 2.0 4
2.2 3.0 8
3.7 5.0 18
(1)
Maximum
Continuous
Amps
3
6
6
12
18
27
3
3
6
12
27
Inductance
12.0 mh
12.0 mh
3.0 mh
1.5 mh
1.25 mh
0.8 mh
20.0 mh
12.0 mh
6.5 mh
12.0 mh
3.0 mh
Watts
Loss
7.5 W
21 W
14.5 W
19.5 W
26 W
36 W
11.3 W
7.5 W
20 W
25.3 W
29 W
Catalog
Number (1)
1321-3R2-A
1321-3R4-D
1321-3R4-A
1321-3R8-A
1321-3R12-A
1321-3R18-A
1321-3R2-B
1321-3R2-A
1321-3R4-B
1321-3R8-C
1321-3R8-B
Catalog numbers listed are for 3% impedance open style units. NEMA Type 1 and 5% impedance
reactor types are also available. Refer to publication 1321-TD001x.
Accessories and Dimensions
B-3
Table B.E EMC Line Filters
Drive Ratings
Input Voltage
120V 50/60 Hz
1-Phase
S Type Filter
Catalog Number (1)
–
–
–
L Type Filter
Catalog Number (3)
22-RF010-AL
22-RF010-AL
22-RF018-BL
22-RF010-AL
240V 50/60 Hz
1-Phase
kW
0.2
0.37
0.75
0.2
0.37
HP
0.25
0.5
1.0
0.25
0.5
1.0
2.0
0.25
0.5
(2)
240V 50/60 Hz
3-Phase
0.75
1.5
0.2
0.37
22-RF9P5-AS
22-RF9P5-AS
22-RF010-AL
22-RF010-AL
22-RF018-BL
22-RF9P5-AL
22-RF9P5-AL
0.75
1.5
2.2
3.7
0.37
0.75
1.5
2.2
3.7
1.0
2.0
3.0
5.0
0.5
1.0
2.0
3.0
5.0
22-RF9P5-AS
22-RF9P5-AS
22-RF021-BS
22-RF021-BS
22-RF5P7-AS
22-RF5P7-AS
22-RF5P7-AS
22-RF012-BS
22-RF012-BS
22-RF9P5-AL
22-RF9P5-AL
22-RF021-BL
22-RF021-BL
22-RF5P7-AL
22-RF5P7-AL
22-RF5P7-AL
22-RF012-BL
22-RF012-BL
480V 50/60 Hz
3-Phase
(1)
(2)
(3)
(2)
(2)
(2)
This filter is suitable for use with a cable length of at least 5 meters for Class A and 1 meter for
Class B environments. The maximum allowable cable length was not available at publication.
These ratings can be ordered with internal “S Type” filters. Refer to the Catalog Number
explanation on page P-4 and Table B.B for details.
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. The maximum allowable cable length was not available at publication.
B-4
Accessories and Dimensions
Table B.F Communication Option Kits
Item
Description
Serial Converter Module Provides serial communication via DF1 protocol for
(RS485 to RS232)
use with DriveExplorer and DriveExecutive software.
Includes:
DSI to RS232 serial converter (1)
1203-SCF serial cable (1)
22-RJ45CBL-C20 cable (1)
DriveExplorer Lite CD (1)
DSI Cable
2.0 meter RJ45 to RJ45 cable, male to male
connectors.
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.
Null Cable Converter
For use when connecting the serial converter to
DriveExplorer on a handheld PC.
DriveExplorer Software Windows based software package that provides an
(CD-ROM) Version 3.01 intuitive means for monitoring or configuring
or later
Allen-Bradley drives and communication adapters
online.
Compatibility:
Windows 95, 98, ME, NT 4.0 (Service Pack 3 or
later), 2000, XP and CE(1)
DriveExecutive software Windows based software package that provides an
(CD-ROM) Version 1.01 intuitive means for monitoring or configuring
or later
Allen-Bradley drives and communication adapters
online and offline.
Compatibility:
Windows 98, ME, NT 4.0 (Service Pack 3 or later),
2000 and XP
(1)
(2)
Catalog Number (2)
22-SCM-232
22-RJ45CBL-C20
1203-SFC
1203-SNM
9306-4EXP01ENE
9303-4DTE01ENE
See www.ab.com/drives/driveexplorer.htm for supported devices.
For pricing information, refer to the PowerFlex 4 Price List, Publication 22A-PL001A-EN-P.
Table B.G IP30/NEMA 1/UL Type 1 Kit
Item
Description
IP30/NEMA 1/UL Type 1 Field installed kit. Converts drive to IP30/
Kit
NEMA 1/UL Type 1 enclosure. Includes
conduit box with mounting screws and
plastic top panel.
(1)
Drive
Frame
A
B
C
Catalog Number (1)
22-JBAA
22-JBAB
22-JBAC
For pricing information, refer to the PowerFlex 4 Price List, Publication 22A-PL001A-EN-P.
Accessories and Dimensions
B-5
Product Dimensions
Figure B.1 PowerFlex 4 Drives – Dimensions are in millimeters and (inches). Weights
are in kilograms and (pounds).
A
D
C
F
GEB
5.5 (0.22)
Frame
A
B
A
80 (3.15)
100 (3.94)
B
185 (7.28)
213 (8.39)
C
136 (5.35)
136 (5.35)
D
67 (2.64)
87 (3.43)
E
152 (5.98)
180 (7.09)
F
G
59.3 (2.33) 140 (5.51)
87.4 (3.44) 168 (6.61)
Shipping
Weight
1.4 (3.1)
2.2 (4.9)
Table B.H PowerFlex 4 Frames – Ratings are in kW and (HP)
Frame
A
120V AC – 1-Phase
0.2 (0.25)
0.37(0.5)
240V AC – 1-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
B
0.75 (1.0)
1.5 (2.0)
240V AC – 3-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
480V AC – 3-Phase
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
Figure B.2 Optional Conduit Box – Dimensions are in millimeters and (inches)
59.2
(2.33)
40.0
(1.57)
20.7
(0.81)
Frame A
∅ 22.2
(0.88)
79.1
(3.11)
64.1
(2.52)
40.6
(1.60)
∅ 22.2
(0.88)
25.6
(1.01)
34.0
(1.34)
35.6
(1.40)
75.3
(2.96)
74.3
(2.93)
Frame B
B-6
Accessories and Dimensions
Figure B.3 Dynamic Brake Modules – Dimensions are in millimeters and (inches)
72
(2.84)
50
(1.97)
14
(0.55)
8
(0.31)
86.4
(3.40)
7.5
(0.30)
B
A
6.86 (0.27)
Mounting Holes,
4 Places
Catalog Number
160-BMA1, -BMB1
160-BMA2, -BMB2
29
(1.14)
A
B
245 (9.64) 225 (8.86)
334 (13.15) 314 (12.36)
Figure B.4 Bulletin 1321-3R Series Line Reactors
– Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).
A
B
E
D
C
Catalog Number
1321-3R2-A
1321-3R2-B
1321-3R4-A
1321-3R4-B
1321-3R8-A
1321-3R8-B
1321-3R12-A
1321-3R18-A
1321-3R18-B
A
112 (4.40)
112 (4.40)
112 (4.40)
112 (4.40)
152 (6.00)
152 (6.00)
152 (6.00)
152 (6.00)
152 (6.00)
B
104 (4.10)
104 (4.10)
104 (4.10)
104 (4.10)
127 (5.00)
127 (5.00)
127 (5.00)
133 (5.25)
133 (5.25)
C
70 (2.75)
70 (2.75)
76 (3.00)
76 (3.00)
76 (3.00)
76 (3.00)
76 (3.00)
79 (3.10)
86 (3.40)
D
50 (1.98)
50 (1.98)
50 (1.98)
50 (1.98)
53 (2.10)
53 (2.10)
53 (2.10)
54 (2.13)
63 (2.48)
E
37 (1.44)
37 (1.44)
37 (1.44)
37 (1.44)
51 (2.00)
51 (2.00)
51 (2.00)
51 (2.00)
51 (2.00)
Weight
1.8 (4)
1.8 (4)
1.8 (4)
1.8 (4)
3.1 (7)
3.6 (8)
4.1 (9)
4.1 (9)
5.4 (12)
Accessories and Dimensions
Figure B.5 Frame A EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL
80
60 (3.15)
(2.36)
27.8
(1.09)
50
(1.97)
219.6
(8.65)
207.6
(8.17)
15.8
(0.62)
5.5 (0.22)
24.0
(0.94)
Figure B.6 Frame B EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF012-BS, -BL; 22-RF018-BS; 22-RF021-BS, -BL
100
78 (3.94)
(3.07)
27.8
(1.09)
50
(1.97)
229
(9.02)
216
(8.50)
5.5 (0.22)
15.8
(0.62)
24.0
(0.94)
B-7
B-8
Notes:
Accessories and Dimensions
Appendix C
RS485 Protocol
The content of this Appendix is being developed.
The latest version of this publication (22A-UM001x) is available online
at http://www.ab.com/manuals/dr.
C-2
Notes:
RS485 Protocol
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, 1-18
Checklist, Start-Up, 2-1, 2-2
Circuit Breakers
Input, 1-6
Comm Loss Fault, 4-4
Command Sources for Start and
Speed, 1-16
Common Symptoms and Corrective
Action, 4-5
Contactors, Input, 1-11
Control, 2 and 3 Wire, 1-14, 1-15
Conventions, Manual, P-2
Cover, Opening, 1-1
Cross Reference, Parameter
by Name, 3-25
D
Dimensions
Drive, B-5
Minimum Clearances, 1-2
Discharging Bus Capacitors, P-3
Display, 2-3
Display Group Parameters, 3-3
Distribution Systems, Ungrounded,
1-3
Drive Frame Size, P-2, B-5
Drive Grounding, 1-4
Drive Overload Fault, 4-4
Drive Ratings, P-4, A-1
DriveExecutive, 3-1
DriveExplorer, 3-1
E
Earthing, see Grounding
EMC/RFI
Grounding, Filter, 1-5
Interference, 1-18
Enclosure Rating, Changing, 1-2
ESD, Static Discharge, P-3
F
Faults
Auto Rstrt Tries, 4-4
Auxiliary Input, 4-3
Comm Loss, 4-4
Drive Overload, 4-4
Ground Fault, 4-3
Heatsink OvrTmp, 4-3
HW OverCurrent, 4-3
I/O Board Fail, 4-4
Motor Overload, 4-3
Motor Stalled, 4-3
OverVoltage, 4-3
Parameter Checksum, 4-4
Phase Short, 4-4
Phase to Ground Short, 4-4
Power Loss, 4-3
Power Unit, 4-4
SW OverCurrent, 4-4
UnderVoltage, 4-3
Filter, RFI, 1-5
Frame Designations, P-2, A-1, B-5
Fuses
Input, 1-6
Ratings, A-1
Index-2
G
General Precautions, P-3
Ground Fault, 4-3
Grounding
Filter, 1-5
General, 1-4
H
Heatsink OvrTmp Fault, 4-3
HW OverCurrent Fault, 4-3
I
I/O
Wiring, 1-11
Wiring Examples, 1-14, 1-15
I/O Board Fail Fault, 4-4
Input Contactor, 1-11
Input Fusing, 1-6
Input Potentiometer, 1-14
Input Power Conditioning, 1-4
Installation, 1-1
Integral Keypad, 2-3
Interference, EMC/RFI, 1-18
K
Keypad, 2-3
L
LEDs, 2-3
M
Minimum Clearances, 1-2
Motor Cable Length, 1-9
Motor Overload Fault, 4-3
Motor Stalled Fault, 4-3
motor starter, 1-6
Mounting Options and Clearances,
1-2
MOVs, 1-3
O
Opening the Cover, 1-1
Operating Temperatures, 1-2
Operator Interface, 2-3
OverVoltage Fault, 4-3
P
Parameter
Descriptions, 3-1
Types, 3-1
Viewing and Editing, 2-4
Parameter Checksum Fault, 4-4
Parameter Cross Reference
by Name, 3-25
Parameters
Advanced Program Group, 3-13
Display Group, 3-3
Program Group, 3-8
PE Ground, 1-5
Phase Short Fault, 4-4
Phase to Ground Fault, 4-4
Potentiometer, Wiring, 1-14
Power Cables/Wiring, 1-8
Power Conditioning, Input, 1-4
Power Loss Fault, 4-3
Power Unit Fault, 4-4
Powering Up the Drive, 2-1, 2-2
Precautions, General, P-3
Product Selection, B-1
Program Group Parameters, 3-8
Programming, 3-1
R
Ratings, A-1
Reflective Wave Protection, 1-9
Removing Cover, 1-1
Repeated Start/Stop, 1-11
Repeated Start/Stop Precautions,
1-11
RFI, see EMC/RFI
RWR (Reflective Wave Reducer), 1-9
S
Safety Ground, 1-5
Shielded Power Cables, 1-8
Short Circuit Protection, 1-6
Software, 3-1
Start and Speed Reference Selection
and Control, 1-16, 1-17
Start/Stop, Repeated, 1-11
Index-3
Start-Up Checklist, 2-1, 2-2
Static Discharge, ESD, P-3
Status LEDs, 2-3
Supply Source, AC, 1-3
SW OverCurrent Fault, 4-4
System Grounding, 1-4
T
Terminal Block
I/O, 1-12
Power, 1-10
Three Wire Control, 1-14, 1-15
Two Wire Control, 1-14, 1-15
U
UnderVoltage Fault, 4-3
Ungrounded Supply, 1-3
Unshielded Power Cables, 1-8
W
Wiring, 1-1
Block Diagram, 1-13
I/O, 1-11
I/O Examples, 1-14, 1-15
Potentiometer, 1-14
Power, 1-8
Index-4
Notes:
www.rockwellautomation.com
Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201
Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
Europe: Rockwell Automation SA/NV, Vorstlaan/Boulevard du Souverain 36-BP 3A/B, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640
Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846
Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
Europe: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 1774
Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733
U.S. Allen-Bradley Drives Technical Support
Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives
Publication 22A-UM001B-EN-E – February 2002
Copyright © 2002 Rockwell Automation. All rights reserved.
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