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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