Powerflex 40 manual

www.abpowerflex.com

Adjustable

Frequency AC

Drive

FRN 1.xx - 6.xx

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation

and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://

www.rockwellautomation.com/literature) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and understanding of the product.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:

• identify a hazard

• avoid the hazard

• recognize the consequences

Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures.

Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.

PLC is a registered trademark of Rockwell Automation, Inc.

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 6.xx User Manual

Summary of Changes

The information below summarizes the changes to the PowerFlex 40

User Manual since the April 2008 release.

Manual Updates

Description of New or Updated Information

Description of A056 revised.

Description of A059/A062 revised.

Fault description for F3 revised.

A table row for electrical specifications added.

Graphic for the “Network Wiring” section revised.

Second last paragraph in the “Network Wiring” section revised.

Text in the “Writing (06) Logic Command Data” section revised.

Frequency source for logic command 001 of bits 14, 13, and 12 corrected.

Text in the “Writing (06) Reference” section revised.

Parameter Updates

The following parameters have been updated with firmware version 6.xx.

Parameter

[Relay Out Sel]

[Relay Out Sel]

Number

A055

Description

Function of option 20, ParamControl, changed.

Option 24, MsgControl, added.

Page

3-16

A058, A061 Function of option 20, ParamControl, changed.

Option 24, MsgControl, added.

3-18

Page(s)

3-17

3-19

4-3

A-4

C-1

C-2

C-4

C-4

C-5


Publication 22B-UM001G-EN-E

soc-2

The information below summarizes the changes to the PowerFlex 40

User Manual since the January 2007 release.

Manual Updates

Description of New or Updated Information

Input description and attention text for Multiple Digital Input Connection example corrected.

New method of changing speed reference for IP66, NEMA/UL Type 4X rated drives described.

Description for Up Arrow and Down Arrow keys revised.

Fault description for F3 revised.

Graphic for the “Network Wiring” section revised.

Descriptions for bits 6, 7, and 15 of register address 8192 (Logic Command) updated.

New information on reading register address 8192 added.

New information on reading register address 8193 added.

Graphic for the “Connecting an RS-485 Network” section corrected.

New method for inverting sign of PID error added.

Page(s)

1-22

2-2

2-4

4-3

C-1

C-4

C-4

C-5

D-4

F-6

New Parameter

The following parameter has been added with firmware version 5.xx.

Parameter

[PID Invert Error]

Number

A167

Description

New

Page

3-44

Parameter Updates

The following parameters have been updated with firmware version 5.xx.

Parameter

[Control Source]

[Start Source]

[Relay Out Sel]

[Relay Out Level]

[Opto Outx Sel]

[Opto Outx Level]

[Internal Freq]

[PID Trim Hi]

[PID Trim Lo]

Number

d012

P036

A055

Description

Options 7 and 8 added.

Description revised for option 6.

Description revised for option 20.

A056 Description revised.

A058, A061 Description revised for option 20.

A059, A062 Description revised.

A069 Default value for IP66, NEMA/

UL Type 4X drives is 0.0 Hz.

Default value for IP20 rated drives is

60.0 Hz.

A130

A131

Description revised.

Description revised.

3-38

3-38

Page

3-5

3-10

3-16

3-17

3-18

3-19

3-22



Table of Contents

Preface

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Appendix A

Appendix B

Overview

Who Should Use this Manual? . . . . . . . . . P-1

Reference Materials . . . . . . . . . . . . . . . . . P-1

Manual Conventions . . . . . . . . . . . . . . . . . P-2

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2

General Precautions . . . . . . . . . . . . . . . . . P-3

Catalog Number Explanation . . . . . . . . . . P-4

Installation/Wiring

Opening the Cover . . . . . . . . . . . . . . . . . . 1-1

Mounting Considerations . . . . . . . . . . . . . 1-3

AC Supply Source Considerations . . . . . . 1-5

General Grounding Requirements . . . . . . 1-7

Fuses and Circuit Breakers . . . . . . . . . . . . 1-8

Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-10

IP66, NEMA/UL Type 4X

Installations . . . . . . . . . . . . . . . . . . . . . 1-14

I/O Wiring Recommendations . . . . . . . . 1-14

Start and Speed Reference Control . . . . . 1-23

EMC Instructions . . . . . . . . . . . . . . . . . . 1-25

Start Up

Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . 3-1

Parameter Organization. . . . . . . . . . . . . . . 3-2

Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3

Basic Program Group . . . . . . . . . . . . . . . . 3-9

Advanced Program Group. . . . . . . . . . . . 3-14

Parameter Cross Reference – by Name. . 3-45

Troubleshooting

Prepare For Drive Start-Up . . . . . . . . . . . . 2-1

Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-4

Viewing and Editing Parameters . . . . . . . . 2-5

Remote HIM Menu Structure . . . . . . . . . . 2-6

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3

Common Symptoms and Corrective

Actions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings . . . A-1

Specifications . . . . . . . . . . . . . . . . . . . . . . A-2

Accessories and Dimensions

Product Selection . . . . . . . . . . . . . . . . . . . B-1

Product Dimensions . . . . . . . . . . . . . . . . . B-7



2

Table of Contents

Appendix C

Appendix D

Appendix E

Appendix F

RS485 (DSI) Protocol

Network Wiring . . . . . . . . . . . . . . . . . . . . . C-1

Parameter Configuration . . . . . . . . . . . . . . C-3

Supported Modbus Function Codes . . . . . C-3

Writing (06) Logic Command Data. . . . . . C-4

Writing (06) Reference . . . . . . . . . . . . . . . C-5

Reading (03) Logic Status Data. . . . . . . . . C-5

Reading (03) Feedback . . . . . . . . . . . . . . . C-6

Reading (03) Drive Error Codes . . . . . . . . C-6

Reading (03) and Writing (06) Drive

Parameters . . . . . . . . . . . . . . . . . . . . . . . C-7

Additional Information . . . . . . . . . . . . . . . C-7

RJ45 DSI Splitter Cable

Connectivity Guidelines . . . . . . . . . . . . . . D-1

DSI Cable Accessories . . . . . . . . . . . . . . . D-2

Connecting One Temporary Peripheral . . . D-3

Connecting One Temporary Peripheral and One Permanent Peripheral . . . . . . . D-3

Connecting Two Permanent Peripherals . . D-4

Connecting an RS-485 Network . . . . . . . . D-4

StepLogic™, Basic Logic and Timer/Counter Functions

StepLogic Using Timed Steps . . . . . . . . . . E-2

StepLogic Using Basic Logic Functions . . E-3

Timer Function . . . . . . . . . . . . . . . . . . . . . E-4

Counter Function . . . . . . . . . . . . . . . . . . . . E-6

PID Set Up

PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

PID Reference and Feedback . . . . . . . . . . F-4

Analog PID Reference Signals . . . . . . . . . F-5

Index



Preface

Overview

The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 40 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

Wiring and Grounding

Guidelines for Pulse Width

Modulated (PWM) AC Drives

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

Publication

DRIVES-IN001…

DRIVES-TD001…

SGI-1.1

100-2.10

8000-4.5.2

Available Online at … www.rockwellautomation.com/ literature



P-2

Overview

Manual Conventions

•

In this manual we refer to the PowerFlex 40 Adjustable Frequency

AC Drive as; drive, PowerFlex 40 or PowerFlex 40 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

Must

Shall

Should

Should Not

Meaning

Possible, able to do something

Not possible, not able to do something

Permitted, allowed

Unavoidable, you must do this

Required and necessary

Recommended

Not Recommended

Drive Frame Sizes

Similar PowerFlex 40 drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, etc. A cross reference of drive catalog numbers and their respective frame sizes is provided in

Appendix B .



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.

ATTENTION: The bus regulator function is extremely useful for preventing nuisance overvoltage faults resulting from aggressive decelerations, overhauling loads, and eccentric loads. However, it can also cause either of the following two conditions to occur.

1. Fast positive changes in input voltage or imbalanced input voltages can cause uncommanded positive speed changes;

2. Actual deceleration times can be longer than commanded deceleration times

However, a “Stall Fault” is generated if the drive remains in this state for 1 minute. If this condition is unacceptable, the bus regulator must be disabled (see parameter

A117 ). In addition, installing a properly sized

dynamic brake resistor will provide equal or better performance in most cases.



P-4

Overview

Catalog Number Explanation

1-3 4 5 6-8 9 10 11

22B A 1P5 N 1 1

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type

12

(1)

4

13-14

AA

Optional

Code

22B PowerFlex 40

Code Voltage Ph.

V

A

B

D

E

120V AC 1

240V AC 1

240V AC 3

480V AC 3

600V AC 3

Output Current

@ 100-120V 50/60 Hz Input

Code Amps kW (HP)

2P3 2.3

5P0 5.0

6P0 6.0

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

Output Current

@ 380-480V 50/60 Hz Input


1P4 1.4

2P3 2.3

0.4 (0.5)

0.75 (1.0)

4P0 4.0

6P0 6.0

010 10.5

012 12

017 17

024 24

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

Code Version

3 No Brake IGBT

4 Standard

Code Rating

0 Not Filtered

1 Filtered

Code Interface Module

1 Fixed Keypad

Code Purpose

AA Reserved for thru custom firmware

ZZ

Code Enclosure

N Panel Mount - IP20, NEMA/UL Type Open

C

F

H

Panel Mount - IP66, NEMA/UL Type 4X

Flange Mount - IP20, NEMA/UL Type Open

Replacement Plate Drive - IP20, NEMA/UL Type Open

- Contact factory for ordering information.

Output Current

@ 200-240V 50/60 Hz Input


2P3 2.3

5P0 5.0

0.4 (0.5)

0.75 (1.0)

8P0 8.0

012 12

017

024

033

17.5

24

33

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10)

Output Current

@ 500-600V 50/60 Hz Input


1P7 1.7

3P0 3.0

4P2 4.2

6P6 6.6

9P9 9.9

012 12.2

019 19

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

(1)

Position 12 of the Catalog Number now indicates drive type. All PowerFlex 40 drives are equipped with RS485 communication.

Additional accessories, options and adapters are available. See Appendix B for details.



Chapter

1

Installation/Wiring

This chapter provides information on mounting and wiring the

PowerFlex 40 Drive.


Opening the Cover

Mounting Considerations

See page

1-1

1-3

AC Supply Source Considerations 1-5

For information on… See page

Fuses and Circuit Breakers 1-8

Power Wiring 1-10

1-14 I/O Wiring

Recommendations

EMC Instructions 1-25

General Grounding Requirements 1-7

Most start-up difficulties are the result of incorrect wiring. Every precaution must be taken to assure that the wiring is done as instructed.

All items must be read and understood before the actual installation begins.

!

ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

Opening the Cover

IP20, NEMA/UL Type Open

1. Press and hold in the tabs on each side of the cover.

2. Pull the cover out and up to release.



1-2

Installation/Wiring

!

IP66, NEMA/UL Type 4X

ATTENTION: To avoid an electric shock hazard, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)] and wait three minutes for capacitors to discharge before removing the external cover.

Once the cover is removed, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the

DC bus voltage at the DC– and DC+ terminals on the Power Terminal

Block (refer to

page 1-13

for Power Terminal descriptions). The voltage must be zero.

1. Loosen the four captive cover screws.

2. Pull cover straight off chassis.

IP66, NEMA/UL Type 4X Cover Installation

1. Squarely align the cover on the chassis.

2. Lightly tighten the four captive cover screws.

3. Torque the cover screws using an alternating pattern.

1

4

1

2

3

2

0.8 ±0.2 N-m

(7.0 ±2.0 lb.-in.)

3



Installation/Wiring

Mounting Considerations

•

Mount the drive upright on a flat, vertical and level surface.

Frame

B

Screw Size

M4 (#8-32)

Screw Torque

1.56-1.96 N-m (14-17 lb.-in.)

DIN Rail

35 mm

C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) –

B (IP66,

Type 4X)

M6 (#12-24) 3.95-4.75 N-m (35-42 lb.-in.) –

•

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.

1-3

120 mm

(4.7 in.)

Closest object that may restrict air flow through the drive heat sink and chassis

120 mm

(4.7 in.)

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

Ambient Operating Temperatures

Table 1.A Enclosure and Clearance Requirements

Ambient Temperature

Minimum Maximum

-10°C (14°F)

Enclosure Rating Minimum Mounting

Clearances

40°C (104°F)

IP20, NEMA/UL Type Open Use Mounting Option A

IP66, NEMA/UL Type 4X

IP30, NEMA/UL Type 1

(1)

Use Mounting Option A

Use Mounting Option B

50°C (122°F) IP20, NEMA/UL Type Open Use Mounting Option B

(1)

Rating requires installation of the PowerFlex 40 IP30, NEMA/UL Type 1 option kit.



1-4

Installation/Wiring

Debris Protection

A plastic top panel is included with the drive. Install the panel to prevent debris from falling through the vents of the drive housing during installation. Remove the panel for IP20, NEMA/UL Type Open applications.

Storage

•

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

1-5

!

AC Supply Source Considerations

Ungrounded Distribution Systems

ATTENTION: PowerFlex 40 drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system.

Disconnecting MOVs

To prevent drive damage, the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed

125% of the nominal line-to-line voltage. To disconnect these devices, remove the jumper shown in the Figures

1.1

and

1.2

.

1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.

3. Tighten the screw to keep it in place.

Figure 1.1 Jumper Location (Typical)

IP20, NEMA/UL Type Open IP66, NEMA/UL Type 4X

Important: Tighten screw after jumper removal.

Figure 1.2 Phase to Ground MOV Removal

Three-Phase

AC Input

R/L1

S/L2

T/L3

Jumper 1 2 3 4



1-6

Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see

Appendix A

). Listed in Table 1.B

are certain input power conditions which may cause component damage or reduction in product life. If any of the conditions exist, as described in

Table 1.B

, install one of the devices listed under the heading Corrective

Action on the line side of the drive.

Important: Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Table 1.B Input Power Conditions

Input Power Condition

Line has power factor correction capacitors

Line has frequent power interruptions

Corrective Action

Low Line Impedance (less than 1% line reactance)

•

Install Line Reactor

(2)

Greater than 120 kVA supply transformer

• or Isolation Transformer

• or Bus Inductor – 5.5 & 11 kW

(7.5 & 15 HP) drives only

•


• or Isolation Transformer

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

240V open delta configuration (stinger leg)

(1)

•

Remove MOV jumper to ground.

• or Install Isolation Transformer with grounded secondary if necessary.

•


(1)

(2)

For drives applied on an open delta with a middle phase grounded neutral system, the phase opposite the phase that is tapped in the middle to the neutral or earth is referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified throughout the system with red or orange tape on the wire at each connection point.

The stinger leg should be connected to the center Phase B on the reactor. Refer to

Table B.D

for specific line reactor part numbers.

Refer to

Appendix B

for accessory ordering information.



Installation/Wiring

1-7

General Grounding Requirements

The drive Safety Ground (PE) must be connected to system 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

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.



1-8

Installation/Wiring

RFI Filter Grounding

Using single phase drives with integral filter, or an external filter with any drive rating, may result in relatively high ground leakage currents.

Therefore, the filter must only be used in installations with grounded

AC supply systems and be permanently installed and solidly

grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked.

!

Fuses and Circuit Breakers

The PowerFlex 40 does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations.

ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in this section.

Fusing

The PowerFlex 40 has been UL tested and approved for use with input fuses. The ratings in the table that follows are the minimum recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide.

Bulletin 140M (Self-Protected Combination Controller)/UL489

Circuit Breakers

When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection.

•

Bulletin 140M can be used in single and group motor applications.

•

Bulletin 140M can be used up stream from the drive without the need for fuses.



Installation/Wiring

1-9

Table 1.C Minimum Recommended Branch Circuit Protective Devices

120V AC –

1-Phase

240V AC –

1-Phase

240V AC –

3-Phase

480V AC –

3-Phase

600V AC –

3-Phase

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10.0)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10.0)

11 (15)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10.0)

11 (15)

Voltage

Rating

Drive Rating

kW (HP)

Fuse Rating

Amps

10

20

30

40

15

35

40

15

20

25

30

50

3

6

10

30

40

60

6

10

15

25

15

20

25

40

6

6

10

(1)

140M Motor

Protectors

(2)

Catalog No.

140M-C2E-C16

140M-D8E-C20

140M-F8E-C32

140M-C2E-B63

140M-C2E-C16

140M-D8E-C20

140M-F8E-C32

140M-C2E-B40

140M-C2E-C10

140M-C2E-C16

140M-C2E-C16

140M-F8E-C25

140M-F8E-C32

140M-G8E-C45

140M-C2E-B25

140M-C2E-B40

140M-C2E-B63

140M-C2E-C10

140M-C2E-C16

140M-D8E-C20

140M-D8E-C20

140M-F8E-C32

140M-C2E-B25

140M-C2E-B40

140M-C2E-B63

140M-C2E-C10

140M-C2E-C16

140M-C2E-C16

140M-D8E-C25

100-C07

100-C09

100-C12

100-C23

100-C23

100-C37

100-C60

100-C07

100-C07

100-C09

100-C09

100-C23

100-C23

100-C23

100-C43

100-C09

100-C09

100-C09

100-C09

100-C16

100-C23

100-C30

Recommended

MCS Contactors

Catalog No.

100-C12

100-C23

100-C37

100-C09

100-C12

100-C23

100-C37

(1)

(2)

Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.

Refer to the Bulletin 140M Motor Protectors Selection Guide, publication

140M-SG001… to determine the frame and breaking capacity required for your application.



1-10

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

A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable must be used.

UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.

UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.

Use copper wire only. Wire gauge requirements and recommendations are based on 75 degree C. Do not reduce wire gauge when using higher temperature wire.

Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet

areas. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations or a high degree of communications / networking are also good candidates for shielded cable.



Installation/Wiring

1-11

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks. Refer to Reflected Wave in “Wiring and

Grounding Guidelines for PWM AC Drives,” publication

DRIVES-IN001A-EN-P.

Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.

A good example of recommended cable is Belden® 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield

(with drain wire) surrounded by a PVC jacket.

Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance.

Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.

Recommended Shielded Wire

Location

Standard

(Option 1)

Standard

(Option 2)

Class I & II;

Division I & II

Rating/Type

600V, 90°C (194°F)

XHHW2/RHW-2

Anixter

B209500-B209507,

Belden 29501-29507, or equivalent

Description

•

Four tinned copper conductors with XLPE insulation.

•

Copper braid/aluminum foil combination shield and tinned

• copper drain wire.

PVC jacket.

Tray rated 600V, 90°C

(194°F) RHH/RHW-2

Anixter OLF-7xxxxx or equivalent

•

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.

Tray rated 600V, 90°C

(194°F) RHH/RHW-2

Anixter 7V-7xxxx-3G or equivalent

•

Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor.

•

Black sunlight resistant PVC jacket overall.

•

Three copper grounds on #10 AWG and smaller.



1-12

Installation/Wiring

Reflected Wave Protection

The drive should be installed as close to the motor as possible.

Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor (reflected wave

phenomena). See Table 1.D

for recommendations.

The reflected wave data applies to all frequencies 2 to 16 kHz.

For 240V ratings, reflected wave effects do not need to be considered.

Table 1.D Maximum Cable Length Recommendations

Reflected Wave

380-480V Ratings Motor Insulation Rating

1000 Vp-p

1200 Vp-p

1600 Vp-p

Motor Cable Only

(1)

15 meters (49 feet)

40 meters (131 feet)


(1)

Longer cable lengths can be achieved by installing devices on the output of the drive.

Consult factory for recommendations.

Output Disconnect

The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used. If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be used to simultaneously disable drive control run commands.



Installation/Wiring

Power Terminal Block

The power terminal block is covered by a finger guard. To remove:

1. Press in and hold the locking tab.

2. Slide finger guard down and out.

Replace the finger guard when wiring is complete.

Figure 1.4 Power Terminal Block (Typical)

1-13

B Frame

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

C Frame

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1

P2, P1

DC- DC+

DC+, DC-

BR+, BR-

BR+ BR-

DC- DC+ BR+ BR-

Terminal

(1)

R/L1, S/L2

Description

1-Phase Input

R/L1, S/L2, T/L3 3-Phase Input

U/T1

V/T2

W/T3

To Motor U/T1

To Motor V/T2

=

Switch any two motor leads to change forward direction.

To Motor W/T3

DC Bus Inductor Connection (C Frame drives only.)

The C Frame drive is shipped with a jumper between

Terminals P2 and P1. Remove this jumper only when a DC

Bus Inductor will be connected. Drive will not power up without a jumper or inductor connected.

DC Bus Connection

Dynamic Brake Resistor Connection

Safety Ground - PE

(1)

Important: Terminal screws may become loose during shipment. Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive.

Table 1.E Power Terminal Block Specifications

Frame Maximum Wire Size

(1)

B

C

5.3 mm

2

(10 AWG)

8.4 mm

2

(8 AWG)

Minimum Wire Size

1.3 mm

2

1.3 mm

2

(16 AWG)

(16 AWG)

(1)

Torque

1.7-2.2 N-m (16-19 lb.-in.)

2.9-3.7 N-m (26-33 lb.-in.)

(1)

Maximum/minimum sizes that the terminal block will accept - these are not recommendations.



1-14

Installation/Wiring

IP66, NEMA/UL Type 4X Installations

Use the plugs supplied with IP66, NEMA/UL Type 4X rated drives to seal unused holes in the conduit entry plate.

Important: Completely seat the plug inner rim for the best seal.

!

!

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.



Installation/Wiring

1-15

Control Wire Types

Table 1.F Recommended Control and Signal Wire

(1)

Wire Type(s)

(2)

Belden 8760/9460

(or equiv.)

Belden 8770

(or equiv.)

Description Minimum

Insulation Rating

0.8 mm

2

(18AWG), twisted pair, 100% shield with drain.

(1)

0.8 mm

2

(18AWG), 3 conductor, shielded for remote pot only.

300V

60 degrees C

(140 degrees F)

(1)

(2)

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.

Stranded or solid wire.

I/O Terminal Block

Table 1.G I/O Terminal Block Specifications

Frame

B & C

Maximum Wire Size

(3)

Minimum Wire Size

(3)

1.3 mm

2

(16 AWG) 0.2 mm

2

(24 AWG)

Torque

0.5-0.8 N-m (4.4-7 lb.-in.)

(3)

Maximum/minimum sizes that the terminal block will accept - these are not recommendations.

Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal 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.



1-16

Installation/Wiring

Figure 1.5 Control Wiring Block Diagram

Enable Jumper

(4)

Relay N.O.

Relay Common

R1

R2

Relay N.C.

R3

SNK SRC

30V DC

50mA

Non-inductive

+24V

+10V

0-10V

0/4-20mA

06

07

04

05

08

09

01

02

03

Stop

(1)(4)

Start/Run FWD

(2)

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

Opto Common

Typical

SRC Wiring

18

19

15

16

11

12

13

14

+24V DC

+10V DC

0-10V (or ±10V) Input

Analog Common

4-20mA Input

Analog Output

Opto Output 1

17

Opto Output 2

RS485 Shield

Typical

SNK Wiring

Pot must be

1-10k ohm

2 Watt Min.

Common

(3)

24V

0-10V

Analog Output Select

ENBL

06 07 08 09

Enable

(4)

Jumper

01 02 03 04 05

0-20mA

R1 R2 R3

SNK

11 12 13 14 15

16 17 18 19

RS485

(DSI)

SRC

(1)

1

30V DC 125V AC 240V AC

Resistive 3.0A

Inductive 0.5A

3.0A

0.5A

3.0A

0.5A

(1)

Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set to

“3-Wire” or “Momt FWD/REV” control. In three wire control, I/O Terminal 01 is controlled by P037 [Stop

Mode]. All other stop sources are controlled by P037

[Stop Mode].

P036 [Start Source]

Keypad

3-Wire

2-Wire

Momt FWD/REV

RS485 Port

Stop

Per P037

Per P037

Per P037

Per P037

Per P037

I/O Terminal 01 Stop

Coast

Per P037

(4)

Coast

Per P037

(4)

Coast

Important: The drive is shipped with a jumper installed between I/O Terminals 01 and 11. Remove this jumper when using I/O Terminal 01 as a stop or enable input.

(2)

Two wire control shown. For three wire control use a momentary input command a start. Use a maintained input

on I/O Terminal 02 to

for I/O Terminal 03 to change direction.

(3)

When using an opto output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to prevent damage to the output.

(4)

When the ENBL enable jumper is removed, I/O Terminal 01 will always act as a hardware enable, causing a coast to stop without software interpretation.



Installation/Wiring

1-17

Table 1.H Control I/O Terminal Designations

No. Signal

R1 Relay N.O.

R2 Relay Common

R3 Relay N.C.

Default

Fault

–

Fault

Description

Normally open contact for output relay.

Common for output relay.

Normally closed contact for output relay.

Param.

A055

A055

Analog Output Select DIP

Switch

0-10V

Sink/Source DIP Switch Source (SRC)

Sets analog output to either voltage or current. Setting must match

A065 [Analog Out Sel].

Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting.

01 Stop

(1)

Coast

02 Start/Run FWD Not Active

03 Direction/Run REV Not Active

04 Digital Common

05 Digital Input 1

06 Digital Input 2

07 Digital Input 3

08 Digital Input 4

09 Opto Common

11 +24V DC

12 +10V DC

13 ±10V In

(2)

15

4-20mA In

(2)

–

Preset Freq

Preset Freq

Local

Jog Forward

–

–

–

Not Active

14 Analog Common –

16 Analog Output

17 Opto Output 1

18 Opto Output 2

Not Active

OutFreq 0-10

MotorRunning

At Frequency

19 RS485 (DSI) Shield –

The factory installed jumper or a normally closed input must be present for the drive to start.

P036

(1)

Command comes from the integral keypad by default.

To disable reverse operation, see A095 [Reverse

Disable].

P036

,

P037

P036

,

P037 ,

A095

For digital inputs. Electronically isolated with digital inputs from analog I/O and opto outputs.

Program with A051 [Digital In1 Sel].




A051

A052

A053

A054

For opto-coupled outputs. Electronically isolated with opto outputs from analog I/O and digital inputs.

Referenced to Digital Common.

Drive supplied power for digital inputs.

Maximum output current is 100mA.

Referenced to Analog Common.

Drive supplied power for 0-10V external potentiometer.

Maximum output current is 15mA.

P038

For external 0-10V (unipolar) or ±10V (bipolar) input supply (input impedance = 100k ohm) or potentiometer wiper.

P038

,

A051 -

A054

,

A123 ,

A132

For 0-10V In or 4-20mA In. Electronically isolated with analog inputs and outputs from digital I/O and opto outputs.

For external 4-20mA input supply

(input impedance = 250 ohm).

Program with A061 [Opto Out2 Sel]

P038

,

A051 -

A054

,

A132

The default analog output is 0-10V. To covert to a current value, change the Analog Output Select DIP

Switch to 0-20mA. Program with A065 [Analog Out

Sel]. Max analog value can be scaled with A066

[Analog Out High].

Maximum Load: 4-20mA = 525 ohm (10.5V)

0-10V = 1k ohm (10mA)

A065

,

A066

Program with A058 [Opto Out1 Sel]

A058

,

A059 ,

A064

A061

,

A062 ,

A064

Terminal should be connected to safety ground - PE when using the RS485 (DSI) communications port.

(1)

(2)

See Footnotes (1) and (4) on

page 1-16

.

0-10V In and 4-20mA In are distinct input channels and may be connected simultaneously.

Inputs may be used independently for speed control or jointly when operating in PID mode.



1-18

Installation/Wiring

I/O Wiring Examples

Input/Output

Potentiometer

1-10k Ohm Pot.

Recommended

(2 Watt minimum)

Connection Example

P038

[Speed Reference] = 2 “0-10V Input”

12

13

14

Analog Input

0 to +10V, 100k ohm impedance

4-20 mA, 250 ohm impedance

Bipolar

P038

[Speed Reference]

= 2 “0-10V Input” and

A123

[10V Bipolar Enbl]

= 1 “Bi-Polar In”

Unipolar (Voltage)

P038 [Speed Reference]

= 2 “0-10V Input”

Unipolar (Current)

P038

[Speed Reference]

= 3 “4-20mA Input”

-/+ 10V

Common

13

14

+

Common

13

14

Common

+

14

15

Analog Input, PTC

For Drive Fault

Wire the PTC and External Resistor (typically matched to the PTC Hot

Resistance) to I/O Terminals 12, 13, 14.

Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11.

A051

[Digital In1 Sel] = 3 “Aux Fault”

A055

[Relay Out Sel] = 10 “Above Anlg V”

A056

[Relay Out Level] = % Voltage Trip

R2

R3

R e

R

PTC

11

12

13

14

05

V

Trip

=

R

PTC (hot)

R

PTC (hot)

+ R e

×

100



Installation/Wiring

1-19

Input/Output

2 Wire SRC Control -

Non-Reversing

P036

[Start Source] =

2, 3 or 4

Input must be active for the drive to run. When input is opened, the drive will stop as specified by

P037

[Stop Mode].

If desired, a User

Supplied 24V DC power source can be used. Refer to the

“External Supply

(SRC)” example.

2 Wire SNK Control -

Non-Reversing


Internal Supply (SRC)

Stop-Run

11

Internal Supply (SNK)

01

02

Stop-Run

01

02

04

External Supply (SRC)

Stop-Run

+24V Common

01

02

04

Each digital input draws 6 mA.


Run FWD/Run REV

P036

[Start Source] =

2, 3 or 4

Input must be active for the drive to run. When input is opened, the drive will stop as specified by

P037

[Stop Mode].

If both Run Forward and Run Reverse inputs are closed at the same time, an undetermined state could occur.


Stop-Run

Forward

Stop-Run

Reverse

11

01

02

03


+24V

Stop-Run

Forward

Stop-Run

Reverse

Common


01

02

03

04



1-20

Installation/Wiring

Input/Output


Run FWD/Run REV



Stop-Run

Forward

Stop-Run

Reverse

01

02

03

04


Non-Reversing

P036

[Start Source] = 1

A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by

P037

[Stop Mode].


Stop

Start

11

01

02


Stop

Start

01

02

04

+24V Common



Non-Reversing


Stop

Start

01

02

03

04


Reversing

P036

[Start Source] = 1

A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by

P037

[Stop Mode]. I/O

Terminal 03 determines direction.


Stop

Start

Direction

11

01

02

03


Stop

+24V

Start

Direction

Common

01

02

03

04




Installation/Wiring

1-21

Input/Output


Reversing



Stop

Start

Direction

01

02

03

04

Opto Output (1 & 2)

A058

[Opto Out1 Sel] determines

Opto-Output 1 (I/O

Terminal 17) operation.

A061

[Opto Out2 Sel] determines

Opto-Output 2 (I/O

Terminal 18) operation.

When using

Opto-Output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to prevent damage to the output.

Analog Output

A065

[Analog Out Sel] determines analog output type and drive conditions.

0-10V,

1k ohm minimum

Opto-Output 1

+24V

CR

Each Opto-Output is rated

30V DC 50 mA (Non-inductive).

Common

17

Common

14

09

A065

[Analog Out Sel] = 0 through 14

The Analog Output Select DIP Switch must be set to match the analog output

signal mode set in A065

[Analog Out Sel].

16

0-20mA/4-20mA,

525 ohm maximum

+



1-22

Installation/Wiring

Typical Multiple Drive Connection Examples

Input/Output

Multiple Digital

Input Connections

Customer Inputs can be wired per

External Supply

(SRC) examples on

1-19

and 1-20

.


02 04

Customer Inputs

02 04

Optional Ground Connection

02 04

When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives. If they are to be tied into another common (such as earth ground or separate apparatus ground) only one point of the daisy chain of I/O Terminal 04 should be connected.

!

ATTENTION: Digital inputs on multiple drives should not be tied together when using SNK (Internal Supply) mode. In SNK mode, if power is removed from one drive, inadvertent operation of other drives that share the same I/O Common connection may occur.

Multiple Analog

Connections

12 13 14 13 14 13 14

Remote Potentiometer Optional Ground Connection

When connecting a single potentiometer to multiple drives it is important to connect I/O Terminal 14 common together for all drives. I/O Terminal 14 common and I/O Terminal 13 (potentiometer wiper) should be daisy-chained to each drive.

All drives must be powered up for the analog signal to be read correctly.



Installation/Wiring

1-23

Start and Speed Reference Control

The drive speed command can be obtained from a number of different sources. The source is normally determined by

P038

[Speed Reference]. However, when A051

-

A054 [Digital Inx Sel] is

set to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, or if A132 is not set to option 0, the speed reference commanded by

P038 [Speed Reference] will be overridden. See

the chart below for the override priority.

Jog Input

Enabled and Active:

A051, A052, A053 or A054 = 2, 11, 12

Yes

No

No

Drive Stopped

(Not Running)

Yes

Drive will Start and Run at Jog Speed.

Direction comes from

I/O Terminal 03 Dir/Run REV or

Jog Forward/Jog Reverse command

Local/Remote Input

Enabled and Active:

[Digital Inx Sel] = 5

Yes

Start, Speed and Direction commands come from Integral Keypad.

No

Comm Select Input

Enabled and Active:


Yes

Start, Speed and Direction commands come from RS485 (DSI) port.

No

0-10V Override

Enabled and Active:


Yes

Speed commands come from 0-10V.

Start and Direction follows P036 [Start Source] or

Bi-Polar input when enabled.

No

4-20mA Override

Enabled and Active:


Yes

Speed commands come from 4-20mA.

Start and Direction follows P036 [Start Source].

No


= 4 or 5

Yes

Run as specified by

P038 [Speed Refernece].

Start and Direction commands come from P036 [Start Source].

No

A051/A052/A053

Preset Inputs Active

Yes

Run as specified by

A071-A077 [Preset Freq 1-7].


No

PID Enabled:

A132 [PID Ref Select]

≠

0

No

Run as specified by

P038 [Speed Reference].


Yes

Run as specified by

A132 [PID Ref Select].




1-24

Installation/Wiring

Accel/Decel Selection

The Accel/Decel rate can be obtained by a variety of methods. The default rate is determined by P039 [Accel Time 1] and P040 [Decel Time

1]. Alternative Accel/Decel rates can be made through digital inputs,

RS485 (DSI) communications and/or parameters. See the chart below for the override priority.

Jog Input

Enabled and Active:

A051, A052, A053 or A054 = 2, 11,12

No

RS485 (DSI) Port

Controls Speed

Yes

Drive Stopped

(Not Running)

Yes

Drive will Start and Run at Jog Speed.

Drive will use A079 [Jog Accel/Decel]

No

Yes

Either

P039 [Accel Time 1]/P040 [Decel Time 1] or

A067 [Accel Time 2]/A068 [Decel Time 2] can be selected when

RS485 (DSI) port is active.

No

Input is programmed as "Accel 2 & Decel 2"

A051, A052, A053 or A054 = 1

No

Yes

A067 [Accel Time 2]/A068 [Decel Time 2] is active when input is active.

Speed is controlled by [Preset Freq x]

Yes

P039 [Accel Time 1]/P040 [Decel Time 1];

A067 [Accel Time 2]/A068 [Decel Time 2] determined by the active

Preset Frequency.

See A070-A077 [Preset Freq 0-7]

No

Speed is controlled by Stp Logic

No

P039 [Accel Time 1]/P040 [Decel Time 1] are used.

Yes

Either

P039 [Accel Time 1]/P040 [Decel Time 1] or

A067 [Accel Time 2]/A068 [Decel Time 2] can be selected by the Digit 3 setting of the Step Logic parameters.

See A140-A147 [Stp Logic 0-7]



Installation/Wiring

1-25

EMC Instructions

CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic

Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official

Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User

Manual.

CE Declarations of Conformity are available 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.



1-26

Installation/Wiring

Essential Requirements for CE Compliance

Conditions 1-3 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3.

1. Grounding as described in Figure 1.6

. Refer to

page 1-8 for

additional grounding recommendations.

2. Output power, control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.

3. Allowable cable length in

Table 1.I

is not exceeded.

Table 1.I Allowable Cable Length

Filter Type EN61800-3 First Environment

Restricted Distribution or

Second Environment

(2)

10 meters (33 feet) Integral

External - S Type

(1)

External - L Type

(1)

10 meters (33 feet)


EN61800-3 First Environment

Unrestricted Distribution

1 meter (3 feet)

1 meter (3 feet)

5 meters (16 feet)

(1)

Refer to

Appendix B for details on optional external filters.

(2)

Equivalent to EN55011 Class A.

(3)

Equivalent to EN55011 Class B.

(3)

Figure 1.6 Connections and Grounding

Shielded Enclosure

(1)

IP 30/NEMA 1/UL Type 1

Option Kit

L1

L2

L3

(2)

EMI Filter

L1'

L2'

L3'

R/L1

S/L2

T/L3

EMI Fittings and Metal Conduit

U/T1

V/T2

W/T3

Enclosure Ground Connection Shielded Motor Cable

Building Structure Steel

(1)

(2)

First Environment Unrestricted Distribution installations require a shielded enclosure.

Keep wire length as short as possible between the enclosure entry point and the EMI filter.

Integral EMI filters are available on 240V, 1-Phase drives.



Installation/Wiring

1-27

EN61000-3-2

•

0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5

HP) 240V 1-Phase drives are suitable for installation on a private low voltage power network. Installations on a public low voltage power network may require additional external harmonic mitigation.

•

Other drive ratings meet the current harmonic requirements of

EN61000-3-2 without additional external mitigation.



1-28

Notes:

Installation/Wiring



Chapter

2

Start Up

This chapter describes how to start up the PowerFlex 40 Drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group.

Important: Read the General Precautions section before proceeding.

!

ATTENTION: Power must be applied to the drive to perform the following start-up procedures. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove All Power including user supplied control voltages. User supplied voltages may exist even when main AC power is not applied to the drive. Correct the malfunction before continuing.

Prepare For Drive Start-Up

Before Applying Power to the Drive

❏

1. Confirm that all inputs are connected to the correct terminals and are secure.

❏

2. Verify that AC line power at the disconnect device is within the rated value of the drive.

❏

3. Verify that any digital control power is 24 volts.

❏

4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to match your control wiring scheme. See

Figure 1.5 on page 1-16 for

location.

Important: The default control scheme is Source (SRC). The Stop terminal is jumpered (I/O Terminals 01 and 11) to allow starting from the keypad. If the control scheme is changed to Sink (SNK), the jumper must be removed from I/O

Terminals 01 and 11 and installed between I/O Terminals

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 2-4 )

before setting any Program Group parameters.

If a fault appears on power up, refer to

Fault Descriptions on page 4-3

for an explanation of the fault code.

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].

Changing the Speed Reference of an IP66, NEMA/UL Type 4X rated drive

When a Display Group parameter, for example, d001

[Output Freq] is

displayed, and P038 [Speed Ref] is set to

A069 [Internal Freq], you can

change the internal frequency using the Up Arrow and Down Arrow keys.

VOLTS

AMPS

HERTZ

RUN

FWD

REV

PROGRAM FAULT

VOLTS

AMPS

HERTZ

When the internal frequency is being adjusted, its value is displayed and the Hertz LED flashes. Any changes are saved immediately. The display then returns to the Display Group parameter previously shown.

TIP: By default, the speed reference of an IP66, NEMA/UL Type 4X

rated drive is set to the internal frequency, A069

[Internal Freq].



Start Up

2-3

TIP: You can also change the speed reference by editing the parameter

A069 [Internal Freq] in program mode. For details on how to enter the

program mode, see Viewing and Editing Parameters on page 2-5 .

Note: The default value of A069

[Internal Freq] is 0 Hz. For IP20 rated

PowerFlex 40 drives, the default value of this parameter is 60 Hz.

Variable Torque Fan/Pump Applications

For improved motor tuning performance when using a premium efficient

motor on a variable torque load, set A084

[Boost Select] to option 2

“35.0, VT”.



2-4

➏

➊

RUN

FWD

REV

Start Up

Integral Keypad

➍

PROGRAM

➐

➋

➎

FAULT

➌

VOLTS

AMPS

HERTZ

➑

➒

Menu Description

Display Group (View Only)

Consists of commonly viewed drive operating conditions.

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

Description

Indicates drive is running and commanded motor direction.

Flashing Red Drive has been commanded to change direction. Indicates actual motor direction while decelerating to zero.

➋

Alphanumeric

Display

Steady Red Indicates parameter number, parameter value, or fault code.

Flashing Red Single digit flashing indicates that digit can be edited.

All digits flashing indicates a fault condition.

➌

Displayed Units Steady Red Indicates the units of the parameter value being displayed.

➍

Program Status Steady Red Indicates parameter value can be changed.

➎

Fault Status Flashing Red Indicates drive is faulted.

➏

Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.

(1)

➐

Start Key Status Steady Green Indicates Start key on Integral Keypad is active.

The Reverse key is also active unless disabled by

A095

[Reverse Disable].

No. Key

➑

➒

Name

Escape

Select

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.

Up Arrow

Down Arrow

Used to adjust internal frequency of IP66, NEMA/UL Type 4X rated drives only when a Display Group parameter is shown

and P038

[Speed Reference] is set to internal frequency,

A069

[Internal Freq].

Enter Advance one step in programming menu.

Save a change to a parameter value.

Potentiometer

(1)

Used to control speed of drive. Default is active.

Controlled by parameter P038

[Speed Reference].

Start

Reverse

Stop

Used to start the drive. Default is active.


[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.


[Stop Mode].

(1)

IP66, NEMA/UL Type 4X rated drives are not equipped with a potentiometer.



Start Up

2-5

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.

Example Displays Step

1. When power is applied, the last user-selected

Display Group parameter number is briefly displayed with flashing characters. The display then defaults to that parameter’s current value.

(Example shows the value of d001 [Output

Freq] with the drive stopped.)

Key(s)

PROGRAM FAULT

VOLTS

AMPS

HERTZ

2. Press Esc once to display the Display Group parameter number shown on power-up. The parameter number will flash.

PROGRAM FAULT

VOLTS

AMPS

HERTZ

3. Press Esc again to enter the group menu. The group menu letter will flash.

4. Press the Up Arrow or Down Arrow to scroll through the group menu (d, P and A).

5. Press Enter or Sel to enter a group. The right digit of the last viewed parameter in that group will flash.

6. Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group.

7. Press Enter or Sel to view the value of a parameter. If you do not want to edit the value, press Esc to return to the parameter number.

8. Press Enter or Sel to enter program mode to edit the parameter value. The right digit will flash and the Program LED will illuminate if the parameter can be edited.

9. Press the Up Arrow or Down Arrow to change the parameter value. If desired, press Sel to move from digit to digit or bit to bit. The digit or bit that you can change will flash.

10. Press Esc to cancel a change. The digit will stop flashing, the previous value is restored and the Program LED will turn off.

Or

Press Enter to save a change. The digit will stop flashing and the Program LED will turn off.

or or or or or or

PROGRAM FAULT

PROGRAM FAULT

PROGRAM FAULT

PROGRAM FAULT

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

PROGRAM FAULT

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.

PROGRAM FAULT

VOLTS

AMPS

HERTZ



2-6

Start Up

The Basic Program Group ( page 3-9 ) contains the most commonly changed parameters.

Remote HIM Menu Structure

The Menu Structure below can be accessed through the following

Human Interface Module options:

HIM Option

Remote Panel Mount Small, LCD Display

Remote Handheld, LCD Display

Catalog Number

22-HIM-C2S

22-HIM-A3

Main Menu:

Diagnostics

Sel

Parameters

Sel

User

Display

Esc Sel

Faults

Device Status

Device Version

Groups

Linear List

Changed Params

PowerFlex 40

Product Data

Series

Firmware

Device Status

STS1

STS2

STS3

STS4

HIM Reference

Increase/Decrease Hz

View Fault Queue

Clear Faults

Clear Fault Queue

Group Name

Parameter Number Name



Sel

Parameter Name

Value Screen

Limits Screen

PowerFlex 40

Connected DSI Devices

Device Select

Sel

Memory Storage

Sel

HIM Setup

Sel

HIM CopyCat

Parameters

Device Version

Device -> HIM

Device <- HIM

Delete File

Device Cat. No.

Device Name

Series

Firmware

Press

Press

Press

Press

Sel

Esc

to move between main menu tabs to select a tab or menu item to move between menu items to move 1 level back in the menu structure

Sel

Files Screen

Stats Screen

Function

File Name

File Name

File Name

File Name

File Name

Parameters

001 Startup Display

002 Startup Param

004 User Disp Line 1

005 User Disp Line 2

006 Large Disp Param

007 LCD Contrast

008 Reset Device

009 Device Type

010 M/S Status



Start Up

2-7

Diagnostics Menu

When a fault trips the drive, use this menu to access detailed data about the drive.

Option

Faults

Device Status

Device Version

Description

View fault queue or fault information, clear faults or clear fault queue.

View status information about the drive or peripheral.

View the firmware version and hardware series of components.

Parameters Menu

Use this menu to access drive parameters. Parameters can be displayed in groups, in a linear list, or only those changed from their defaults.

Device Select Menu

Use this menu to access the drive or peripheral that the drive is to access.

Memory Storage Menu

Drive data can be saved to, or recalled from HIM sets.

HIM sets are files stored in permanent nonvolatile HIM memory.

Option

HIM Copycat

Device -> HIM

Device <- HIM

Delete File

Description

Save data to a HIM set or load data from a HIM set to active drive memory. A maximum of 5 HIM set can be stored.

Delete a HIM set.

HIM Setup Menu

The HIM and drive have features that you can customize.

Option

Parameters

Device Version

Description

Access parameters in HIM to set display options.

View HIM version, hardware series and firmware version



2-8

Notes:

Start Up



Programming and Parameters

Chapter

3

Chapter 3 provides a complete listing and description of the PowerFlex

40 parameters. Parameters are programmed (viewed/edited) using the integral keypad. As an alternative, 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.


About Parameters

Parameter Organization

Basic Program Group

Advanced Program Group

Parameter Cross Reference – by Name

See page…

3-1

3-2

3-9

3-14

3-45

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

Refer to page 3-45 for an alphabetical listing of parameters.

Displa y Group Program Gr oup

See page 3-3

Output Freq

Commanded Freq

Output Current

Output Voltage

DC Bus Voltage

Drive Status

Fault 1 Code

Fault 2 Code

Fault 3 Code

Process Display

Control Source

Contrl In Status

Dig In Status

Comm Status

Control SW Ver

Drive Type

Elapsed Run Time

Testpoint Data

Analog In 0-10V

Analog In 4-20mA

Output Power

Output Power Fctr

Drive Temp

Counter Status

Timer Status

Stp Logic Status

Torque Current

Program Gr oup

See page 3-9

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 Defalts

Voltage Class

Motor OL Ret d018 d019 d020 d021 d022 d023 d024 d025 d026 d028 d029 d009 d010 d012 d013 d014 d015 d016 d017 d001 d002 d003 d004 d005 d006 d007 d008

P031

P032

P033

P034

P035

P036

P037

P038

P039

P040

P041

P042

P043

Jog Frequency

Jog Accel/Decel

DC Brake Time

DC Brake Level

DB Resistor Sel

S Curve %

Boost Select

Start Boost

Break Voltage

Break Frequency

Maximum Voltage

Current Limit 1

Motor OL Select

PWM Frequency

Auto Rstrt Tries

Auto Rstrt Delay

Start At 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

See page 3-14

Digital In1 Sel

Digital In2 Sel

Digital In3 Sel

Digital In4 Sel

Relay Out Sel

Relay Out Level

Opto Out1 Sel

Opto Out1 Level

Opto Out2 Sel

Opto Out2 Level

Opto Out Logic

Analog Out Sel

Analog Out High

Accel Time 2

Decel Time 2

Internal Freq

Preset Freq 0

Preset Freq 1

Preset Freq 2

Preset Freq 3

Preset Freq 4

Preset Freq 5

Preset Freq 6

Preset Freq 7



A096

A097

A098

A099

A100

A101

A090

A091

A092

A093

A094

A095

A084

A085

A086

A087

A088

A089

A078

A079

A080

A081

A082

A083

A102

A103

A104

A105

A072

A073

A074

A075

A076

A077

A066

A067

A068

A069

A070

A071

A058

A059

A061

A062

A064

A065

A051

A052

A053

A054

A055

A056

PID Setpoint

PID Deadband

PID Preload

Stp Logic 0

Stp Logic 1

Stp Logic 2

Stp Logic 3

Stp Logic 4

Stp Logic 5

Stp Logic 6

Stp Logic 7

Stp Logic Time 0

Stp Logic Time 1

Stp Logic Time 2

Stp Logic Time 3

Stp Logic Time 4

Stp Logic Time 5

Stp Logic Time 6

Stp Logic Time 7

EM Brk Off Delay

EM Brk On Delay

MOP Reset Sel

DB Threshold

Comm Write Mode

Anlg Loss Delay

Analog In Filter

PID Invert Error

See page 3-14

Comm Loss Time

Comm Format

Language

Anlg Out Setpt

Anlg In 0-10V Lo

Anlg In 0-10V Hi

Anlg In4-20mA Lo

Anlg In4-20mA Hi

Slip Hertz @ FLA

Process Time Lo

Process Time Hi

Bus Reg Mode

Current Limit 2

Skip Frequency

Skip Freq Band

Stall Fault Time

Analog In Loss

10V Bipolar Enbl

Var PWM Disable

Torque Perf Mode

Motor NP FLA

Autotune

IR Voltage Drop

Flux Current Ref

PID Trim Hi

PID Trim Lo

PID Ref Sel

PID Feedback Sel

PID Prop Gain

PID Integ Time

PID Diff Rate

A146

A147

A150

A151

A152

A153

A154

A155

A138

A139

A140

A141

A142

A143

A144

A145

A156

A157

A160

A161

A162

A163

A164

A165

A166

A167

A130

A131

A132

A133

A134

A135

A136

A137

A122

A123

A124

A125

A126

A127

A128

A129

A114

A115

A116

A117

A118

A119

A120

A121

A106

A107

A108

A109

A110

A111

A112

A113


3-3

Display Group

d001 [Output Freq]

Related Parameter(s): d002

, d010

,

P034 , P035

,

P038

Output frequency present at T1, T2 & T3 (U, V & W).

Values

Default:

Min/Max:

Display:

Read Only

0.0/ P035

[Maximum Freq]

0.1 Hz

d002 [Commanded Freq]


, d013

,

P034 , P035

,

P038

Value of the active frequency command. Displays the commanded frequency even if the drive is not running.

Important: The frequency command can come from a number of sources. Refer to Start and Speed

Reference Control on page 1-23

for details.

Values

Default: Read Only

Min/Max:

0.0/ P035

[Maximum Freq]

Display: 0.1 Hz

d003 [Output Current]

The output current present at T1, T2 & T3 (U, V & W).

Values

Default:

Min/Max:

Read Only

0.00/(Drive Rated Amps

×

2)

Display: 0.01 Amps

d004 [Output Voltage]

Output voltage present at terminals T1, T2 & T3 (U, V & W).

Values

Default: Read Only

Related Parameter(s):

P031 ,

A084

,

A088

Min/Max: 0/Drive Rated Volts

Display: 1 VAC

d005 [DC Bus Voltage]

Present DC bus voltage level.

Values

Default:

Min/Max:

Display:

Read Only

Based on Drive Rating

1 VDC



3-4


Display Group

(continued)

d006 [Drive Status]

Present operating condition of the drive.


A095

Running

Forward

Accelerating

Decelerating

1 = Condition True, 0 = Condition False

Bit 0

Bit 1

Bit 2

Bit 3

Values

Default:

Min/Max:

Display:

Read Only

0/1

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

Min/Max:

Display:

F2/F122

F1

d010 [Process Display]

32

32 bit parameter.

The output frequency scaled by

A099 [Process Factor].

Output

Freq x

Process

Factor

=

Process

Display

Values

Default:

Min/Max:

Display:

Read Only

0.00/9999

0.01 – 1


,

A099




3-5

Display Group

(continued)

d012 [Control Source]


P036 ,

P038 ,

A051

-

A054

Displays the active source of the Start Command and Speed Command which are normally defined by the settings of

P036 [Start Source] and

P038 [Speed Reference] but may be overridden by digital

inputs. Refer to the flowcharts on pages

1-23

and 1-24

for details.

Values

Default:

Min/Max:

Display:

Start Command

0 = Keypad

1 = 3-Wire

2 = 2-Wire

3 = 2-Wire Level Sensitive

4 = 2-Wire High Speed

5 = RS485 (DSI) Port

9 = Jog

Digit 0

Speed Command

0 = Drive Potentiometer

1 = A069

[Internal Freq]

2 = 0-10V Input/Remote Potentiometer

3 = 4-20mA Input

Digit 1

4 = A070 A077

[Preset Freq x]

( A051 - A053

[Digital Inx Sel] must be set to 4)

5 = RS485 (DSI) Port

6 = StepLogic Control (Parameters A140

- A147

)

7 = Anlg In Mult

8 = PID

9 = Jog Freq

Reserved

Reserved

Digit 2

Digit 3

Read Only

0/9

1

d013 [Contrl In Status]


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)

1 = Input Present, 0 = Input Not Present

Start / Run FWD Input (I/O Terminal 02) Bit 0

Direction / Run REV Input (I/O Terminal 03)

Stop Input

(1)

(I/O Terminal 01)

Dynamic Brake Transistor On

Bit 1

Bit 2

Bit 3

The stop input must be present in order to start the drive.

When this bit is a 1 the drive can be started.

When this bit is a 0 the drive will stop.

Values

Default:

Min/Max:

Display:

Read Only

0/1

1



3-6


Display Group

(continued)

d014 [Dig In Status]

Status of the control terminal block digital inputs.

1 = Input Present, 0 = Input Not Present

Digital In1 Sel (I/O Terminal 05) Bit 0

Digital In2 Sel (I/O Terminal 06)



Bit 1

Bit 2

Bit 3

Related Parameter(s): A051

-

A054

Values

Default:

Min/Max:

Display:

d015 [Comm Status]

Status of the communications ports.

Read Only

0/1

1

Receiving Data

1 = Condition True, 0 = Condition False

Bit 0

Transmitting Data

RS485 (DSI) Based Option Connected

(Allen-Bradley devices only.)

Communication Error Occurred

Bit 1

Bit 2

Bit 3

Values

Default:

Min/Max:

Display:

Read Only

0/1

1

d016 [Control SW Ver]

Main Control Board software version.

Values

Default:

Min/Max:

Display:

Read Only

1.00/99.99

0.01

d017 [Drive Type]

Used by Rockwell Automation field service personnel.

Values

Default: Read Only

Min/Max: 1001/9999

Display: 1


-

A107




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:

Display:

0/9999 Hrs

1 = 10 Hrs

d019 [Testpoint Data]

The present value of the function selected in A102

[Testpoint Sel].

Values

Default: Read Only

Min/Max: 0/FFFF

Display: 1 Hex


A102

d020 [Analog In 0-10V]


,

A111

The present value of the voltage at I/O Terminal 13 (100.0% = 10 volts).

Values

Default: Read Only

Min/Max:

Display:

0.0/100.0%

0.1%

d021 [Analog In 4-20mA]


,

A113

The present value of the current at I/O Terminal 15 (0.0% = 4mA, 100.0% = 20mA).

Values

Default: Read Only

Min/Max: 0.0/100.0%

Display: 0.1%

d022 [Output Power]

Output power present at T1, T2 & T3 (U, V & W).

Values

Default:

Min/Max:

Read Only

0.00/(Drive Rated Power

×

2)

Display: 0.01 kW

d023 [Output Powr Fctr]

The angle in electrical degrees between motor voltage and motor current.

Values

Default: Read Only

Min/Max:

Display:

0.0/180.0 deg

0.1 deg



3-8


Display Group

(continued)

d024 [Drive Temp]

Present operating temperature of the drive power section.

Values

Default: Read Only

Min/Max:

Display:

0/120 degC

1 degC

d025 [Counter Status]

The current value of the counter when counter is enabled.

Values

Default: Read only

Min/Max: 0/9999

Display: 1

d026 [Timer Status]

32

32 bit parameter.

The current value of the timer when timer is enabled.

Values

Default: Read Only

Min/Max: 0.0/9999 Secs

Display: 0.1 Secs

d028 [Stp Logic Status]

When P038

[Speed Reference] is set to 6 “Stp Logic”, this parameter will display the current step of the StepLogic profile as defined by parameters

A140 A147

[Stp Logic x].

Values

Default: Read Only

Min/Max: 0/7

Display: 1

d029 [Torque Current]

The current value of the motor torque current.

Values

Default:

Min/Max:

Read Only


×

2)

Display: 0.01 Amps




3-9


P031 [Motor NP Volts]


, A084

,

A085 , A086

,

A087

Stop drive before changing this parameter.

Set to the motor nameplate rated volts.

Values

Default: Based on Drive Rating

Min/Max: 20/Drive Rated Volts

Display: 1 VAC

P032 [Motor NP Hertz]


A084 ,

A085

,

A086 , A087

,

A090


Set to the motor nameplate rated frequency.

Values

Default: 60 Hz

Min/Max: 15/400 Hz

Display: 1 Hz

P033 [Motor OL Current]


,

A058 , A061

,

A089

,

A090 ,

A098 ,

A114

,

A118

Set to the maximum allowable motor current.

The drive will fault on an F7 Motor Overload

if the value of this parameter is exceeded by 150% for 60 seconds.

Values

Default:

Min/Max:



×

2)

Display: 0.1 Amps

P034 [Minimum Freq]


,

d002 ,

d013

,

P035

,

A085 ,

A086

,

A087

, A110

,

A112

Sets the lowest frequency the drive will output continuously.

Values

Default: 0.0 Hz

Min/Max:

Display:

0.0/400.0 Hz

0.1 Hz

P035 [Maximum Freq]


,

d002 ,

d013

,

P034

,

A065 ,

A078 ,

A085 , A086

,

A087 ,

A111

,

A113


Sets the highest frequency the drive will output.

Values

Default: 60 Hz

Min/Max: 0/400 Hz

Display: 1 Hz



3-10



(continued)

P036 [Start Source]


,

P037


Sets the control scheme used to start the drive.

Refer to Start and Speed Reference Control on page 1-23 for details about how other drive settings

can override the setting of this parameter.

Important: For all settings except option 3, the drive must 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”

3 “2-W Lvl Sens”


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-W Hi Speed”

5 “Comm Port”

6 “Momt FWD/REV”

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.

•


•

Remote communications. Refer to Appendix C for details.

•


•

Drive will start after a momentary input from either the

Run FWD Input (I/O Terminal 02) or the Run REV Input (I/

O Terminal 03).

•





3-11


(continued)

P037 [Stop Mode]

Related Parameter(s): P036 ,

A080 , A081

,

A082

, A105

,

A160

Active stop mode for all stop sources [e.g. keypad, run forward (I/O Terminal 02), run reverse (I/O

Terminal 03), RS485 port] except as noted below.

Important: I/O Terminal 01 is always a coast to stop input except when P036

[Start Source] is set for

“3-Wire” control. When in three wire control, I/O Terminal 01 is controlled by

P037 [Stop Mode].

Hardware Enable Circuitry

By default, I/O Terminal 01 is a coast to stop input. The status of the input is interpreted by drive software. If the application requires the drive to be disabled without software interpretation, a “dedicated” hardware enable configuration can be utilized. This is accomplished by removing the ENBL enable jumper on the control board. In this case, the drive will always coast to a stop regardless of the

settings of P036

[Start Source] and

P037 [Stop Mode].

Options

0 “Ramp, CF”

(1)

(Default) Ramp to Stop. “Stop” command clears active fault.

1 “Coast, CF”

(1)

2 “DC Brake, CF”

(1)

Coast to Stop. “Stop” command clears active fault.

DC Injection Braking Stop. “Stop” command clears active fault.

3 “DCBrkAuto,CF”

(1)

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”

5 “Coast”

6 “DC Brake”

7 “DC BrakeAuto”

Ramp to Stop.

Coast to Stop.

8 “Ramp+EM B,CF”

DC Injection Braking Stop.

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.

Ramp to Stop with EM Brake Control. “Stop” Command clears active fault.

9 “Ramp+EM Brk” Ramp to Stop with EM Brake Control.

(1)

Stop input also clears active fault.



3-12



(continued)

P038 [Speed Reference]


d001 , d002

, d012

,

d020 , d021

,

P039

,

P040 ,

A051

-

A054 ,

A069

, A070

-

A077

, A110

A113

,

A123 ,

A132

,

A140 A147 ,

A150

-

A157

Sets the source of the speed reference to the drive.

The drive speed command can be obtained from a number of different sources. The source is

normally determined by P038

[Speed Reference]. However, when A051 - A054

[Digital Inx Sel] is set

to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, or if A132

[PID Ref Sel] is not set to option 0, the speed reference commanded by

P038 [Speed Reference] will be overridden. Refer to

the flowchart on page 1-23 for more information on speed reference control priority.

Options

0 “Drive Pot” (Default) Frequency command from the potentiometer on the integral keypad.

Important: This option is not available with IP66, NEMA/UL

Type 4X rated drives. Internal frequency command comes from A069 [Internal Freq].

1 “InternalFreq”

(IP66, NEMA/UL Type

4X Default)

2 “0-10V Input”

Internal frequency command from A069 [Internal Freq]. Must be set when using MOP function.

3 “4-20mA Input”

4 “Preset Freq”

External frequency command from the 0-10V or ±10V analog input or remote potentiometer.

External frequency command from the 4-20mA analog input.

External frequency command as defined by

A070 - A077

[Preset Freq x] when

A051 - A054

[Digital Inx Sel] are programmed as “Preset Frequencies” and the digital inputs are active.

5 “Comm Port”

6 “Stp Logic”

7 “Anlg In Mult”

External frequency command from the communications port.

Refer to Appendix C for details.

External frequency command as defined by

A070 - A077

[Preset Freq x] and

A140 - A147

[Stp Logic x].

External frequency command as defined by the product of the analog inputs (shown in

d020 [Analog In 0-10V] and d021

[Analog In 4-20mA]).

[Analog In 0-10V]

×

[Analog In 4-20mA] = Speed Command

Example: 100%

×

50% = 50%

P039 [Accel Time 1]

Sets the rate of acceleration for all speed increases.

Maximum Freq

Accel Time

=

Accel Rate

Values

Default:

Min/Max:

Display:

10.0 Secs

0.0/600.0 Secs

0.1 Secs


P038 ,

P040

,

A051 A054 ,

A067 ,

A070 A077 ,

A140

-

A147

P035 [Maximum Freq]

Speed

ation

Acceler

0

0

P039 or A067

[Accel Time x]

Time

Deceler ation

P040 or A068

[Decel Time x]




3-13


(continued)

P040 [Decel Time 1]

Sets the rate of deceleration for all speed decreases.

Maximum Freq

Decel Time

=

Decel Rate


P038 , P039

,

A051 A054 ,

A068 ,

A070 A077 ,

A140

-

A147

Values

Default:

Min/Max:

Display:

10.0 Secs

0.1/600.0 Secs

0.1 Secs

P035 [Maximum Freq]

Speed

ation

Acceler

0

0

P039 or A067

[Accel Time x]

Time

Deceler ation

P040 or A068

[Decel Time x]

P041 [Reset To Defalts]


Resets all parameter values to factory defaults.

Options

0 “Ready/Idle” (Default)

1 “Factory Rset”

•

After the reset function is complete, this parameter will set itself back to “0”.

•

Causes an F48 Params Defaulted

fault.

P042 [Voltage Class]


Sets the voltage class of 600V drives.

Options

2 “Low Voltage” 480V

3 “High Voltage”

(Default)

600V

P043 [Motor OL Ret]


P033

Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor overload counter is saved at power-down and restored at power-up. A change to this parameter setting resets the counter.

Options

0 “Disabled” (Default)

1 “Enabled”



3-14



A051 [Digital In1 Sel]

(I/O Terminal 05)


(I/O Terminal 06)


(I/O Terminal 07)


(I/O Terminal 08)


,

d014 ,

P038

,

P039

,

P040 ,

A067 , A068 ,

A070

-

A077 , A078

,

A079 ,

A118 ,

A140

-

A147


Selects the function for the digital inputs. Refer to the flowchart on

page 1-23 for more information on

speed reference control priority.

Options

0 “Not Used”

1 “Acc & Dec 2”

2 “Jog”

3 “Aux Fault”

4 “Preset Freq”

(A051 & A052 Default)

5 “Local”

(A053 Default)

6 “Comm Port”

7 “Clear Fault”

8 “RampStop,CF”

9 “CoastStop,CF”

10 “DCInjStop,CF”

11 “Jog Forward”

(A054 Default)

12 “Jog Reverse”

Terminal has no function but can be read over network communications via

d014 [Dig In Status].

•

When active, A067 [Accel Time 2] and A068 [Decel Time

2] are used for all ramp rates except Jog.

•

Can only be tied to one input.

Refer to the flowchart on

page 1-24 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 - A077 [Preset Freq x].

Important: Digital Inputs have priority for frequency control when programmed as Preset Speed and are active. Refer to

the flowchart on page 1-23 for more information on speed

reference control priority.

When active, sets integral keypad as start source and potentiometer on the integral keypad as speed source.

Important: Speed source for IP66, NEMA/UL Type 4X rated drives comes from A069 [Internal Freq].

•

When active, sets communications device as default start/ speed command source.

•

Can only be tied to one input.

When active, clears an active fault.

Causes drive to immediately ramp to a stop regardless of how

P037 [Stop Mode] is set.

Causes drive to immediately coast to a stop regardless of

how P037

[Stop Mode] is set.

Causes drive to immediately begin a DC Injection stop

regardless of how P037 [Stop Mode] is set.

Drive accelerates to A078

[Jog Frequency] according to A079

[Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start will override this command.

Drive accelerates to A078

[Jog Frequency] according to A079

[Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start will override this command.




3-15

A051 -

A054

Options

(Cont.)

13 “10V In Ctrl”

14 “20mA In Ctrl”

15 “PID Disable”

16 “MOP Up”

17 “MOP Down”

18 “Timer Start”

19 “Counter In”

20 “Reset Timer”

21 “Reset Countr”

22 “Rset Tim&Cnt”

23 “Logic In1”

24 “Logic In2”

25 “Current Lmt2”

26 “Anlg Invert”

27 “EM Brk Rlse”

Selects 0-10V or ±10V control as the frequency reference.

Start source is not changed.

Selects 4-20mA control as the frequency reference. Start source is not changed.

Disables PID function. Drive uses the next valid non-PID speed reference.

Increases the value of A069 [Internal Freq] at the current

Accel rate if P038 [Speed Reference] is set to 1

“InternalFreq”.

For IP20 rated drives, the default for A069 is 60.0 Hz.

For IP66, NEMA/UL Type 4X drives, the default for A069 is

0.0 Hz.

Decreases the value of A069 [Internal Freq] at the current

Decel rate if P038 [Speed Reference] is set to 1

“InternalFreq”.

For IP20 rated drives, the default for A069 is 60.0 Hz.

For IP66, NEMA/UL Type 4X drives, the default for A069 is

0.0 Hz.

Clears and starts the timer function. May be used to control the relay or opto outputs.

Starts the counter function. May be used to control the relay or opto outputs.

Clears the active timer.

Clears the active counter.

Clears the active timer and counter.

Logic function input number 1. May be used to control the

relay or opto outputs (see parameters A055

,

A058 , A061

Options 11-14). May be used in conjunction with StepLogic

parameters A140

-

A147 [Stp Logic x].

Logic function input number 2. May be used to control the

relay or opto outputs (see parameters A055

,

A058 , A061

Options 11-14). May be used in conjunction with StepLogic

parameters A140

-

A147 [Stp Logic x].

When active,

A118 [Current Limit 2] determines the drive

current limit level.

Inverts the scaling of the analog input levels set in

A110 [Anlg In 0-10V Lo] and A111

[Anlg In 0-10V Hi] or

A112 [Anlg In4-20mA Lo] and

A113

[Anlg In4-20mA Hi].

If EM brake function is enabled, this input releases the brake.

!

ATTENTION:

If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used.



3-16



(continued)

A055 [Relay Out Sel]


P033 ,

A056

,

A092 ,

A140 A147

,

A150 A157 ,

A160

,

A161

Sets the condition that changes the state of the output relay contacts.

Options

0 “Ready/Fault”

(Default)

Relay changes state when power is applied. This indicates that the drive is ready for operation. Relay returns drive to shelf state when power is removed or a fault occurs.

1 “At Frequency”

2 “MotorRunning”

Drive reaches commanded frequency.

Motor is receiving power from the drive.

3 “Reverse”

4 “Motor Overld”

5 “Ramp Reg”

6 “Above Freq”

7 “Above Cur”

8 “Above DCVolt”

9 “Retries Exst”

10 “Above Anlg V”

11 “Logic In 1”

12 “Logic In 2”

13 “Logic 1 & 2”

14 “Logic 1 or 2”

15 “StpLogic Out”

16 “Timer Out”

17 “Counter Out”

18 “Above PF Ang”

Drive is commanded to run in reverse direction.

Motor overload condition exists.

Ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or overvoltage fault from occurring.

•

Drive exceeds the frequency (Hz) value set in

A056 [Relay

Out Level].

•

Use A056 to set threshold.

•

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.

•

Drive exceeds the DC bus voltage value set in

A056

[Relay Out Level].

•


Value set in A092

[Auto Rstrt Tries] is exceeded.

•

Analog input voltage (I/O Terminal 13) exceeds the value

set in A056

[Relay Out Level].

•

Do not use if A123

[10V Bipolar Enbl] is set to 1 “Bi-Polar In”.

•

This parameter setting can also be used to indicate a PTC trip point when the input (I/O Terminal 13) is wired to a

PTC and external resistor.

•


An input is programmed as “Logic In 1” and is active.


Both Logic inputs are programmed and active.

One or both Logic inputs are programmed and one or both is active.

Drive enters StepLogic step with Digit 3 of Command Word

( A140 - A147 ) set to enable StepLogic output.

•

Timer has reached value set in A056 [Relay Out Level].

•


•

Counter has reached value set in

A056 [Relay Out Level].

•


•

Power Factor angle has exceeded the value set in A056

[Relay Out Level].

•





3-17

A055

Options

(Cont.)

19 “Anlg In Loss”

20 “ParamControl”

21 “NonRec Fault”

22 “EM Brk Cntrl”

23 “Above Fcmd”

24 “MsgControl”

Analog input loss has occurred. Program A122 [Analog In

Loss] for desired action when input loss occurs.

Prior to FRN 4.01, this option enables the output to be controlled over network communications by writing to

A056

[Relay Out Level]. (0 = Off, 1 = On.)

With FRN 4.01 and later, the logic command word bit 15 has

full control of A056

. See

Writing (06) Logic Command

Data on page C-4

.

•

Value set in A092


•

A092 [Auto Rstrt Tries] in not enabled.

•

A Non-resettable fault has occurred.

EM brake is energized. Program

A160 [EM Brk Off Delay] and

A161 [EM Brk On Delay] for desired action.

The current commanded frequency exceeds the value set in

A056 [Relay Out Level].

With FRN 4.01 and later, this option enables the output to be controlled over network communications by writing to

A056

[Relay Out Level]. (0 = Off, 1 = On.)

A056 [Relay Out Level]

32

32 bit parameter.


A055

Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7, 8, 10, 16, 17,

18 or 20.

With FRN 4.01 and later, when the value of A055

is set to 20, the logic command word bit 15 has full control of A056.

A055 Setting

6

7

8

10

16

17

18

20

23

Values

Default:

Min/Max:

Display:

A056 Min/Max

0/400 Hz

0/180%

0/815 Volts

0/100%

0.1/9999 Secs

1/9999 Counts

1/180 degs

0/1

0/400 Hz

0.0

0.0/9999

0.1



3-18



(continued)

A058 [Opto Out1 Sel]

A061 [Opto Out2 Sel]


P033 ,

A059 , A062 ,

A092

,

A122

,

A123 ,

A160 ,

A161

,

A140 A147 ,

A150

-

A157

Determines the operation of the programmable opto outputs.

Options

0 “Ready/Fault” Opto outputs are active when power is applied. This indicates that the drive is ready for operation. Opto outputs are inactive when power is removed or a fault occurs.

Drive reaches commanded frequency.

1 “At Frequency”

(A061 Default)

2 “MotorRunning”

(A058 Default)

3 “Reverse”

Motor is receiving power from the drive.

Drive is commanded to run in reverse direction.

4 “Motor Overld”

5 “Ramp Reg”

6 “Above Freq”

7 “Above Cur”

8 “Above DCVolt”

9 “Retries Exst”

10 “Above Anlg V”

11 “Logic In 1”

12 “Logic In 2”

13 “Logic 1 & 2”

14 “Logic 1 or 2”

15 “StpLogic Out”

16 “Timer Out”

17 “Counter Out”

Motor overload condition exists.

Ramp regulator is modifying the programmed accel/decel times to avoid an overcurrent or overvoltage fault from occurring.

•

Drive exceeds the frequency (Hz) value set in A059 or

A062 [Opto Outx Level].

•

Use A059 or A062 to set threshold.

•

Drive exceeds the current (% Amps) value set in A059 or


•


Important: Value for A059 or A062 [Opto Outx Level] must be entered in percent of drive rated output current.

•

Drive exceeds the DC bus voltage value set in A059 or


•


Value set in A092


•

Analog input voltage (I/O Terminal 13) exceeds the value set in A059 or A062 [Opto Outx Level].

•

Do not use if

A123 [10V Bipolar Enbl] is set to 1 “Bi-Polar

In”.

•

This parameter setting can also be used to indicate a PTC trip point when the input (I/O Terminal 13) is wired to a

PTC and external resistor.

•




Both Logic inputs are programmed and active.

One or both Logic inputs are programmed and one or both is active.

Drive enters StepLogic step with Digit 3 of Command Word

( A140 - A147 ) set to enable StepLogic output.

•

Timer has reached value set in A059 or A062 [Opto Outx

Level].

•


•

Counter has reached value set in A059 or A062 [Opto

Outx Level].

•




A058,

A061

Options

(Cont.)

18 “Above PF Ang”

19 “Anlg In Loss”

20 “ParamControl”

21 “NonRec Fault”

22 “EM Brk Cntrl”

23 “Above Fcmd”

24 “MsgControl”


3-19

•

Power Factor angle has exceeded the value set in A059 or


•


Analog input loss has occurred. Program A122 [Analog In

Loss] for desired action when input loss occurs.

Prior to FRN 4.01, this option enables the output to be controlled over network communications by writing to A059 or

A062 [Opto Outx Level]. (0 = Off, 1 = On.)

With FRN 4.01 and later:

Setting this option for A058 means the logic command word bit 6 has full control of A059.

Setting this option for A059 means the logic command word bit 7 has full control of A062.

See Writing (06) Logic Command Data on page C-4 .

•

Value set in A092


•

A092 [Auto Rstrt Tries] in not enabled.

•

A Non-resettable fault has occurred.

EM brake is energized. Program

A160 [EM Brk Off Delay] and

A161 [EM Brk On Delay] for desired action.

The current commanded frequency exceeds the value set in

A059 or A062 [Opto Outx Level].

With FRN 4.01 and later:

Enables the output to be controlled over the network communications by writing to A059 or A062 [Opto Outx

Level]. (0 = Off, 1 = On.)

A059 [Opto Out1 Level]

A062 [Opto Out2 Level]

32

32 bit parameter.


,

A061

Determines the on/off point for the opto outputs when A058 or A061

[Opto Outx Sel] is set to option 6,

7, 8, 10, 16, 17, 18 or 20.

With FRN 4.01 and later, when the value of A058 is set to 20, the logic command word bit 6 has full control of A059 and when the value of A061 is set to 20, bit 7 has full control of A062.

A058 & A061 Setting

6

7

8

10

16

17

18

20

23

Values

Default:

Min/Max:

Display:

A059 & A062 Min/Max

0/400 Hz

0/180%

0/815 Volts

0/100%

0.1/9999 Secs

1/9999 Counts

1/180 degs

0/1

0/400 Hz

0.0

0.0/9999

0.1



3-20



(continued)

A064 [Opto Out Logic]

Determines the logic (Normally Open/NO or Normally Closed/NC) of the opto outputs.

A064 Option Opto Out1 Logic

2

3

0

1

NO (Normally Open)

NC (Normally Closed)

NO (Normally Open)


Values

Default:

Min/Max:

Display:

Opto Out2 Logic

NO (Normally Open)

NO (Normally Open)



0

0/3

1

A065 [Analog Out Sel]

Related Parameter(s): P035

, A066

Sets the analog output signal mode (0-10V, 0-20mA, or 4-20mA). The output is used to provide a signal that is proportional to several drive conditions.

Option

Output

Range

0 “OutFreq 0-10” 0-10V

1 “OutCurr 0-10” 0-10V

2 “OutVolt 0-10” 0-10V

3 “OutPowr 0-10” 0-10V

4 “TstData 0-10” 0-10V

5 “OutFreq 0-20” 0-20mA

6 “OutCurr 0-20” 0-20mA

7 “OutVolt 0-20” 0-20mA

8 “OutPowr 0-20” 0-20mA

9 “TstData 0-20” 0-20mA

10 “OutFreq 4-20” 4-20mA

11 “OutCurr 4-20” 4-20mA

12 “OutVolt 4-20” 4-20mA

13 “OutPowr 4-20” 4-20mA

14 “TstData 4-20” 4-20mA

15 “OutTorq 0-10” 0-10V

16 “OutTorq 0-20” 0-20 mA

17 “OutTorq 4-20” 4-20 mA

18 “Setpnt 0-10” 0-10V

19 “Setpnt 0-20” 0-20 mA

20 “Setpnt 4-20” 4-20 mA

21 “MinFreq 0-10” 0-10V

22 “MinFreq 0-20” 0-20 mA

23 “MinFreq 4-20” 4-20 mA

Values

Default:

Min/Max:

Display:

Minimum Output

Value

0V = 0 Hz

0V = 0 Amps

0V = 0 Volts

0V = 0 kW

0V = 0000

0 mA = 0 Hz

Maximum Output Value

A066 [Analog Out High]

DIP Switch

Position

P035 [Maximum Freq] 0-10V

200% Drive Rated Output Current 0-10V

120% Drive Rated Output Volts

200% Drive Rated Power

65535 (Hex FFFF)

P035 [Maximum Freq]

0-10V

0-10V

0-10V

0-20mA

0 mA = 0 Amps 200% Drive Rated Output Current 0-20mA

0 mA = 0 Volts 120% Drive Rated Output Volts 0-20mA

0 mA = 0 kW

0 mA = 0000

200% Drive Rated Power

65535 (Hex FFFF)

0-20mA

0-20mA

4 mA = 0 Hz P035 [Maximum Freq] 0-20mA

4 mA = 0 Amps 200% Drive Rated Output Current 0-20mA

4 mA = 0 Volts 120% Drive Rated Output Volts

4 mA = 0 kW 200% Drive Rated Power

0-20mA

0-20mA

4 mA = 0000

0V = 0 Amps

65535 (Hex FFFF)

200% Drive Rated FLA

0 mA = 0 Amps 200% Drive Rated FLA

4 mA = 0 Amps 200% Drive Rated FLA

0V = 0%

0 mA = 0%

100.0% Setpoint Setting

100.0% Setpoint Setting

4 mA = 0% 100.0% Setpoint Setting

0V = Min. Freq P035 [Maximum Freq]

0 mA = Min. Freq P035 [Maximum Freq]

4 mA = Min. Freq P035 [Maximum Freq]

0-20mA

0-10V

0-20 mA

0-20 mA

0-10V

0-20 mA

0-20 mA

0-10V

0-20 mA

0-20 mA

d003 d004

d022 d019

d001 d003 d004

d022

Related

Parameter

d001 d003 d004

d022 d019

d001

d019

d029 d029 d029

A109

A109

A109

d001 d001 d001

0

0/23

1




3-21


(continued)

A066 [Analog Out High]


A065

Scales the Maximum Output Value for the

A065 [Analog Out Sel] source setting.

Examples:

A066 Setting

50%

90%

Values

Default:

Min/Max:

Display:

A065 Setting

1 “OutCurr 0-10”

8 “OutPowr 0-20”

A065 Max. Output Value

5V for 200% Drive Rated Output Current

18mA for 200% Drive Rated Power

100%

0/800%

1%

A067 [Accel Time 2]


P039 ,

A051 A054

,

A070 A077 ,

A140

-

A147

When active, sets the rate of acceleration for all speed increases except jog. Refer to the flowchart on page

1-24

for details.

Maximum Freq

Accel Time

=

Accel Rate

Values

Default:

Min/Max:

Display:

20.0 Secs

0.0/600.0 Secs

0.1 Secs

P035 [Maximum Freq]

Speed

ation

Acceler

0

0

P039 or A067

[Accel Time x]

Time

Deceler ation

P040 or A068

[Decel Time x]



3-22



(continued)

A068 [Decel Time 2]


P040 ,

A051 A054

,

A070 A077 ,

A140

-

A147

When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart

on page 1-24 for details.

Maximum Freq

Decel Time

=

Decel Rate

Values

Default:

Min/Max:

Display:

20.0 Secs

0.1/600.0 Secs

0.1 Secs

P035 [Maximum Freq]

Speed

ation

Acceler

0

0

P039 or A067

[Accel Time x]

Time

Deceler ation

P040 or A068

[Decel Time x]

A069 [Internal Freq]


,

A162

Provides the frequency command to the drive when

P038 [Speed Reference] is set to 1 “Internal

Freq”. When enabled, this parameter will change the frequency command in “real time” using the integral keypad Up Arrow or Down Arrow when in program mode.

Important: Once the desired command frequency is reached, the Enter key must be pressed to store this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return to the original value following the normal accel/decel curve.

If A051

-

A054 [Digital Inx Sel] is set to 16 “MOP Up” or 17 “MOP Down” this parameter acts as the

MOP frequency reference.

Values

Default: 60.0 Hz for IP20 rated drives

0.0 Hz for IP66, NEMA/UL Type 4X drives

Min/Max: 0.0/400.0 Hz

Display: 0.1 Hz




3-23


(continued)

A070 [Preset Freq 0]

(1)








Values

A070 Default:

(1)

A071 Default:

A072 Default:

A073 Default:

A074 Default:

A075 Default:

A076 Default:

A077 Default:

Min/Max:

Display:


,

P039 ,

P040

,

A051 A053 ,

A067 , A068 ,

A140 A147 ,

A150

-

A157

0.0 Hz

5.0 Hz

10.0 Hz

20.0 Hz

30.0 Hz

40.0 Hz

50.0 Hz

60.0 Hz

0.0/400.0 Hz

0.1 Hz

Provides a fixed frequency command value when A051 - A053 [Digital Inx Sel] is set to 4 “Preset

Frequencies”.

An active preset input will override speed command as shown in the flowchart on page 1-23

.

(1)

To activate A070 [Preset Freq 0] set P038

[Speed Reference] to option 4 “Preset Freq 0-3”.

Input State of Digital In 1

(I/O Terminal 05 when A051 = 4)

0

1

0

1

0

1

0

1

(2)


(I/O Terminal 06 when A052 = 4)

0

0

1

1

0

0

1

1


(I/O Terminal 07 when A053 = 4) Frequency Source Accel / Decel Parameter Used

(2)

0

0

1

0

0

1

1

1

A070 [Preset Freq 0] [Accel Time 1] / [Decel Time 1]

A071 [Preset Freq 1]







[Accel Time 1] / [Decel Time 1]







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]


P035 ,

A051 A054

,

A079

Sets the output frequency when a jog command is issued.

Values

Default:

Min/Max:

Display:

10.0 Hz

0.0/[Maximum Freq]

0.1 Hz



3-24



(continued)

A079 [Jog Accel/Decel]

Related Parameter(s): A078 ,

A051

-

A054

Sets the acceleration and deceleration time when a jog command is issued.

Values

Default: 10.0 Secs

Min/Max:

Display:

0.1/600.0 Secs

0.1 Secs

A080 [DC Brake Time]


,

A081

Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter

A081 [DC

Brake Level].

Values

Default:

Min/Max:

Display:

0.0 Secs

0.0/99.9 Secs (A setting of 99.9 = Continuous)

0.1 Secs

A081 [DC Brake Level]


,

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:

Min/Max:

Drive Rated Amps

×

0.05


×

1.8)

Display: 0.1 Amps

P037 Ramp-to-Stop Mode P037 DC Injection Braking Mode

Voltage

Stop Command

Voltage

Speed

Time

[DC Brake Time]

[DC Brake Level]

Speed

[DC Brake Time]

Stop Command

Time

[DC Brake Level]

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.

!




3-25


(continued)

A082 [DB Resistor Sel]


Enables/disables external dynamic braking.


P037

Setting

0

1

2

3-99

Min/Max

“Disabled”

“Normal RA Res” (5% Duty Cycle) – Refer to Table B.C on page B-2

.

“NoProtection” (100% Duty Cycle)

“x%Duty Cycle” Limited (3% – 99% of Duty Cycle)

The drive is able to provide full braking indefinitely. Braking power is limited by the external DB resistor. When this parameter is set to 1 “Normal RA Res” and an appropriate resistor is used (see

selection Table B.C

), the drive provides calculated resistor overload protection. However, the drive

cannot protect against a brake IGBT failure.

!

ATTENTION: A risk of fire exists if external braking resistors are not protected. The external resistor package must be self-protected from over temperature or the protective circuit shown in

Figure B.9 on page B-13 , or equivalent, must be supplied.

Values

Default:

Min/Max:

Display:

0

0/99

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:

Min/Max:

0% (Disabled)

0/100%

Display: 1%

Example:

Accel Time = 10 Seconds

S Curve Setting = 50%

S Curve Time = 10

×

0.5 = 5 Seconds

Total Time = 10 + 5 = 15 Seconds

Target

50% S Curve

Target/2

1/2 S Curve Time

2.5 Seconds

Accel Time

10 Seconds

1/2 S Curve Time

2.5 Seconds

Total Time to Accelerate = Accel Time + S Curve Time



3-26



(continued)

A084 [Boost Select]

Sets the boost voltage (% of P031

[Motor NP Volts]) and redefines the Volts per Hz curve.

Active when A125 [Torque Perf Mode] = 0 “V/Hz”.

Drive may add additional voltage unless Option 5 is selected.

Options

0 “Custom V/Hz”


d004 ,

P031

,

P032

,

A085 ,

A086 , A087

,

A125

1 “30.0, VT”

2 “35.0, VT”

3 “40.0, VT”

4 “45.0, VT”

5 “0.0 no IR”

6 “0.0”

7 “2.5, CT”

[Default for

4.0, 5.5, 7.5 & 11 kW

(5.0, 7.5, 10 & 15 HP)

Drives]

8 “5.0, CT” (Default)

9 “7.5, CT”

10 “10.0, CT”

11 “12.5, CT”

12 “15.0, CT”

13 “17.5, CT”

14 “20.0, CT”

Variable Torque (Typical fan/pump curves.)

Constant Torque

100

50

1/2 [Motor NP Volts]

2

1

4

3

Settings

5-14

0 50

% P032 [Motor NP Hertz]

100




3-27


(continued)

A085 [Start Boost]


P031 , P032

,

P034

,

P035 ,

A084 ,

A086

,

A087 ,

A088

,

A125

Sets the boost voltage (% of P031

[Motor NP Volts]) and redefines the Volts per Hz curve when A084

[Boost Select] = 0 “Custom V/Hz” and A125 [Torque Perf Mode] = 0 “V/Hz”.

Drive may add additional voltage unless Option 5 is selected.

Values

Default: 2.5%

Min/Max:

Display:

0.0/25.0%

0.1%

A088 [Maximum Voltage]

P031 [Motor NP Volts]

A087 [Break Frequency]

A034 [Minimum Freq]

Frequency

P032 [Motor NP Hertz]

P035 [Maximum Freq]

A086 [Break Voltage]

Sets the frequency where break voltage is applied when A084 [Boost Select] = 0 “Custom V/Hz” and

A125 [Torque Perf Mode] = 0 “V/Hz”

Values

Default: 25.0%

Min/Max: 0.0/100.0%


P031 , P032

,

P034

,

P035 ,

A084 ,

A085

,

A087 ,

A088

,

A125

Display: 0.1%

A087 [Break Frequency]

Sets the frequency where break frequency is applied when A084 [Boost Select] = 0 “Custom V/Hz” and A125 [Torque Perf Mode] = 0 “V/Hz”

Values

Default: 15.0 Hz

Min/Max: 0.0/400.0 Hz


P031 , P032

,

P034

,

P035 ,

A084 ,

A085

,

A086 ,

A088

,

A125

Display: 0.1 Hz



3-28



(continued)

A088 [Maximum Voltage]

Sets the highest voltage the drive will output.

Values

Default:

Min/Max:

Display:


,

A085 , A086

,

A087

Drive Rated Volts

20/Drive Rated Volts

1 VAC

A089 [Current Limit 1]


,

A118

Maximum output current allowed before current limiting occurs.

Values

Default:

Min/Max:

Display:

Drive Rated Amps

×

1.5

0.1/Drive Rated Amps

×

1.8

0.1 Amps

A090 [Motor OL Select]


,

P033

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I

2 t overload function.

Options

0 “No Derate” (Default)

1 “Min Derate”

2 “Max Derate”

No Derate

100

80

60

40

20

0

0 25 50 75 100 125 150 175 200

Min Derate

100

80

60

40

20

0

0 25 50 75 100 125 150 175 200

Max Derate

100

80

60

40

20

0

0 25 50 75 100 125 150 175 200

A091 [PWM Frequency]


A124

Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting.

Important: Ignoring derating guidelines can cause reduced drive performance.

Values

Default: 4.0 kHz

Min/Max: 2.0/16.0 kHz

Display: 0.1 kHz

100

96

92

88

84

80

76

72

68

64

60

56

52

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16




3-29


(continued)

A092 [Auto Rstrt Tries]


,

A058 , A061

,

A093

Sets the maximum number of times the drive attempts to reset a fault and restart.

Clear a Type 1 fault and restart the drive.

1. Set A092 [Auto Rstrt Tries] to a value other than “0”.

2. Set

A093 [Auto Rstrt Delay] to a value other than “0”.

Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.

1. Set A092 [Auto Rstrt Tries] to a value other than “0”.

2. Set

A093 [Auto Rstrt Delay] to “0”.

!

ATTENTION:

Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.

Values

Default:

Min/Max:

Display:

0

0/9

1

A093 [Auto Rstrt Delay]


A092

Sets the time between restart attempts when

A092 [Auto Rstrt Tries] is set to a value other than zero.

Values

Default: 1.0 Secs

Min/Max: 0.0/300.0 Secs

Display: 0.1 Secs

A094 [Start At PowerUp]


Enables/disables a feature that allows a Start or Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored. Requires a digital input configured for Run or Start and a valid start contact.

This parameter will not function if parameter

P036 [Start Source] is set to 4 “2-W High Speed”.

!

ATTENTION:

Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.

Options


1 “Enabled”



3-30



(continued)

A095 [Reverse Disable]



d006

Enables/disables the function that allows the direction of motor rotation to be changed. The reverse command may come from a digital command, the keypad or a serial command. All reverse inputs including two-wire Run Reverse will be ignored with reverse disabled.

Options

0 “Rev Enabled”

(Default)

1 “Rev Disabled”

A096 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.

Options


1 “Enabled”

A097 [Compensation]

Enables/disables correction options that may improve problems with motor instability.

Options

0 “Disabled”

1 “Electrical” (Default)

2 “Mechanical”

Some drive/motor combinations have inherent instabilities which are exhibited as non-sinusodial motor currents. This setting attempts to correct this condition.

Some motor/load combinations have mechanical resonances which can be excited by the drive current regulator. This setting slows down the current regulator response and attempts to correct this condition.

3 “Both”

A098 [SW Current Trip]

Enables/disables a software instantaneous (within 100 ms) current trip.

Values

Default:

Min/Max:

Display:

0.0 (Disabled)


×

2)

0.1 Amps


P033

A099 [Process Factor]

Scales the output frequency value displayed by d010

[Process Display].

Output

Freq x

Process

Factor

=

Process

Display


d010

Values

Default:

Min/Max:

Display:

30.0

0.1/999.9

0.1





(continued)

A100 [Fault Clear]


Resets a fault and clears the fault queue. Used primarily to clear a fault over network communications.

Options


1 “Reset Fault”

2 “Clear Buffer”

(Parameters d007 d009

[Fault x Code])

3-31

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:

Display:

0/FFFF

1 Hex


d019

A103 [Comm Data Rate]


d015

Sets the serial port rate for the RS485 (DSI) port.

Important: Power to drive must be cycled before any changes will affect drive operation.

Options

0 “1200”

1 “2400”

2 “4800”

3 “9600” (Default)

4 “19.2K”

5 “38.4K”

A104 [Comm Node Addr]


d015

Sets the drive node address for the RS485 (DSI) port if using a network connection.


Values

Default:

Min/Max:

Display:

100

1/247

1



3-32



(continued)

A105 [Comm Loss Action]


d015

, P037

,

A106

Selects the drive’s response to a loss of the communication connection or excessive communication errors.

Options

0 “Fault” (Default) Drive will fault on an F81 Comm Loss and coast to stop.

1 “Coast Stop”

2 “Stop”

3 “Continu Last”

Stops drive via coast to stop.

Stops drive via

P037 [Stop Mode] setting.

Drive continues operating at communication commanded speed saved in RAM.

A106 [Comm Loss Time]


,

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:

Display:

0.1/60.0 Secs

0.1 Secs

A107 [Comm Format]


d015

Selects the protocol (RTU only), data bits (8 data bits only), parity (None, Even, Odd), and stop bits (1 stop bit only) used by the RS485 port on the drive.

Refer to Appendix C

for details on using the drive communication features.


Options

0 “RTU 8-N-1” (Default)

1 “RTU 8-E-1”

2 “RTU 8-O-1”

3 “RTU 8-N-2”

4 “RTU 8-E-2”

5 “RTU 8-O-2”

A108 [Language]

Selects the language displayed by the remote communications option.

Options

1 “English” (Default)

2 “Français”

3 “Español”

4 “Italiano”

5 “Deutsch”

6 “Reserved”

7 “Português”

8 “Reserved”

9 “Reserved”

10 “Nederlands”




3-33


(continued)

A109 [Anlg Out Setpt]


A065

When A065 [Analog Out Sel] is set to option 18, 19 or 20, this parameter sets the percentage of analog output desired.

Values

Default: 0.0%

Min/Max:

Display:

0.0/100.0%

0.1%

A110 [Anlg In 0-10V Lo]


,

P034 ,

P038

,

A122

Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038

[Speed Reference].

Analog inversion can be accomplished by setting this value larger than A111 [Anlg In 0-10V Hi].

Values

Default: 0.0%

Min/Max:

Display:

0.0/100.0%

0.1%

P035 [Maximum Freq]

Speed Reference

P034 [Minimum Freq]

0

0

A110 [Anlg In 0-10V Lo] A111 [Anlg In 0-10V Hi]

A111 [Anlg In 0-10V Hi]

Related Parameter(s): d020 ,

P035

,

P038 ,

A122

,

A123

Sets the analog input level that corresponds to P035 [Maximum Freq] if a 0-10V input is used by P038

[Speed Reference].

Analog inversion can be accomplished by setting this value smaller than A110 [Anlg In 0-10V Lo].

Values

Default: 100.0%

Min/Max: 0.0/100.0%

Display: 0.1%

A112 [Anlg In4-20mA Lo]


d021 ,

P034

,

P038

Sets the analog input level that corresponds to P034 [Minimum Freq] if a 4-20mA input is used by


Analog inversion can be accomplished by setting this value larger than A113 [Anlg In4-20mA Hi].

Values

Default: 0.0%

Min/Max: 0.0/100.0%

Display: 0.1%



3-34



(continued)

A113 [Anlg In4-20mA Hi]


d021 ,

P035

,

P038

Sets the analog input level that corresponds to P035

[Maximum Freq] if a 4-20mA input is used by


Analog inversion can be accomplished by setting this value smaller than A112 [Anlg In4-20mA Lo].

Values

Default: 100.0%

Min/Max:

Display:

0.0/100.0%

0.1%

A114 [Slip Hertz @ FLA]


P033

Compensates for the inherent slip in an induction motor. This frequency is added to the commanded output frequency based on motor current.

Values

Default: 2.0 Hz

Min/Max:

Display:

0.0/10.0 Hz

0.1 Hz

A115 [Process Time Lo]


,

P034

Scales the time value when the drive is running at

P034 [Minimum Freq]. When set to a value other

than zero,

d010 [Process Display] indicates the duration of the process.

Values

Default:

Min/Max:

0.00

0.00/99.99

Display: 0.01

A116 [Process Time Hi]


,

P035

Scales the time value when the drive is running at

P035 [Maximum Freq]. When set to a value other

than zero,

d010 [Process Display] indicates the duration of the process.

Values

Default: 0.00

Min/Max:

Display:

0.00/99.99

0.01

A117 [Bus Reg Mode]

Controls the operation of the drive voltage regulation, which is normally operational at decel or when the bus voltage rises.

Refer to the Attention statement on page

P-3 for important information on bus regulation.

Options

0 “Disabled”

1 “Enabled” (Default)

A118 [Current Limit 2]


P033 ,

A051 A054

,

A089

Maximum output current allowed before current limiting occurs. This parameter is only active if

A051 - A054 [Digital Inx Sel] is set to 25 “Current Lmt2” and is active.

Values

Default:

Min/Max:

Display:

Drive Rated Amps

×

1.5


×

1.8)

0.1 Amps




3-35


(continued)

A119 [Skip Frequency]

Sets the frequency at which the drive will not operate.

A setting of 0 disables this parameter.

Values

Default: 0 Hz

Min/Max:

Display:

0/400 Hz

1 Hz


A120

A120 [Skip Freq Band]


A119

Determines the bandwidth around

A119

[Skip Frequency]. A120 [Skip Frequency Band] is split applying 1/2 above and 1/2 below the actual skip frequency.

A setting of 0.0 disables this parameter.

Values

Default: 0.0 Hz

Min/Max:

Display:

0.0/30.0 Hz

0.1 Hz

Frequency

Command

Frequency

Drive Output

Frequency

Skip Frequency

2x Skip

Frequency Band

Time

A121 [Stall Fault Time]

Sets the time that the drive will remain in stall mode before a fault is issued.

Options

0 “60 Seconds” (Default)

1 “120 Seconds”

2 “240 Seconds”

3 “360 Seconds”

4 “480 Seconds”

5 “Flt Disabled”



3-36



(continued)

A122 [Analog In Loss]


A110 , A111

,

A132

Selects drive action when an input signal loss is detected. Signal loss is defined as an analog signal less than 1V or 2mA. The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1.5V or 3mA. If using a 0-10V analog input, set

A110 [Anlg In 0-10V

Lo] to a minimum of 20% (i.e. 2 volts).

Options


1 “Fault (F29)”

2 “Stop”

3 “Zero Ref”

4 “Min Freq Ref”

5 “Max Freq Ref”

6 “Int Freq Ref”

F29 Analog Input Loss

Uses P037 [Stop Mode]

Drive runs at zero speed reference.

Drive runs at minimum frequency.

Drive runs at maximum frequency.

Drive runs at internal frequency.

A123 [10V Bipolar Enbl]


,

A111

Enables/disables bipolar control. In bipolar mode direction is commanded by the sign of the reference.

Options

0 “Uni-Polar In” (Default) 0 to 10V only

1 “Bi-Polar In” ±10V

A124 [Var PWM Disable]


A091


Enables/disables a feature that varies the carrier frequency for the PWM output waveform defined by

A091 [PWM Frequency].

Disabling this feature when low frequency conditions exist may result in IGBT stress and nuisance tripping.

Options

0 “Enabled” (Default)

1 “Disabled”

A125 [Torque Perf Mode]


A084

, A085

,

A086 , A087

,

A127


Enables/disables sensorless vector control operation.

Options

0 “V/Hz”

1 “Sensrls Vect” (Default)

A126 [Motor NP FLA]

Set to the motor nameplate rated full load amps.

Values

Default:

Min/Max:

Drive Rated Amps


×

2)

Display: 0.1 Amps


A127




3-37


(continued)

A127 [Autotune]


,

A126 ,

A128

,

A129


Provides an automatic method for setting A128 [IR Voltage Drop] and A129 [Flux Current Ref], which

affect sensorless vector performance. Parameter A126

[Motor NP FLA] must be set to the motor nameplate full load amps before running the Autotune procedure.

Options


1 “Static Tune”

2 “Rotate Tune”

“Ready” (0) = Parameter returns to this setting following a “Static Tune” or “Rotate Tune.”

“Static Tune” (1) = A temporary command that initiates a non-rotational motor stator resistance test for the best possible automatic setting of A128 [IR Voltage Drop]. A start command is required following initiation of this setting. The parameter returns to “Ready” (0) following the test, at which time another start transition is required operate the drive in normal mode. Used when motor cannot be uncoupled from the load.

“Rotate Tune” (2) = A temporary command that initiates a “Static Tune” followed by a rotational test for the best possible automatic setting of A129 [Flux Current Ref]. A start command is required following initiation of this setting. The parameter returns to “Ready” (0) following the test, at which time another start transition is required to operate the drive in normal mode. Important: Used when motor is uncoupled from the load. Results may not be valid if a load is coupled to the motor during this procedure.

!

ATTENTION:

Rotation of the motor in an undesired direction can occur during this procedure. To guard against possible injury and/or equipment damage, it is recommended that the motor be disconnected from the load before proceeding.

If the Autotune routine fails, an F80 SVC Autotune fault is displayed.

A128 [IR Voltage Drop]

Value of volts dropped across the resistance of the motor stator.

Values

Default: Based on Drive Rating

Min/Max:

Display:

0.0/230.0 VAC

0.1 VAC


A127

A129 [Flux Current Ref]

Value of amps for full motor flux.

Values

Default:

Min/Max:

Display:


0.00/[Motor NP FLA]

0.01 Amps


A127



3-38



(continued)

A130 [PID Trim Hi]

Sets the maximum positive value that is added to the speed reference when PID trim is used.

Values

Default: 60.0

Min/Max:

Display:

0.0/400.0

0.1

A131 [PID Trim Lo]

Sets the maximum positive value that is subtracted from the PID reference when PID trim is used.

Values

Default: 0.0

Min/Max: 0.0/400.0

Display: 0.1

A132 [PID Ref Sel]


,

A122


Enables/disables PID mode and selects the source of the PID reference. Refer to

Appendix F for

details.

Options

0 “PID Disabled”

(Default)

1 “PID Setpoint”

2 “0-10V Input”


4 “Comm Port”

5 “Setpnt, Trim”

6 “0-10V, Trim”

7 “4-20mA, Trim”

8 “Comm, Trim”

A133 [PID Feedback Sel]

Select the source of the PID feedback. Refer to

Appendix F

for details.

Options

0 “0-10V Input” (Default) The PID will not function with a bipolar input. Negative voltages are treated as 0 volts.


2 “Comm Port”

A134 [PID Prop Gain]

Sets the value for the PID proportional component when the PID mode is enabled by A132 [PID Ref

Sel].

Values

Default: 0.01

Min/Max:

Display:

0.00/99.99

0.01




3-39


(continued)

A135 [PID Integ Time]

Sets the value for the PID integral component when the PID mode is enabled by A132 [PID Ref Sel].

Values

Default: 0.1 Secs


Display: 0.1 Secs

A136 [PID Diff Rate]

Sets the value for the PID differential component when the PID mode is enabled by A132 [PID Ref

Sel].

Values

Default: 0.01 (1/Secs)

Min/Max:

Display:

0.00/99.99 (1/Secs)

0.01 (1/Secs)

A137 [PID Setpoint]

Provides an internal fixed value for process setpoint when the PID mode is enabled by A132 [PID Ref

Sel].

Values

Default: 0.0%

Min/Max: 0.0/100.0%

Display: 0.1%

A138 [PID Deadband]

Sets the lower limit of the PID output.

Values

Default:

Min/Max:

Display:

0.0%

0.0/10.0%

0.1%

A139 [PID Preload]

Sets the value used to preload the integral component on start or enable.

Values

Default: 0.0 Hz

Min/Max: 0.0/400.0 Hz

Display: 0.1 Hz



3-40



(continued)

A140 [Stp Logic 0]








Values

Default:


,

P039 ,

P040

,

A051 A054 ,

A055 ,

A058 , A061

, A067 , A068 ,

A070 A077

, A150

-

A157


Min/Max:

Display:

00F1

0001/bAFF

4 Digits

Parameters A140-A147 are only active if

P038

[Speed Reference] is set to 6 “Stp Logic”.

These parameters can be used to create a custom profile of frequency commands. Each “step” can be based on time, status of a Logic input or a combination of time and the status of a Logic input.

Digits 0-3 for each [Stp Logic x] parameter must be programmed according to the desired profile.

A Logic input is established by setting a digital input, parameters A051

-

A054 [Digital Inx Sel], to 23

“Logic In1” and/or 24 “Logic In2”.

A time interval between steps can be programmed using parameters A150 - A157

[Stp Logic Time x].

See the table below for related parameters.

The speed for any step is programmed using parameters

A070 - A077

[Preset Freq x].

StepLogic Parameter

(Active when P038 = 6 “Stp Logic”)

A140 [Stp Logic 0]

A141 [Stp Logic 1]

A142 [Stp Logic 2]

A143 [Stp Logic 3]

A144 [Stp Logic 4]

A145 [Stp Logic 5]

A146 [Stp Logic 6]

A147 [Stp Logic 7]

Related Preset Frequency Parameter

(Can be activated independent of

StepLogic Parameters)









Related StepLogic Time Parameter

(Active when A140-A147 Digit 0 or 1 are set to 1, b, C, d or E)

A150 [Stp Logic Time 0]








How StepLogic Works

The StepLogic sequence begins with a valid start command. A normal sequence always begins with

A140 [Stp Logic 0].

Digit 0: Logic For Next Step

This digit defines the logic for the next step. When the condition is met the program advances to the next step. Step 0 follows Step 7. Example: Digit 0 is set 3. When “Logic In2” becomes active, the program advances to the next step.

Digit 1: Logic to Jump to a Different Step

For all settings other than F, when the condition is met, the program overrides Digit 0 and jumps to the step defined by Digit 2.

Digit 2: Different Step to Jump

When the condition for Digit 1 is met, the Digit 2 setting determines the next step or to end the program.




3-41

Digit 3: Step Settings

This digit defines what accel/decel profile the speed command will follow and the direction of the command for the current step. In addition, if a relay or opto output (parameters A055, A058 and A061) is set to 15 “StpLogic Out”, this parameter can control the status of that output.

Any StepLogic parameter can be programmed to control a relay or opto output, but you can not control different outputs based on the condition of different StepLogic commands.

StepLogic Settings

The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit.

Refer to Appendix E for details.

Logic For Next Step

Logic to Jump to a Different Step

Different Step to Jump

Step Settings

Digit 3 Settings

Required

Setting

7

8

9

A b

0

1

2

3

4

5

6

Accel/Decel

Param. Used

Accel/Decel 1

Accel/Decel 1

Accel/Decel 1

Accel/Decel 1

Accel/Decel 1

Accel/Decel 1

Accel/Decel 2

Accel/Decel 2

Accel/Decel 2

Accel/Decel 2

Accel/Decel 2

Accel/Decel 2

Digit 2 Settings

0 = Jump to Step 0

1 = Jump to Step 1

2 = Jump to Step 2

3 = Jump to Step 3

4 = Jump to Step 4

5 = Jump to Step 5

6 = Jump to Step 6

7 = Jump to Step 7

8 = End Program (Normal Stop)

9 = End Program (Coast to Stop)

A = End Program and Fault (F2)

Digit 0

Digit 1

Digit 2

Digit 3

StepLogic

Output State

Off

Off

Off

On

On

On

Off

Off

Off

On

On

On

Commanded

Direction

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

Digit 1 and Digit 0 Settings

0 = Skip Step (Jump Immediately)

1 = Step Based on [Stp Logic Time x]

2 = Step if “Logic In1” is Active

3 = Step if “Logic In2” is Active

4 = Step if “Logic In1” is Not Active

5 = Step if “Logic In2” is Not Active

6 = Step if either “Logic In1” or “Logic In2” is Active

7 = Step if both “Logic In1” and “Logic In2” is Active

8 = Step if neither “Logic In1” or “Logic In2” is Active

9 = Step if “Logic In1” is Active and “Logic In2” is Not Active

A = Step if “Logic In2” is Active and “Logic In1” is Not Active b = Step after [Stp Logic Time x] and “Logic In1” is Active

C = Step after [Stp Logic Time x] and “Logic In2” is Active d = Step after [Stp Logic Time x] and “Logic In1” is Not Active

E = Step after [Stp Logic Time x] and “Logic In2” is Not Active

F = Do Not Step/Ignore Digit 2 Settings



3-42



(continued)

A150 [Stp Logic Time 0]









P038 ,

A055

,

A058

,

A061 ,

A070 A077 ,

A140

-

A147

Sets the time to remain in each step if the corresponding StpLogic command word is set to “Step after

Time”.

Values

Default: 30.0 Secs


Display: 0.1 Secs

A160 [EM Brk Off Delay]


P037

Sets the time the drive remains at minimum frequency before the relay or an opto output is energized and the drive ramps to the commanded frequency.

The relay or opto output is typically connected to a user-supplied electromechanical brake coil relay.

Set P037

[Stop Mode] to 8 “Ramp+EM B,CF” or 9 “Ramp+EM Brk” to enable the electromechanical brake option.

Set A055

[Relay Out Sel], A058

or

A061 [Opto Outx Sel] to 22 “EM Brk Cntrl” to control brake

operation.

Values

Default: 2.00 Secs

Min/Max:

Display:

0.01/10.00 Secs

0.01 Secs

Frequency

A160 [EM Brk Off Delay]

Ramp Decel

A161 [EM Brk On Delay]

Ramp Accel

Minimum Freq

Start

Commanded

EM Brk

Energized (Off)

Time

Stop

Commanded

EM Brk

De-Energized (On)

Drive Stops




3-43


(continued)

A161 [EM Brk On Delay]


P037

Sets the time the drive remains at minimum frequency before the relay or an opto output is de-energizing and the drive stops.

The relay or opto output is typically connected to a user-supplied electromechanical brake coil relay.

Set P037

[Stop Mode] to 8 “Ramp+EM B,CF” or 9 “Ramp+EM Brk” to enable the electromechanical brake option.

Set A055

[Relay Out Sel], A058

or

A061 [Opto Outx Sel] to 22 “EM Brk Cntrl” to control brake

operation.

Values

Default: 2.00 Secs

Min/Max:

Display:

0.01/10.00 Secs

0.01 Secs

A162 [MOP Reset Sel]


Set the drive to save the current MOP reference command.

Options

0 “Zero MOP Ref” This option clamps drive is not running.

A069 [Internal Freq] at 0.0 Hz when the

1 “Save MOP Ref”

(Default)

Reference is saved in A069 [Internal Freq].

A163 [DB Threshold]


,

A080 , A081

,

A082

Sets the DC bus Voltage Threshold for Dynamic Brake operation. If the DC bus voltage falls below the value set in this parameter, the Dynamic Brake will not turn on. Lower values will make the Dynamic

Braking function more responsive but may result in nuisance Dynamic Brake activation.

Values

Default

Min/Max:

100.0%

0.0/110.0%

Display: 0.0%

!

ATTENTION:

Equipment damage may result if this parameter is set a value that causes the dynamic braking resistor to dissipate excessive power.

Parameter settings less than 100% should be carefully evaluated to ensure that the dynamic brake resistor’s wattage rating is not exceeded. In general, values less than 90% are not needed. This parameter’s setting is especially important if parameter A082 [DB Resistor Sel] is set to 2 “No Protection”.



3-44



(continued)

A164 [Comm Write Mode]

Determines whether parameter changes made over communication port are saved and stored in

Non-Volatile Storage (NVS) or RAM only. If they are stored in RAM, the values will be lost at power-down.

Options

0 “Save” (Default)

1 “RAM Only”

!

ATTENTION:

Risk of equipment damage exists. If a controller is programmed to write parameter data to Non-Volatile Storage (NVS) frequently, the NVS will quickly exceed its life cycle and cause the drive to malfunction. Do not create a program that frequently uses configurable outputs to write parameter data to NVS unless A164

[Comm Write Mode] is set to option 1.

A165 [Anlg Loss Delay]


A122

Sets the length of time after power-up during which the drive will not detect an analog signal loss. The drive response to an analog signal loss is set in

A122 [Analog In Loss].

Values

Default: 0.0 Secs


Display: 0.1 Secs

A166 [Analog In Filter]

Sets level of additional filtering of the analog input signals. A higher number increases filtering and decreases bandwidth. Each setting doubles the applied filtering (1 = 2x filter, 2 = 4x filter, etc...). No additional filtering is applied when set to “0”.

Values

Default: 0

Min/Max: 0/14

Display: 1

A167 [PID Invert Error]

When set to “Inverted”, changes the sign of the PID error. This causes an increase in the drive output frequency with PID Feedback greater than PID Setpoint, and a decrease in drive output frequency with PID Feedback less than PID Setpoint.

Options

0 “Not Inverted” (Default)

1 “Inverted”




3-45

Parameter Name

10V Bipolar Enbl

Compensation

Contrl In Status

Control Source

Control SW Ver

Counter Status

Current Limit x

DB Resistor Sel

DB Threshold

DC Brake Level

DC Brake Time

DC Bus Voltage

Decel Time 1

Decel Time 2

Dig In Status

Digital Inx Sel

Drive Status

Drive Temp

Drive Type

Elapsed Run Time

EM Brk Off Delay

EM Brk On Delay

Fault Clear

Fault x Code

Flux Current Ref

Flying Start En

Internal Freq

IR Voltage Drop

Accel Time 1

Accel Time 2

Analog In 0-10V

Analog In 4-20mA

Analog In Filter

Analog In Loss

Analog Out High

Analog Out Sel

Anlg In 0-10V Hi

Anlg In 0-10V Lo

Anlg In4-20mA Hi

Anlg In4-20mA Lo

Anlg Loss Delay

Anlg Out Setpt

Auto Rstrt Delay

Auto Rstrt Tries

Autotune

Boost Select

Break Frequency

Break Voltage

Bus Reg Mode

Comm Data Rate

Comm Format

Comm Loss Action

Comm Loss Time

Comm Node Addr

Comm Status

Comm Write Mode

Commanded Freq

No.

A123

Group

Advanced Program

A103

A107

A105

A106

A104

d015

A164

d002

A109

A093

A092

A127

A084

A087

A086

A117

P039

A067

d020 d021

A166

A122

A066

A065

A111

A110

A113

A112

A166

A097

d013 d012

Advanced Program

Display

Display

d016

d025

Display

Display

A089

,

A118

Advanced Program

A082

A163

Advanced Program

Advanced Program

A081

A080

d005

P040

A068

d014

Advanced Program

Advanced Program

Display

Basic Program

Advanced Program

Display

A051

-

A054

Advanced Program

d006

Display

d024

d017

d018

A160

A161

A100

Display

Display

Display

Advanced Program

Advanced Program

Advanced Program

d007 d009

Display

A129

Advanced Program

A096

A069

A128

Advanced Program

Advanced Program

Advanced Program

Basic Program

Advanced Program

Display

Display

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Display

Advanced Program

Display

Parameter Cross Reference – by Name

Parameter Name

Jog Accel/Decel

Jog Frequency

Language

PID Setpoint

PID Trim Hi

PID Trim Lo

Preset Freq x

Process Display

Process Factor

Process Time Hi

Process Time Lo

Program Lock

PWM Frequency

Relay Out Level

Relay Out Sel

Reset To Defalts

Reverse Disable

S Curve %

Skip Freq Band

Skip Frequency

Slip Hertz @ FLA

Stp Logic Status

Stp Logic x

Stp Logic Time x

Speed Reference

Stall Fault Time

Start At PowerUp

Start Boost

Start Source

Stop Mode

SW Current Trip

Maximum Freq

Maximum Voltage

Minimum Freq

MOP Reset Sel

Motor NP FLA

Motor NP Hertz

Motor NP Volts

Motor OL Current

Motor OL Ret

Motor OL Select

Opto Out Logic

Opto Outx Level

Opto Outx Sel

Output Current

Output Freq

Output Power

Output Powr Fctr

Output Voltage

PID Deadband

PID Diff Rate

PID Feedback Sel

PID Integ Time

PID Invert Error

PID Preload

PID Prop Gain

PID Ref Sel

No.

A079

A078

A108

Group

Advanced Program

Advanced Program

Advanced Program

P035

A088

P034

A162

A126

P032

P031

P033

P043

A090

Basic Program

Advanced Program

Basic Program

Advanced Program

Advanced Program

Basic Program

Basic Program

Basic Program

Basic Program

Advanced Program

A138

A136

A133

A135

A167

A139

A134

A132

A064 Advanced Program

A059 , A062 Advanced Program

A058 , A061

Advanced Program

d003 d001

d022 d023

d004

Display

Display

Display

Display

Display

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

A101

A091

A056

A055

P041

A095

A083

A120

A137

A130

A131

Advanced Program

Advanced Program

Advanced Program

A070 A077

Advanced Program

d010

Display

A099

Advanced Program

A116

A115

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Basic Program

Advanced Program

Advanced Program

Advanced Program

A119

A114

d028

Advanced Program

Advanced Program

Display

A140 A147

Advanced Program

A150 A157

Advanced Program

P038

Basic Program

A121

A094

Advanced Program

Advanced Program

A085

P036

P037

A098

Advanced Program

Basic Program

Basic Program

Advanced Program



3-46


Parameter Name

Testpoint Data

Testpoint Sel

Timer Status

Torque Current

Torque Perf Mode

Var PWM Disable

Voltage Class

No.

d019

A102

d026 d029

A125

A124

P042

Group

Display

Advanced Program

Display

Display

Advanced Program

Advanced Program

Basic Program



Chapter

4

Troubleshooting

Chapter 4 provides information to guide you in troubleshooting the

PowerFlex 40 drive. Included is a listing and description of drive faults

(with possible solutions, when applicable).


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 2-4

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.

➁

Non-Resetable This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared.



4-2

Troubleshooting

Fault Indication

Condition

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.

Display

RUN

FWD

REV

PRGOGRAM FAULT

VOLTS

AMPS

HERTZ

Manually Clearing Faults

Step

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 A054 [Digital Inx Sel] is set to option 7

“Clear Fault”.

Key(s)

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

Table 4.A Fault Types, Descriptions and Actions

No.

Fault

F2 Auxiliary Input

F3 Power Loss

F4 UnderVoltage

F5 OverVoltage

F6 Motor Stalled

F7 Motor Overload

F8 Heatsink

OvrTmp

F12 HW OverCurrent

F13 Ground Fault

F29 Analog Input

Loss

Description Action

➀

Auxiliary input interlock is open.

1. Check remote wiring.

2. Verify communications programming for intentional fault.

➁

Excessive DC Bus voltage ripple. 1. Monitor the incoming line for phase loss or line imbalance.

2. Check input line fuse.

➀

DC bus voltage fell below the minimum value.

➀

DC bus voltage exceeded maximum value.

Monitor the incoming AC line for low voltage or line power interruption.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option.

➀

Drive is unable to accelerate motor.

Increase P039

-

A067

[Accel Time x] or reduce load so drive output current does not exceed the current

set by parameter A089 [Current

Limit 1].

➀

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].

➀

Heatsink temperature exceeds a predefined value.

2. Verify

A084 [Boost Select]

setting

1. Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded

40

°

C (104

°

F) for IP30, NEMA UL

Type 1 installations or 50°C (122°F) for IP20/Open type installations.

➁

The drive output current has exceeded the hardware current limit.

➁

A current path to earth ground has been detected at one or more of the drive output terminals.

➀

An analog input is configured to fault on signal loss. A signal loss has occurred.

Configure with

A122 [Analog In

Loss].

2. Check fan.

Check programming. Check for excess load, improper

A084 [Boost

Select] setting, DC brake volts set too high or other causes of excess current.

Check the motor and external wiring to the drive output terminals for a grounded condition.

1. Check parameters.

2. Check for broken/loose connections at inputs.



4-4

Troubleshooting

(1)

See page 4-1

for a description of fault types.

No.

Fault

F33 Auto Rstrt Tries

F38 Phase U to Gnd

F39 Phase V to Gnd

F40 Phase W to Gnd

F41 Phase UV Short

F42 Phase UW Short

F43 Phase VW Short

F48 Params

Defaulted

F63 SW OverCurrent

F64 Drive Overload

F70 Power Unit

F71 Net Loss

F80 SVC Autotune

F81 Comm Loss

Description

➁

Drive unsuccessfully attempted to reset a fault and resume running for the programmed

number of A092

[Auto Rstrt

Tries].

➁

A phase to ground fault has been detected between the drive and motor in this phase.

➁

Excessive current has been

➀ detected between these two output terminals.

The drive was commanded to write default values to EEPROM.

Programmed

A098 [SW Current

Trip] has been exceeded.

➁

Drive rating of 150% for 1 minute or 200% for 3 seconds has been exceeded.

➁

Failure has been detected in the drive power section.

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.

1. Check the motor and drive output terminal wiring for a shorted condition.


1. Clear the fault or cycle power to the drive.

2. Program the drive parameters as needed.

Check load requirements and A098

[SW Current Trip] setting.

Reduce load or extend Accel Time.

The communication network has faulted.

The autotune function was either cancelled by the user or failed.

➁

RS485 (DSI) port stopped communicating.

1. Cycle power.


1. Cycle power.

2. Check communications cabling.

3. Check network adapter setting.

4. Check external network status.

Restart procedure.

1. If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required.

2. Check connection.

3. An adapter was intentionally disconnected.

4. Turn off using

A105 [Comm Loss

Action].



Troubleshooting

4-5

No.

Fault

F100 Parameter

Checksum

F122 I/O Board Fail

Description

➁

The checksum read from the board does not match the checksum calculated.

➁

Failure has been detected in the drive control and I/O section.

Action

Set

P041 [Reset To Defalts] to

option 1 “Reset Defaults”.

1. Cycle power.


(1)

See page 4-1

for a description of fault types.

Common Symptoms and Corrective Actions

Motor does not Start.

Cause(s)

No output voltage to the motor.

Improper boost setting at initial start-up.

Drive is Faulted

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.

None

Set A084

[Boost Select] to option 2

“35.0, VT”.

Flashing red status light Clear fault.

•

Press Stop

•

Cycle power

•

Set A100 [Fault Clear] to option 1

“Clear Faults”.

•


A051 - A054

[Digital Inx Sel] is set to option 7

“Clear Fault”.



4-6

Troubleshooting

Drive does not Start from Start or Run Inputs wired to the terminal block.

Cause(s)

Drive is Faulted

Incorrect programming.

•

P036

[Start Source] is set to option 0 “Keypad” or option 5

“RS485 (DSI) Port”.

•

A051

-

A054 [Digital Inx Sel] is

set to option 5 “Local” and the input is active.

Incorrect input wiring.

See 1-18 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.

Incorrect Sink/Source DIP switch setting.

None

None

Indication Corrective Action

Flashing red status light Clear fault.

•

Press Stop

•

Cycle power

•

Set A100 [Fault Clear] to option 1

“Clear Faults”.

•


A051 - A054

[Digital Inx Sel] is set to option 7

“Clear Fault”.

None Check parameter settings.

Wire inputs correctly and/or install jumper.

Set switch to match wiring scheme.

Drive does not Start from Integral Keypad.

Cause(s) Indication

Integral keypad is not enabled. Green LED above Start key is not illuminated.

I/O Terminal 01 “Stop” input is not present.

None

Corrective Action

•

Set parameter P036 [Start

Source] to option 0 “Keypad”.

•

Set parameter A051 - A054

[Digital Inx Sel] to option 5

“Local” and activate the input.

Wire inputs correctly and/or install jumper.



Troubleshooting

4-7

Drive does not respond to changes in speed command.

Cause(s)

No value is coming from the source of the command.

Incorrect reference source is being selected via remote device or digital inputs.

Indication

The drive “Run” indicator is lit and output is 0 Hz.

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 - A054

[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 1-23

.

Motor and/or drive will not accelerate to commanded speed.

Cause(s) Indication

Acceleration time is excessive. None

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

None

Speed command source or value is not as expected.

None

Programming is preventing the drive output from exceeding limiting values.

Torque performance does not match motor characteristics.

None

None

Corrective Action

Reprogram

P039

[Accel Time 1] or

A067 [Accel Time 2].

Compare d003

[Output Current] with

A089 [Current Limit 1].

Remove excess load or reprogram

P039

[Accel Time 1] or A067 [Accel

Time 2].

Check for improper

A084 [Boost

Select] 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.

Set motor nameplate full load amps in parameter

A126 [Motor NP FLA].

Perform

A127 [Autotune] “Static

Tune” or “Rotate Tune” procedure.

Set A125

[Torque Perf Mode] to option 0 “V/Hz”.



4-8

Troubleshooting

Motor operation is unstable.

Cause(s)

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

[Boost Select] to reduce boost level.

Drive will not reverse motor direction.

Cause(s)

Digital input is not selected for reversing control.

Indication

None

Digital input is incorrectly wired.

Motor wiring is improperly phased for reverse.

Reverse is disabled.

None

None

None

Drive does not power up.

Cause(s)

No input power to drive.

Indication

None

Jumper between I/O Terminals

P2 and P1 not installed and/or

DC Bus Inductor not connected.

None

Corrective Action

Check [Digital Inx Sel]

(See page 3-14)

. Choose correct input and program for reversing mode.

Check input wiring.

(See page 1-17)

Switch two motor leads.

Check A095

[Reverse Disable].

Corrective Action

Check the power circuit.

•

Check the supply voltage.

•

Check all fuses and disconnects.

Install jumper or connect DC Bus

Inductor.



Appendix

A

Supplemental Drive Information


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

Refer to listings in the following tables for recommended circuit breakers (inverse time or instantaneous trip) and 140M Self-Protecting

Motor Starters.

(1)

(2)

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.

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

(1)

Output Ratings

kW (HP) Amps

Input Ratings

Voltage

Range kVA Amps

100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output

Branch Circuit Protection

Fuses

140M Motor

Protectors

(3)

Contactors

22B-V2P3x104 0.4 (0.5) 2.3

90-132 1.15

9.0

15 140M-C2E-C16 100-C12

35

40

140M-D8E-C20 100-C23

140M-F8E-C32 100-C37

22B-V5P0x104 0.75 (1.0) 5.0

90-132 2.45

20.3

22B-V6P0x104 1.1 (1.5) 6.0

90-132 3.0

24.0

200 - 240V AC (±10%) – 1-Phase

(2)

Input, 0 - 230V 3-Phase Output

22B-A2P3x104

22B-A5P0x104

22B-A8P0x104

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.3

5.0

8.0

180-264

180-264

180-264

1.15

6.0

2.45

12.0

4.0

18.0

10

20

30

40 22B-A012x104 2.2 (3.0) 12.0

180-264 5.5

25.0


22B-B2P3x104 0.4 (0.5) 2.3

180-264 1.15

2.5

140M-C2E-B63 100-C09

140M-C2E-C16 100-C12

140M-D8E-C20 100-C23

140M-F8E-C32 100-C37

22B-B5P0x104

22B-B8P0x104

22B-B012x104

22B-B017x104

22B-B024x104

22B-B033x104

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10.0)

5.0

8.0

12.0

17.5

24.0

33.0

180-264

180-264

180-264

180-264

180-264

180-264

2.45

5.7

4.0

9.5

5.5

15.5

8.6

21.0

11.8

26.1

16.3

34.6

6

10

15

25

30

40

60

140M-C2E-B40 100-C07

140M-C2E-C10 100-C09

140M-C2E-C16 100-C12

140M-C2E-C16 100-C23

140M-F8E-C25 100-C23

140M-F8E-C32 100-C37

140M-G8E-C45 100-C60


22B-D1P4x104

22B-D2P3x104

0.4 (0.5)

0.75 (1.0)

1.4

2.3

342-528

342-528

1.4

2.3

1.8

3.2

22B-D4P0x104

22B-D6P0x104

22B-D010x104

22B-D012x104

22B-D017x104

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10.0)

4.0

6.0

10.5

12.0

17.0

342-528

342-528

342-528

342-528

342-528

4.0

5.9

5.7

7.5

10.3

13.0

11.8

14.2

16.8

18.4

22B-D024x104 11.0 (15.0) 24.0

342-528 23.4

26.0


22B-E1P7x104

22B-E3P0x104

0.75 (1.0)

1.5 (2.0)

1.7

3.0

414-660

414-660

2.1

2.3

3.65

3.8

22B-E4P2x104

22B-E6P6x104

22B-E9P9x104

22B-E012x104

22B-E019x104

2.2 (3.0)

4.0 (5.0)

4.2

6.6

5.5 (7.5)

7.5 (10.0)

9.9

12.2

11.0 (15.0) 19.0

414-660

414-660

414-660

414-660

414-660

5.2

8.1

5.3

8.3

12.1

11.2

14.9

13.7

23.1

24.1

3

6

10

15

20

25

30

50

6

6

10

15

20

25

40

140M-C2E-B25 100-C07

140M-C2E-B40 100-C07

140M-C2E-B63 100-C09

140M-C2E-C10 100-C09

140M-C2E-C16 100-C23

140M-D8E-C20 100-C23

140M-D8E-C20 100-C23

140M-F8E-C32 100-C43

140M-C2E-B25 100-C09

140M-C2E-B40 100-C09

140M-C2E-B63 100-C09

140M-C2E-C10 100-C09

140M-C2E-C16 100-C16

140M-C2E-C16 100-C23

140M-D8E-C25 100-C30

(1)

(2)

(3)

In the Catalog Numbers listed “x” represents enclosure type. Specifications are valid for all enclosure types. IP66, NEMA/UL Type 4X drive ratings are only available as Frame B drives. Refer

to Table B.B

.

200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N104 to N114. Filter option is not available for IP66, NEMA/UL Type 4X rated drives.

Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to determine the frame and breaking capacity required for your application.




A-3

Input/Output Ratings

Output Frequency: 0-400 Hz (Programmable)

Efficiency: 97.5% (Typical)

Approvals

LIS

TED 966X

LIS

TED 966X

IND

CO N T E

Q

UL508C

C

CSA 22.2

LV:

IND

CO N T E

Q

EMC Directive 89/336

EN 50178, EN 60204

EMC: EN 61800-3, EN 50081-1, EN 50082-2

Digital Control Inputs (Input Current = 6mA)

SRC (Source) Mode:

18-24V = ON

0-6V = OFF

SNK (Sink) Mode:

0-6V = ON

18-24V = OFF

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

Opto Outputs

30V DC, 50mA

Non-inductive

Fuses and Circuit Breakers

Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.

Recommended Circuit Breakers: HMCP circuit breakers or equivalent.

Analog Outputs (10 bit)

0-10V, 1k ohm Min.

4-20mA, 525 ohm Max.

Protective Features

Motor Protection: I

2 t 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)




Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)



460-600V AC Input – If P042 = 3 “High Voltage” trip occurs at 487V DC bus voltage (344V AC incoming line);

If P042 = 2 “Low Voltage” trip occurs at 390V DC bus voltage (275V AC incoming line)

Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs

Faultless Power Ride Through: 100 milliseconds

Dynamic Braking

Internal brake IGBT included with all ratings except when no brake is specified.

Refer to Appendix B for DB resistor ordering information.



A-4


Category Specification

Environment

Altitude:

Maximum Surrounding Air

Temperature without derating:

IP20, NEMA/UL Type Open:

IP30, NEMA/UL Type 1:

Flange Mount:

1000 m (3300 ft) max. without derating

–10 to 50° C (14 to 122° F)

–10 to 40° C (14 to 104° F)

Heatsink: –10 to 40° C (14 to 104° F)

Drive: –10 to 50° C (14 to 122° F)

–10 to 40° C (14 to 104° F) IP66, NEMA/UL Type 4X:

Cooling Method

Convection:

Fan:

Control

Storage Temperature:

Atmosphere:

Relative Humidity:

Shock (operating):

Vibration (operating):

Carrier Frequency

Frequency Accuracy

Digital Input:

Analog Input:

Analog Output:

Speed Regulation - Open Loop with Slip Compensation:

Stop Modes:

0.4 kW (0.5 HP) drives

All other drive ratings and 0.4 kW (0.5 HP)

1-Phase drives with Integral “S Type” EMC Filter

–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,

10-Bit resolution

±2% of full scale, 10-Bit resolution

±1% of base speed across a 60:1 speed range.

Electrical

Accel/Decel:

Intermittent Overload:

Electronic Motor Overload

Protection:

Voltage Tolerance:

Frequency Tolerance:

Input Phases:

Displacement Power Factor:

Maximum Short Circuit Rating:

Actual Short Circuit Rating:

Transistor Type:

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 and power-down overload retention function.

100-120V ±10%

200-240V ±10%

380-480V ±10%

460-600V ±10%

48-63 Hz

Three-phase input provides full rating. Single-phase operation provides 35% rated current.

0.98 across entire speed range

100,000 Amps Symmetrical

Determined by AIC Rating of installed fuse/circuit breaker

Insulated Gate Bipolar Transistor (IGBT)




A-5

PowerFlex 40 Estimated Watts Loss (Rated Load, Speed & PWM)

Voltage

100–120V

200–240V

380–480V

460–600V kW (HP)

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

0.4 (0.5)

0.75 (1.0)

1.1 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10)

0.4 (0.5)

0.75 (1.0)

1.1 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

17

30

48

75

135

140

175

260

22

40

63

100

150

200

265

30

48

75

135

140

175

260

External Watts

22

40

58

25

35

35

40

18

20

22

25

18

20

22

25

30

35

40

20

22

25

25

35

35

40

Internal Watts

18

20

22

35

50

70

100

160

175

210

300

40

60

85

125

180

235

305

50

70

100

160

175

210

300

Total Watts Loss

40

60

80



A-6

Notes:




Appendix

B

Accessories and Dimensions

Product Selection

Table B.A Catalog Number Description

22B -

Drive

A 1P5 N 1 1

Voltage Rating Rating Enclosure HIM Emission Class

4

Type

Table B.B PowerFlex 40 Drives

Drive Ratings

Input Voltage kW

120V 50/60 Hz

1-Phase

No Filter

0.4

HP

0.5

0.75

1.0

1.1

0.4

1.5

0.5

240V 50/60 Hz

1-Phase

With Integral “S

Type” EMC

Filter

0.75

1.5

1.0

2.0

240V 50/60 Hz

1-Phase

No Filter

2.2

0.4

0.75

1.5

3.0

0.5

1.0

2.0

240V 50/60 Hz

3-Phase

No Filter

2.2

0.4

3.0

0.5

0.75

1.0

1.5

2.0

480V 50/60 Hz

3-Phase

No Filter

IP20, NEMA/UL Type Open

Output

Current Catalog Number

Frame

Size

2.3A

5.0A

6.0A

2.3A

5.0A

8.0A

22B-V2P3N104

22B-V5P0N104

22B-V6P0N104

22B-A2P3N114

2.2

3.7

5.5

7.5

0.4

0.5

0.75

1.0

1.5

2.2

2.0

3.0

3.0

5.0

12.0A

17.5A

22B-B012N104

22B-B017N104

7.5

24.0A

22B-B024N104

10.0

33.0A

22B-B033N104

1.4A

2.3A

4.0A

6.0A

22B-D1P4N104

22B-D2P3N104

22B-D4P0N104

22B-D6P0N104

B

B

22B-A5P0N114 B

22B-A8P0N114 B

12.0A

22B-A012N114

2.3A

22B-A2P3N104

5.0A

8.0A

22B-A5P0N104 B

22B-A8P0N104 B

C

B

12.0A

22B-A012N104

2.3A

22B-B2P3N104

5.0A

8.0A

22B-B5P0N104

22B-B8P0N104

C

B

B

B

B

B

B

B

B

B

B

B

C

C

IP20 Flange

Mount

(1)

IP66, NEMA/UL

Type 4X

Catalog Number Catalog Number

–

–

22B-V2P3F104

22B-V5P0F104

22B-V6P0F104

–

22B-B012F104

22B-B017F104

22B-B024F104

22B-B033F104

22B-D1P4F104

22B-D2P3F104

22B-D4P0F104

22B-D6P0F104

22B-V2P3C104

22B-V5P0C104

22B-V6P0C104

–

–

–

–

22B-A2P3F104

–

22B-A2P3C104

22B-A5P0F104 22B-A5P0C104

22B-A8P0F104 22B-A8P0C104

22B-A012F104

22B-B2P3F104

22B-B5P0F104

22B-B8P0F104

–

22B-B2P3C104

22B-B5P0C104

22B-B8P0C104

–

–

22B-B012C104

22B-B017C104

22B-D1P4C104

22B-D2P3C104

22B-D4P0C104

22B-D6P0C104

600V 50/60 Hz

3-Phase

No Filter

(1)

(2)

4.0

5.5

5.0

7.5

10.5A

12.0A

22B-D010N104

22B-D012N104

7.5

10.0

17.0A

22B-D017N104

11.0

15.0

24.0A

22B-D024N104

0.75

1.0

1.5

2.0

2.2

4.0

3.0

5.0

1.7A

3.0A

4.2A

6.6A

22B-E1P7N104

22B-E3P0N104

22B-E4P2N104

22B-E6P6N104

B

C

C

C

B

B

B

B

22B-D010F104

22B-D012F104

22B-D017F104

22B-D024F104

22B-E1P7F104

22B-E3P0F104

22B-E4P2F104

22B-E6P6F104

(2)

22B-D010C104

–

–

–

22B-E1P7C104

22B-E3P0C104

22B-E4P2C104

22B-E6P6C104

5.5

7.5

7.5

9.9A

22B-E9P9N104

10.0

12.0A

22B-E012N104

C

C

22B-E9P9F104

22B-E012F104

–

–

11.0

15.0

19.0A

22B-E019N104 C 22B-E019F104 –

Meets IP40/54/65 (NEMA 1/12/4/4X) when installed in an enclosure of like rating.

Requires use of external DC Bus Inductor or AC Line Reactor. See

Table B.E

for details.



B-2

Accessories and Dimensions

Table B.C Dynamic Brake Modules

Drive Ratings

Input Voltage

120V 50/60 Hz

1-Phase

240V 50/60 Hz

1-Phase

0.4

0.75

1.5

2.2

kW

0.4

0.75

1.1

0.5

1.0

2.0

3.0

HP

0.5

1.0

1.5

48

48

48

32

Minimum

Resistance

Ω

48

48

48

Catalog Number

(1) (2)

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-047P500

240V 50/60 Hz

3-Phase

3.7

5.5

7.5

0.4

0.4

0.75

1.5

2.2

5.0

7.5

10.0

0.5

0.5

1.0

2.0

3.0

7.5

10.0

15.0

1.0

1.0

2.0

3.0

5.0

19

13

10

97

48

48

48

32

55

39

24

120

97

97

97

77

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-047P500

AK-R2-047P500

AK-R2-030P1K2

AK-R2-030P1K2

AK-R2-360P500

(1)

(2)

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

(3)

0.75

1.5

2.2

4.0

5.5

7.5

11.0

0.75

1.5

2.2

4.0

5.5

2.0

3.0

5.0

7.5

120

82

82

51

AK-R2-360P500

AK-R2-360P500

AK-R2-120P1K2

AK-R2-120P1K2

AK-R2-120P1K2

AK-R2-120P1K2

AK-R2-120P1K2

(3)

AK-R2-360P500

AK-R2-360P500

AK-R2-120P1K2

AK-R2-120P1K2

AK-R2-120P1K2

7.5

11.0

10.0

15.0

51

51

AK-R2-120P1K2

AK-R2-120P1K2

(3)

The resistors listed in this tables are rated for 5% duty cycle.

Use of Rockwell resistors is always recommended. The resistors listed have been carefully selected for optimizing performance in a variety of applications. Alternative resistors may be used, however care must be taken when making a selection. Refer to the PowerFlex Dynamic Braking

Resistor Calculator, publication PFLEX-AT001.

Requires two resistors wired in parallel.




B-3

Table B.D Bulletin 1321-3R Series Line Reactors

Input Voltage kW HP

240V 50/60 Hz

3-Phase

0.4

0.75

0.5

1.0

4

8

Fundamental

Amps

1.5

2.0

8

2.2

3.0

12

3.7

5.0

18

5.5

7.5

25

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

7.5

0.4

0.75

1.5

2.2

3.0

8

4.0

5.0

12

5.5

7.5

12

7.5

10.0

18

11.0

0.75

1.5

2.2

10.0

0.5

1.0

2.0

15.0

1.0

2.0

3.0

35

2

4

4

25

2

4

4

4.0

5.0

8

5.5

7.5

12

7.5

10.0

12

11.0

15.0

18

6

6

37.5

3

12

18

18

27

6

6

52.5

3

Maximum

Continuous

Amps

Inductance mh

6

12

12

18

27

37.5

12.0

3.0

1.5

1.25

0.8

0.5

Watts

Loss

21 W

29 W

Catalog

Number

(1)

1321-3R4-D

1321-3R8-B

19.5 W 1321-3R8-A

26 W 1321-3R12-A

36 W

48 W

1321-3R18-A

1321-3R25-A

0.4

20.0

9.0

6.5

49 W

11.3 W

20 W

20 W

1321-3R35-A

1321-3R2-B

1321-3R4-C

1321-3R4-B

12

18

18

27

5.0

2.5

2.5

1.5

1.2

20.0

6.5

6.5

5.0

2.5

2.5

1.5

25.3 W

31 W

31 W

43 W

52 W

11.3 W 1321-3R2-B

20 W

20 W

25.3 W

31 W

31 W

43 W

1321-3R8-C

1321-3R12-B

1321-3R12-B

1321-3R18-B

1321-3R25-B

1321-3R4-B

1321-3R4-B

1321-3R8-C

1321-3R12-B

1321-3R12-B

1321-3R18-B

(1)

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-TD001….

Table B.E DC Bus Inductors

Input Voltage

240V 50/60 Hz

3-Phase

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

(2)

kW

5.5

7.5

5.5

7.5

11.0

5.5

7.5

11.0

HP

7.5

10.0

7.5

10.0

15.0

7.5

10.0

15.0

Use MTE RB Series or equivalent inductors.

12

18

25

Amps

32

40

18

25

32

6.0

6.0

4.0

Inductance mh

0.85

0.5

3.75

4.0

2.68

MTE Catalog Number

(2)

32RB001

40RB001

18RB004

25RB005

32RB003

12RB004

18RB005

25RB005



B-4


Table B.F EMC Line Filters

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

600V 50/60 Hz

3-Phase

11.0

0.75

1.5

2.2

2.2

4.0

5.5

7.5

4.0

5.5

7.5

11.0

7.5

0.4

0.75

1.5

1.5

2.2

3.7

5.5

1.5

2.2

0.4

0.75

kW

0.4

0.75

1.1

0.4

0.75

15.0

1.0

2.0

3.0

3.0

5.0

7.5

10.0

5.0

7.5

10.0

15.0

10.0

0.5

1.0

2.0

2.0

3.0

5.0

7.5

2.0

3.0

0.5

1.0

HP

0.5

1.0

1.5

0.5

1.0

(2)

(2)

(2)

–

–

(2)

S Type Filter

Catalog Number

(1)

–

22-RF021-BS

(3)

22-RF021-BS

(3)

22-RF021-BS

(3)

22-RF021-BS

(3)

22-RF021-BS

(3)

22-RF034-CS

22-RF034-CS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF018-CS

22-RF018-CS

–

–

–

–

–

–

22-RF026-CS

–

22-RF012-BL

22-RF012-BL

22-RF018-CL

22-RF018-CL

22-RF026-CL

22-RF8P0-BL

22-RF8P0-BL

22-RF8P0-BL

22-RF8P0-BL

22-RF015-CL

22-RF015-CL

22-RF024-CL

L Type Filter

Catalog Number

(4)

22-RF018-BL

22-RF018-BL

22-RF018-BL

22-RF018-BL

22-RF018-BL

22-RF018-BL

22-RF025-CL

22-RF021-BL

22-RF021-BL

22-RF021-BL

22-RF021-BL

22-RF021-BL

22-RF034-CL

22-RF034-CL

22-RF012-BL

22-RF012-BL

22-RF012-BL

(1)

(2)

(3)

(4)

This filter is suitable for use with a cable length of at least 10 meters (33 feet) for Class A and 1 meter for Class B environments.

These ratings can be ordered with internal “S Type” filters. Refer to the Catalog Number

explanation on page P-4

and Table B.B

for details.

Filter must be Series B or later.

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.




B-5

Table B.G Human Interface Module (HIM) Option Kits and Accessories

Item

LCD Display, Remote Panel

Mount

LCD Display, Remote Panel

Mount

Description

Digital speed control

CopyCat capable

IP66 (NEMA Type 4X/12) indoor use only

Includes 2.9 meter cable

Digital speed control

CopyCat capable

IP66 (NEMA Type 4X/12) indoor use only


LCD Display, Remote Handheld Digital speed control

Full numeric keypad

CopyCat capable

IP30 (NEMA Type 1)


Panel mount with optional Bezel Kit

Bezel Kit

DSI HIM Cable

(DSI HIM to RJ45 cable)

Panel mount for LCD Display, Remote

Handheld unit, IP30 (NEMA Type 1)

1.0 Meter (3.3 Feet)

2.9 Meter (9.51 Feet)

Catalog Number

22-HIM-C2S

22-HIM-C2

22-HIM-A3

22-HIM-B1

22-HIM-H10

22-HIM-H30

Table B.H IP30/NEMA 1/UL Type 1 Kit

Item

IP30/NEMA 1/UL Type 1

Kit

Description

Field installed kit. Converts drive to IP30/

NEMA 1/UL Type 1 enclosure. Includes conduit box with mounting screws and plastic top panel.

IP30/NEMA 1/UL Type 1

Kit for Communication

Option

Field installed kit. Converts drive to IP30/

NEMA 1/UL Type 1 enclosure. Includes communication option conduit box with mounting screws and plastic top panel.

Drive

Frame Catalog Number

B 22-JBAB

C 22-JBAC

B 22-JBCB

C 22-JBCC



B-6


Table B.I Communication Option Kits and Accessories

Item

Communication

Adapters

Description

Embedded communication options for use with the PowerFlex 4-Class drives.

Requires a Communication Adapter Cover (IP20,

NEMA/UL Type 1 only. Ordered Separately)

BACnet®

ControlNet™

DeviceNet™

EtherNet/IP™

LonWorks®

PROFIBUS™ DP

External mounting kit for 22-COMM communication options

External DSI™

Communications Kit

External Comms Power

Supply

Compact I/O Module

Optional 100-240V AC Power Supply for External

DSI Communications Kit.

Three channel.

Communication Adapter

Cover

Cover that houses the DeviceNet Communication

Adapter (IP20, NEMA/UL Type 1 only)

B Frame Drive

C Frame Drive

Catalog Number

22-COMM-B

22-COMM-C

22-COMM-D

22-COMM-E

22-COMM-L

22-COMM-P

22-XCOMM-DC-BASE

20-XCOMM-AC-PS1

1769-SM2

22B-CCB

22B-CCC

22-SCM-232 Serial Converter Module

(RS485 to RS232)

Provides serial communication via DF1 protocol for use with DriveExplorer and DriveExecutive software. Includes:

DSI to RS232 serial converter (1)

1203-SFC serial cable (1)

22-RJ45CBL-C20 cable (1)

DriveExplorer Lite CD (1)

DSI Cable

Serial Cable

2.0 meter RJ45 to RJ45 cable, male to male connectors.

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.

22-RJ45CBL-C20

1203-SFC

Null Cable Converter

Splitter Cable

DriveExplorer Software

(CD-ROM) Version 3.01 or later

For use when connecting the serial converter to

DriveExplorer on a handheld PC.

RJ45 one to two port splitter cable

Terminating Resistors RJ45 120 Ohm resistors (2 pieces)

Terminal Block RJ45 Two position terminal block (5 pieces)

Windows based software package that provides an intuitive means for monitoring or configuring

Allen-Bradley drives and communication adapters online.

Compatibility:

Windows 95, 98, ME, NT 4.0 (Service Pack 3 or later), 2000, XP and CE

(1)

1203-SNM

AK-U0-RJ45-SC1

AK-U0-RJ45-TR1

AK-U0-RJ45-TB2P

9306-4EXP01ENE

DriveExecutive software

(CD-ROM) Version 1.01 or later

Windows based software package that provides an intuitive means for monitoring or configuring

Allen-Bradley drives and communication adapters online and offline.

Compatibility:

Windows 98, ME, NT 4.0 (Service Pack 3 or later), 2000 and XP

9303-4DTE01ENE

(1)

See www.ab.com/drives/driveexplorer.htm for supported devices.




B-7

Product Dimensions

Table B.J PowerFlex 40 Frames – Ratings are in kW and (HP)

Frame

B

C

(1)

(1)

120V AC –

1-Phase

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

240V AC –

1-Phase

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

240V AC –

3-Phase

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

5.5 (7.5)

7.5 (10.0)

2.2 (3.0)

3.7 (5.0)

480V AC –

3-Phase

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

5.5 (7.5)

7.5 (10.0)

2.2 (3.0)

4.0 (5.0)

IP66, NEMA/UL Type 4X rated drives are not availble in Frame C drive ratings.

600V AC –

3-Phase

0.75 (1.0)

1.5 (2.0)

11.0 (15.0) 5.5 (7.5)

7.5 (10.0)

2.2 (3.0)

4.0 (5.0)

11.0 (15.0)

A

D

Figure B.1 IP20, NEMA/UL Type Open

C

Dimensions are in millimeters and (inches).

Weights are in kilograms and (pounds).

E

B

F

Frame A

B 100

(3.94)

C 130

(5.1)

B

180

(7.09)

260

(10.2)

C

136

(5.35)

180

(7.1)

D

87

(3.43)

116

(4.57)

E

168

(6.61)

246

(9.7)

F

87.4

(3.44)

–

Ship

Weight

2.2

(4.9)

4.3

(9.5)

5.5 (0.22)

Figure B.2 IP30, NEMA/UL Type 1 Option Kit without Communication Option

79.1 (3.11)

64.1 (2.52)

40.6 (1.60)

25.6 (1.01) ∅

22.2

(0.87)

74.3

(2.93)

109.9

(4.33)

33.0

(1.30)

Frame B - 22-JBAB

107.0 (4.21)

66.0 (2.60)

24.0 (0.94)

∅

28.5

(1.12)

∅

22.2

(0.87)

111.2

(4.38)

152.2

(5.99)

60.0

(2.36)

Frame C - 22-JBAC



B-8


Figure B.3 IP30, NEMA/UL Type 1 Option Kit with Communication Option –

Dimensions are in millimeters and (inches)

25.0

(0.98)

77.5 (3.05)

50.0 (1.97)

22.5 (0.89)

∅

22.2

(0.87)

134.3

(5.29)

105.3

(4.15)

76.3

(3.00) 64.0

(2.52)

Frame B - 22-JBCB

25.0

(0.98)

60.0

(2.36)

Frame C - 22-JBCC

108.7 (4.28)

92.2 (3.63)

69.2 (2.72)

45.7 (1.80)

22.2 (0.87)

∅

28.5

(1.12)

∅

22.2

(0.87)

179.8

(7.08)

144.8

(5.70)

109.8

(4.32)




B-9

Figure B.4 PowerFlex 40 Flange Mount Drives – Dimensions are in millimeters and

(inches)

244

(9.61)

214

(8.43)

94.3

(3.71)

63.1

(2.48)

250

(9.84)

300

(11.81)

Frame B

130.3

(5.13)

105.8

(4.17)

138.2

(5.44)

325

(12.8)

22B-CCC

Frame C



B-10


Figure B.5 PowerFlex 40 Flange Mount Cutout Dimensions – Dimensions are in millimeters and (inches)

6.5

(0.26)

145

(5.71)

23.5

(0.93)

197

(7.76)

225

(8.86)

98.5

(3.88)

210

(8.27)

307.5

(12.11)

14

(0.55)

31

(1.22)

49

(1.93)

98

(3.86)

160

(6.30)

Frame B

8

(0.31)

164

(6.46)

230.6

(9.08)

153.8

(6.06)

76.9

(3.03)

90

(3.54)

180

(7.09)

Frame C



7.5

(0.30)

5.3

(0.21)

291.5

(11.48)

5.3

(0.21)

8

(0.31)


B-11

Figure B.6 PowerFlex 40 Replacement Plate Drive Dimensions – Dimensions are in millimeters and (inches)

112

(4.41)

80

(3.15)

125

(4.92)

88

(3.46)

9.5

(0.37)

192

(7.56)

204

(8.03)

96

(3.78)

180

(7.09)

100

(3.94)

142

(5.59)

80

(3.15)

155

(6.10)

5.3

(0.21)

Frame B

123.5

(4.86)

98.5

(3.88)

9.5

(0.37)

272

(10.71)

284

(11.18)

260

(10.24)

136

(5.35)

130

(5.12)

5.3

(0.21)

Frame C

22B-CCC



B-12


Figure B.7 IP66, NEMA Type/UL Type 4X – Dimensions are in millimeters and (inches)


165

(6.50)

146

(5.75)

6.5

(0.26)

46

(1.81)

23

(0.91)

270

(10.63)

253

(9.96)

28

(1.10)

22

(0.87)

198

(7.80)

124

(4.88)

89

(3.50)

82.5

(3.25)

Weight

5.2 (11.5)




B-13

Figure B.8 Dynamic Brake Modules – Dimensions are in millimeters and (inches).


17.0

(0.67)

Frame A

30.0

(1.18)

60.0

(2.36)

31.0

(1.22)

61.0

(2.40)

Frame B

59.0

(2.32)

316.0

(12.44)

335.0

(13.19)

386.0

(15.20)

405.0

(15.94)

SURFACES MAY BE

13.0

(0.51)

Frame

A

B

Catalog Number Weight

AK-R2-091P500, AK-R2-047P500, AK-R2-360P500 1.1 (2.5)

AK-R2-030P1K2, AK-R2-120P1K2 2.7 (6)

Figure B.9 Recommended External Brake Resistor Circuitry

Three-Phase

AC Input

(Input Contactor) M

R (L1)

S (L2)

T (L3)

Power Off Power On

Power Source

M

M

DB Resistor Thermostat



B-14


Figure B.10 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

1321-3R4-C

1321-3R4-D

1321-3R8-A

1321-3R8-B

1321-3R8-C

1321-3R12-A

1321-3R12-B

1321-3R18-A

1321-3R18-B

1321-3R25-A

1321-3R35-A

A B C D E Weight

112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4)

112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4)

112 (4.40) 104 (4.10) 76 (3.00) 50 (1.98) 37 (1.44) 1.8 (4)

112 (4.40) 104 (4.10) 76 (3.00) 50 (1.98) 37 (1.44) 1.8 (4)

112 (4.40) 104 (4.10) 86 (3.38) 60 (2.35) 37 (1.44) 2.3 (5)

112 (4.40) 104 (4.10) 92 (3.62) 66 (2.60) 37 (1.44) 2.7 (6)

152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.1 (7)

152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.6 (8)

152 (6.00) 127 (5.00) 85 (3.35) 63 (2.48) 51 (2.00) 4.9 (11)

152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 4.1 (9)

152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 4.5 (10)

152 (6.00) 133 (5.25) 79 (3.10) 54 (2.13) 51 (2.00) 4.1 (9)

152 (6.00) 133 (5.25) 86 (3.40) 63 (2.48) 51 (2.00) 5.4 (12)

183 (7.20) 146 (5.76) 85 (3.35) 60 (2.35) 76 (3.00) 4.9 (11)

193 (7.60) 146 (5.76) 91 (3.60) 66 (2.60) 76 (3.00) 6.3 (14)




B-15

Figure B.11 Frame B EMC Line Filters – Dimensions are in millimeters and (inches)

Catalog Numbers: 22-RF8P0-BL, 22-RF012-BS, -BL (Series B); 22-RF018-BS;

22-RF021-BS, -BL

29.8

(1.17)

50

(1.97)

78

(3.07)

100

(3.94)

217

(8.54)

229

(9.02)

216

(8.50)

17.8

(0.70)

24.0

(0.94)

5.5 (0.22)



B-16


Figure B.12 Frame C EMC Line Filters – Dimensions are in millimeters and (inches)

Catalog Numbers: 22-RF018-CS, -CL; 22-RF025-CL; 22-RF026-CS, -CL; 22-RF034-CS,

-CL

32

(1.26)

60

(2.36)

90

(3.54)

130

(5.12)

297

(11.69)

309

(12.17)

297

(11.69)

17

(0.67)

30

(1.18)

5.5 (0.22)




B-17

Figure B.13 Remote (Panel Mount) Small HIM – Dimensions are in millimeters and

(inches) Catalog Number: 22-HIM-C2S

25

(0.98)

93

(3.66)

180

(7.09)

2m

67

(2.64)

60

(2.36)

19.1

(0.75)

4.8

(0.19)

77

(3.03)

154

(6.06)

23.5

(0.93)



B-18


Figure B.14 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches)

Catalog Number: 22-HIM-B1

93

(3.66)

11.1

(0.44)

25.2

(0.99)

180

(7.09)

2m

67

(2.64)

60

(2.36)

4.8

(0.19)

19.1

(0.75)

23.5

(0.93)

77

(3.03)

154

(6.06)



Appendix

C

RS485 (DSI) Protocol

PowerFlex 40 drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some

Modbus functions are supported to allow simple networking. PowerFlex

40 drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.

Controller

For information regarding DeviceNet or other communication protocols, refer to the appropriate user manual.

Network Wiring

Network wiring consists of a shielded 2-conductor cable that is daisy-chained from node to node.

Figure C.1 Network Wiring Diagram

Master

TxRxD+

TxRxD-

PowerFlex 40

Node 1

4

TxRxD+

PowerFlex 40

Node 2

4

120 ohm resistor

TxRxD-

5 5

Shield Shield

TxRxD+

PowerFlex 40

Node "n"

4

120 ohm resistor

TxRxD-

5

Shield

PIN 1

PIN 8

FRONT

NOTE: The shield should be grounded at ONLY ONE location.

01 02 03 04 05 06 07 08 09

01 02 03 04 05 06 07 08 09

R/L1 S/L2

11 12 13 14 15 16 17 18 19

RS485

(DSI)

T/L3 U/T1 V/T2 W/T3

11 12 13 14 15 16 17 18 19

RS485

(DSI)

AK-U0-RJ45-TB2P

TxRxD-

TxRxD+

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

TxRxD-

TxRxD+

DC- DC+ BR+ BR-

DC- DC+ BR+ BR-



C-2

RS485 (DSI) Protocol

Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 40 RJ45 socket must not be connected because they contain power, etc. for other Rockwell Automation peripheral devices.

Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+” and “TxRxD-” are shown for illustration purposes only. Refer to the master controller’s user manual for network terminations. Note that there is no standard for the “+” and

“-” wires, and consequently Modbus device manufacturers interpret them differently. If you have problems with initially establishing communications, try swapping the two network wires at the master controller.

Standard RS485 wiring practices apply.

•

Termination resistors need to be applied at each end of the network cable.

•

RS485 repeaters may need to be used for long cable runs, or if greater than 32 nodes are needed on the network.

•

Network wiring should be separated from power wires by at least 0.3 meters (1 foot).

•

Network wiring should only cross power wires at a right angle.

I/O Terminal 19 on the PowerFlex 40 is connected to the metal shield around the RJ45 connector. It is recommended to ground this terminal

(there are two PE terminals on the drive). See

Table 1.H

for more

information.

Network Common is internally tied to I/O Terminal 04 (Digital

Common). Tying I/O Terminal 04 to PE ground may improve noise immunity in some applications.




C-3

Parameter Configuration

The following PowerFlex 40 parameters are used to configure the drive to operate on a network.

Parameter Details

P036 [Start Source] Set to 5 “RS485 (DSI) Port” if Start is controlled from the network.

P038 [Speed Reference] Set to 5 “RS485 (DSI) Port” if the Speed Reference is controlled from the network.

Reference

Page 3-10

Page 3-12

A103 [Comm Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes on the network must be set to the same data rate.

A104 [Comm Node Addr] Sets the node address for the drive on the network.

Each device on the network requires a unique node address.

A105 [Comm Loss Action] Selects the drive’s response to communication problems.

A106 [Comm Loss Time] Sets the time that the drive will remain in communication loss before the drive implements A105

[Comm Loss Action].

A107 [Comm Format] Sets the transmission mode, data bits, parity and stop bits for the RS485 (DSI) Port. All nodes on the network must be set to the same setting.

Page 3-31

Page 3-31

Page 3-32

Page 3-32

Page 3-32

Supported Modbus Function Codes

The peripheral interface (DSI) used on PowerFlex 40 drives supports some of the Modbus function codes.

Modbus Function Code (Decimal) Command

03 Read Holding Registers

06

16 (10 Hexadecimal)

Preset (Write) Single Register

Preset (Write) Multiple Registers

Important: Modbus devices can be 0-based (registers are numbered starting at 0) or 1-based (registers are numbered starting at

1). Depending on the Modbus Master used, the register addresses listed on the following pages may need to be offset by +1. For example, Logic Command may be register address 8192 for some master devices (e.g. ProSoft

3150-MCM SLC Modbus scanner) and 8193 for others

(e.g. PanelViews).



C-4


Writing (06) Logic Command Data

The PowerFlex 40 drive can be controlled via the network by sending

Function Code 06 writes to register address 8192 (Logic Command).

P036 [Start Source] must be set to 5 “RS485 (DSI) Port” in order to accept the commands.

In addition to being written, register address 8192 can be read using

Function Code 03.

Address (Decimal) Bit(s)

0

1

2

3

8192

5,4

6

7

9,8

11,10

14,13,12

15

Logic Command

Description

1 = Stop, 0 = Not Stop

1 = Start, 0 = Not Start

1 = Jog, 0 = No Jog

1 = Clear Faults, 0 = Not Clear Faults

00 = No Command

01 = Forward Command

10 = Reverse Command

11 = No Command

Not Used in FRN 3.03 and earlier.

In FRN 4.01 and later, activates Opto Output 1.

Note: This bit controls the output when the value of parameter

A058 is set to 20.


In FRN 4.01 and later, activates Opto Output 2.


A061 is set to 20.

00 = No Command

01 = Accel Rate 1 Enable

10 = Accel Rate 2 Enable

11 = Hold Accel Rate Selected

00 = No Command

01 = Decel Rate 1 Enable

10 = Decel Rate 2 Enable

11 = Hold Decel Rate Selected

000 = No Command

001 = Freq. Source = P038 [Speed Reference]

010 = Freq. Source = A069 [Internal Freq]

011 = Freq. Source = Comms (Addr 8193)

100 = A070 [Preset Freq 0]





In FRN 4.01 and later, activates C-form relay.


A055 is set to 20.




C-5

Writing (06) Reference

The Speed Reference to a PowerFlex 40 drive can be controlled via the network by sending Function Code 06 writes to register address 8193

(Reference). P038 [Speed Reference] must be set to 5 “RS485 (DSI)

Port” in order to accept the Speed Reference.

In addition to being written, register address 8193 can be read using

Function Code 03.

Reference

Address (Decimal) Description

8193

A decimal value entered as xxx.x where the decimal point is fixed. For example, a decimal “100” equals 10.0 Hz and “543” equals 54.3 Hz.

Reading (03) Logic Status Data

The PowerFlex 40 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 (Logic Status).

Address (Decimal) Bit(s)

0

1

2

3

8448

8

9

10

11

4

5

6

7

12

13

14

15

(1)

Logic Status

Description

1 = Ready, 0 = Not Ready

1 = Active (Running), 0 = Not Active

1 = Cmd Forward, 0 = Cmd Reverse

1 = Rotating Forward, 0 = Rotating Reverse

1 = Accelerating, 0 = Not Accelerating

1 = Decelerating, 0 = Not Decelerating

1 = Alarm, 0 = No Alarm

1 = Faulted, 0 = Not Faulted

1 = At Reference, 0 = Not At Reference

1 = Reference Controlled by Comm

1 = Operation Cmd Controlled by Comm

1 = Parameters have been locked

Digital Input 1 Status



(1)


(1)

This status is available only with firmware revision FRN 2.xx and higher.



C-6


Reading (03) Feedback

The Feedback (Output Frequency) from the PowerFlex 40 drive can be read via the network by sending Function Code 03 reads to register address 8451 (Feedback).

Feedback

(2)

Address (Decimal) Description

8451

A xxx.x decimal value where the decimal point is fixed. For example, a decimal

“123” equals 12.3 Hz and “300” equals 30.0 Hz.

(2)

Returns the same data as Reading (03) Parameter d001 [Output Freq].

Reading (03) Drive Error Codes

The PowerFlex 40 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error

Codes).

Logic Status

Address (Decimal) Value (Decimal) Description

0

2

3

4

No Fault

Auxiliary Input

Power Loss

Undervoltage

5

6

7

8

Overvoltage

Motor Stalled

Motor Overload

Heatsink Overtemperature

8449 38

39

40

41

12

13

29

33

HW Overcurrent (300%)

Ground Fault

Analog Input Loss

Auto Restart Tries

Phase U to Ground Short

Phase V to Ground Short

Phase W to Ground Short

Phase UV Short

70

80

81

100

122

42

43

63

64

Phase UW Short

Phase VW Short

Software Overcurrent

Drive Overload

Power Unit Fail

AutoTune Fail

Communication Loss

Parameter Checksum Error

I/O Board Fail




Reading (03) and Writing (06) Drive Parameters

To access drive parameters, the Modbus register address equals the parameter number. For example, a decimal “1” is used to address

Parameter d001 [Output Freq] and decimal “39” is used to address

Parameter P039 [Accel Time 1].

C-7

Additional Information

Refer to

http://www.ab.com/drives/

for additional information.



C-8

Notes:




Appendix

D

RJ45 DSI Splitter Cable

The PowerFlex 40 drive provides a RJ45 port to allow the connection of a single peripheral device. The RJ45 DSI Splitter Cable can be used to connect a second DSI peripheral device to the drive.

Connectivity Guidelines

!

ATTENTION: Risk of injury or equipment damage exists. The peripherals may not perform as intended if these Connectivity

Guidelines are not followed. Precautions should be taken to follow these Connectivity Guidelines.

•

Two peripherals maximum can be attached to a drive.

•

If a single peripheral is used, it must be connected to the Master port

(M) on the splitter and configured for “Auto” (default) or “Master.”

Parameter 9 [Device Type] on the DSI / MDI keypads and Parameter

1 [Adapter Cfg] on the Serial Converter are used to select the type

(Auto / Master / Slave).

•

Do not use the RJ45 Splitter Cable with a drive that has an

internal network communication adapter installed. Since only one additional peripheral can be added, the second peripheral can be connected directly to the RJ45 port on the drive. The internal Comm is always the Master, therefore the external peripheral must be configured as “Auto” (for temporary connections) or “Slave” (for permanent connections).

•

If two peripherals will be powered up at the same time, one must be configured as the “Master” and connected to the Master port (M) and the other must be connected as the “Slave” and connected to the

Slave port (S).



D-2

RJ45 DSI Splitter Cable

DSI Cable Accessories

RJ45 Splitter Cable

– Catalog Number: AK-U0-RJ45-SC1

Slave Port

Master Port

PIN 1 PIN 8

RJ45 Two-Position Terminal Block Adapter

–

Catalog Number: AK-U0-RJ45-TB2P

TB2

(PIN 5) PIN 8

TB1

(PIN 4) PIN 1

RJ45 Adapter with Integrated Termination Resistor

–

Catalog Number: AK-U0-RJ45-TR1

PIN 8

PIN 1




Connecting One Temporary Peripheral

DSI / MDI Drive

Serial Converter

DSI / MDI

Hand Held or

M

DSI

S

Parameter 1 [Adapter Cfg] set to "Auto"

(default) or "Master" and connected to

Master port (M) on RJ45 Splitter Cable

D-3

Parameter 9 [Device Type] set to "Auto"

(default) or "Master" and connected to

Master port (M) on RJ45 Splitter Cable

Connecting One Temporary Peripheral and

One Permanent Peripheral

NEMA 1 Bezel with DSI / MDI Hand Held

NEMA 4

Panel Mount Unit

DSI / MDI Drive or

DSI

M

S

Parameter 1 [Adapter Cfg] set to "Auto" (default) or

"Slave" and connected to

Slave port (S) on RJ45 Splitter Cable Serial Converter

Parameter 9 [Device Type] set to "Master" and connected to Master port (M) on RJ45 Splitter Cable



D-4


Connecting Two Permanent Peripherals

NEMA 1 Bezel with DSI / MDI Hand Held

NEMA 4

Panel Mount Unit

DSI / MDI Drive or

M

S

Parameter 9 [Device Type] set to

"Master" and connected to Master port (M) on RJ45 Splitter Cable

Parameter 9 [Device Type] set to "Slave" and connected to Slave port (S) on RJ45 Splitter Cable or

Connecting an RS-485 Network

DSI / MDI Drives

AK-U0-RJ45-TR1

Terminating Resistor

(end of network)

AK-U0-RJ45-SC1

AK-U0-RJ45-TB2P

Two-position Terminal Block or or

Customer supplied RJ45 male-to-RJ45 male cables with wires connected at pins 4 and 5 only.

Both the Master (M) and Slave (S) ports on the RJ45 Splitter

Cable operate as standard RS-485 ports in this configuration.



Appendix

E

StepLogic™, Basic Logic and

Timer/Counter Functions

Four PowerFlex 40 logic functions provide the capability to program simple logic functions without a separate controller.

•

StepLogic Function

Steps through up to eight preset speeds based on programmed logic.

Programmed logic can include conditions that need to be met from digital inputs programmed as “Logic In1” and “Logic In2” before stepping from one preset speed to the next. A timer is available for each of the eight steps and is used to program a time delay before stepping from one preset speed to the next. The status of a digital output can also be controlled based on the step being executed.

•

Basic Logic Function

Up to two digital inputs can be programmed as “Logic In1” and/or

“Logic In2”. A digital output can be programmed to change state based on the condition of one or both inputs based on basic logic functions such as AND, OR, NOR. The basic logic functions can be used with or without StepLogic.

•

Timer Function

A digital input can be programmed for “Timer Start”. A digital output can be programmed as a “Timer Out” with an output level programmed to the desired time. When the timer reaches the time programmed into the output level the output will change state. The timer can be reset via a digital input programmed as “Reset Timer”.

•

Counter Function

A digital input can be programmed for “Counter In”. A digital output can be programmed as “Counter Out” with an output level programmed to the desired number of counts. When the counter reaches the count programmed into the output level the output will change state. The counter can be reset via a digital input programmed as “Reset Counter”.



E-2

StepLogic™, Basic Logic and Timer/Counter Functions

StepLogic Using Timed Steps

To activate this function, set parameter P038 [Speed Reference] to 6 “Stp

Logic”. Three parameters are used to configure the logic, speed reference and time for each step.

•

Logic is defined using parameters A140-A147 [Stp Logic x].

•

Preset Speeds are set with parameters A070-A077 [Preset Freq x].

•

Time of operation for each step is set with parameters A150-A157

[Stp Logic Time x].

The direction of motor rotation can be forward or reverse.

Figure E.1 Using Timed Steps

Step 0 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7

Forward

0

Reverse

Time

StepLogic Sequence

•

Sequence begins with a valid start command.

•

A normal sequence begins with Step 0 and transition to the next step when the corresponding StepLogic time has expired.

•

Step 7 is followed by Step 0

•

Sequence repeats until a stop is issued or a fault condition occurs.




E-3

StepLogic Using Basic Logic Functions

Digital input and digital output parameters can be configured to use logic to transition to the next step. Logic In1 and Logic In2 are defined by programming parameters A051-A054 [Digital Inx Sel] to option 23

“Logic In1” or option 24 “Logic In2”.

Example

•

Run at Step 0.

•

Transition to Step 1 when Logic In1 is true.

Logic senses the edge of Logic In1 when it transitions from off to on.

Logic In1 is not required to remain “on”.

•

Transition to Step 2 when both Logic In1 and Logic In2 are true.

The drive senses the level of both Logic In1 and Logic In2 and transitions to Step 2 when both are on.

•

Transition to Step 3 when Logic In2 returns to a false or off state.

Inputs are not required to remain in the “on” condition except under the logic conditions used for the transition from Step 2 to Step 3.

Start Step 0 Step 1 Step 2 Step 3

Frequency

Logic In1

Logic In2

Time

The step time value and the basic logic may be used together to satisfy machine conditions. For instance, the step may need to run for a minimum time period and then use the basic logic to trigger a transition to the next step.

Start Step 0 Step 1

Frequency

Logic In1

Logic In2

Time



E-4


Timer Function

Digital inputs and outputs control the timer function and are configured with parameters A051-A054 [Digital Inx Sel] set to 18 “Timer Start” and

20 “Reset Timer”.

Digital outputs (relay and opto type) define a preset level and indicate when the level is reached. Level parameters A056 [Relay Out Level],

A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the desired time in seconds.

Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061

[Opto Out2 Sel] are set to option 16 “Timer Out” and causes the output to change state when the preset level is reached.

Example

•

Drive starts up and accelerates to 30 Hz.

•

After 30Hz has been maintained for 20 seconds, a 4-20mA analog input becomes the reference signal for speed control.

•

The timer function is used to select a preset speed with a 20 second run time that overrides the speed reference while the digital input is active.

•

Parameters are set to the following options:

–

P038 [Speed Reference] = 3 “4-20mA Input”

–

A051 [Digital In1 Sel] = 4 “Preset Freq”

–

A052 [Digital In2 Sel] = 18 “Timer Start”

–

A055 [Relay Out Sel] = 16 “Timer Out”

–

A056 [Relay Out Level] = 20.0 Secs

–

A071 [Preset Freq 1] = 30.0 Hz

•

The control terminal block is wired such that a start command will also trigger the timer start.

•

The relay output is wired to I/O Terminal 05 (Digital Input 1) so that it forces the input on when the timer starts.

•

After the timer is complete, the output is turned off releasing the preset speed command. The drive defaults to following the analog input reference as programmed.




E-5

Output

Frequency

Start

Relay Out

Photo Eye

Digital In1

Counter In

Digital In2

Reset Counter

Limit Switch

Note that a “Reset Timer” input is not required for this example since the

“Timer Start” input both clears and starts the timer.



E-6


Counter Function

Digital inputs and outputs control the counter function and are configured with parameters A051-A054 [Digital Inx Sel] set to 19

“Counter In” and 21 “Reset Counter”.

Digital outputs (relay and opto type) define a preset level and indicate when the level is reached. Level parameters A056 [Relay Out Level],

A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the desired count value.

Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061

[Opto Out2 Sel] are set to 17 “Counter Out” which causes the output to change state when the level is reached.

Example

•

A photo eye is used to count packages on a conveyor line.

•

An accumulator holds the packages until 5 are collected.

•

A diverter arm redirects the group of 5 packages to a bundling area.

•

The diverter arm returns to its original position and triggers a limit switch that resets the counter.

•

Parameters are set to the following options:

–

A051 [Digital In1 Sel] set to 19 to select “Counter In”

–

A052 [Digital In2 Sel] set to 21 to select “Reset Counter”

–

A055 [Relay Out Sel] set to 17 to select “Counter Out”

–

A056 [Relay Out Level] set to 5.0 (counts)




E-7

StepLogic Parameters

Table E.A Code Descriptions for Parameters A140-A147

Digit 3

0

Digit 2

0

Digit 1

F

Digit 0

1

8

9

A b

4

5

6

7

1

2

3

Setting

0

Table E.B Digit 3 – Defines the action during the step currently executing.

2

2

2

2

1

1

2

2

1

1

1

1

Accel/Decel

Parameters Used

Off

On

On

On

On

On

Off

Off

StepLogic Output

State

Off

Off

Off

On

Commanded Direction

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

Table E.C Digit 2 – Defines what step to jump to or how to end program when the logic conditions specified in Digit 1 are met.

5

6

7

8

9

A

1

2

3

4

Setting

0

Logic

Jump to Step 0

Jump to Step 1

Jump to Step 2

Jump to Step 3

Jump to Step 4

Jump to Step 5

Jump to Step 6

Jump to Step 7

End Program (Normal Stop)

End Program (Coast to Stop)

End Program and Fault (F2)



E-8

StepLogic™, Basic Logic and Timer/Counter Functions b

C d

E

F

6

7

8

9

2

3

4

5

Table E.D Digit 1 – Defines what logic must be met to jump to a step other than the very next step.

Setting

0

1

A

Description

Skip Step (jump immediately)

Logic

SKIP

Step based on the time programmed in the respective [Stp Logic Time x] parameter.

TIMED

Step if “Logic In1” is active (logically true)


Step if “Logic In1” is not active (logically false)


TRUE

TRUE

FALSE

FALSE

Step if either “Logic In1” or “Logic In2” is active (logically true)

Step if both “Logic In1” and “Logic In2” is active (logically true)

Step if neither “Logic In1” or “Logic In2” is active (logically true)

Step if “Logic In1” is active (logically true) and “Logic In2” is not active

(logically false)

OR

AND

NOR

XOR


(logically false)

Step after [Stp Logic Time x] and “Logic In1” is active (logically true)

XOR

TIMED AND

Step after [Stp Logic Time x] and “Logic In2” is active (logically true) TIMED AND

Step after [Stp Logic Time x] and “Logic In1” is not active (logically false) TIMED OR


Do not step OR no “jump to”, so use Digit 0 logic IGNORE d

E b

C

F

2

3

4

5

6

7

8

9

Table E.E Digit 0 – Defines what logic must be met to jump to the very next step.

Setting

0

1

A

Description

Skip Step (jump immediately)

Logic

SKIP

Step based on the time programmed in the respective [Stp Logic Time x] parameter.

TIMED





Step if either “Logic In1” or “Logic In2” is active (logically true)

TRUE

TRUE

FALSE

FALSE

OR

Step if both “Logic In1” and “Logic In2” is active (logically true)

Step if neither “Logic In1” or “Logic In2” is active (logically true)


(logically false)


(logically false)



AND

NOR

XOR

XOR

TIMED AND

TIMED AND



Use logic programmed in Digit 1 IGNORE



Appendix

F

PID Set Up

PID Loop

The PowerFlex 40 has a built-in PID (proportional, integral, differential) control loop. The PID loop is used to maintain a process feedback (such as pressure, flow or tension) at a desired set point. The PID loop works by subtracting the PID feedback from a reference and generating an error value. The PID loop reacts to the error, based on the PID Gains, and outputs a frequency to try to reduce the error value to 0. To enable the

PID loop, parameter A132 [PID Ref Sel] must be set to an option other than 0 “PID Disabled”.

Exclusive Control and Trim Control are two basic configurations where the PID loop may be used.



F-2

PID Set Up

Exclusive Control

In Exclusive Control, the Speed Reference becomes 0, and the PID

Output becomes the entire Freq Command. Exclusive Control is used when A132 [PID Ref Sel] is set to option 1, 2, 3 or 4. This configuration does not require a master reference, only a desired set point, such as a flow rate for a pump.

PID Ref

PID Fdbk

–

+

PID

Error

PID Loop

PID Prop Gain

PID Integ Time

+

+

+

PID Diff Rate

PID

Output

PID Enabled

Accel/Decel

Ramp

Freq

Command

Example

•

In a pumping application, the PID Reference equals the Desired

System Pressure set point.

•

The Pressure Transducer signal provides PID Feedback to the drive.

Fluctuations in actual system pressure, due to changes in flow, result in a PID Error value.

•

The drive output frequency increases or decreases to vary motor shaft speed to correct for the PID Error value.

•

The Desired System Pressure set point is maintained as valves in the system are opened and closed causing changes in flow.

•

When the PID Control Loop is disabled, the Commanded Speed is the Ramped Speed Reference.

PID Feedback =

Pressure Transducer Signal

Pump

PID Reference =

Desired System Pressure



PID Set Up

F-3

Trim Control

In Trim Control, the PID Output is added to the Speed Reference. In

Trim mode, the output of the PID loop bypasses the accel/decel ramp as shown. Trim Control is used when A132 [PID Ref Sel] is set to option 5,

6, 7 or 8.

PID Ref

PID Fdbk

–

+

PID

Error

PID Loop

PID Prop Gain

PID Integ Time

+

+

+

PID Diff Rate

PID

Output

PID Enabled


Accel/Decel

+

Ramp

+

Output

Freq

Example

•

In a winder application, the PID Reference equals the Equilibrium set point.

•

The Dancer Pot signal provides PID Feedback to the drive.

Fluctuations in tension result in a PID Error value.

•

The Master Speed Reference sets the wind/unwind speed.

•

As tension increases or decreases during winding, the Speed

Reference is trimmed to compensate. Tension is maintained near the

Equilibrium set point.

PID Reference =

Equilibrium Set Point

0 Volts

PID Feedback =

Dancer Pot Signal

10 Volts




F-4

PID Set Up

PID Reference and Feedback

Parameter A132 [PID Ref Sel] is used to enable the PID mode (A132 ¦ 0

“PID Disabled”) and to select the source of the PID Reference. If A132

[PID Ref Sel] is not set to 0 “PID Disabled”, PID can still be disabled by

select programmable digital input options (parameters A051

-

A054

) such as “Jog”, “Local” or “PID Disable”.

Table F.A A132 [PID Ref Sel] Options

Option

0 “PID Disabled”

1 “PID Setpoint“

2 “0-10V Input”


4 “Comm Port”

5 “Setpnt, Trim”

6 “0-10V, Trim”

7 “4-20mA, Trim”

8 “Comm, Trim”

Description

Disables the PID loop (default setting)

Selects Exclusive Control. A137 [PID Setpoint] will be used to set the value of the PID Reference

Selects Exclusive Control. Selects the 0-10V Input. Note that the PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero.

Selects Exclusive Control. Selects the 4-20mA Input.

Selects Exclusive Control. The reference word from a communication network (see

Appendix C

for details on the reference word) such as Modbus RTU or DeviceNet becomes the PID Reference. The value sent over the network is scaled so that P035 [Maximum Freq] x 10 = 100% reference. For example, with [Maximum Freq] = 60 Hz, a value of 600 sent over the network would represent 100% reference.

Selects Trim Control. A137 [PID Setpoint] will be used to set the value of the PID Reference.

Selects Trim Control. Selects the 0-10V Input. Note that the

PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero.

Selects Trim Control. Selects the 4-20mA Input.

Selects Trim Control. The reference word from a communication network (see

Appendix C

for details on the reference word) such as Modbus RTU or DeviceNet becomes the PID Reference. The value sent over the network is scaled so that P035 [Maximum Freq] x 10 = 100% reference. For example, with [Maximum Freq] = 60 Hz, a value of 600 sent over the network would represent 100% reference.

A133 [PID Feedback Sel] is used to select the source of the PID feedback.

Table F.B A133 [PID Feedback Sel] Options

Option

0 “0-10V Input”

1 “4-20mA Input“

2 “Comm Port”

Description

Selects the 0-10V Input (default setting). Note that the PID will not function with a bipolar analog input. It will ignore any negative voltages and treat them like a zero.

Selects the 4-20mA Input.

The reference word from a communication network (see

Appendix C of the PowerFlex 40 User Manual for details on the reference word) such as Modbus RTU or DeviceNet becomes the PID Feedback. The value sent over the network is scaled so that P035 [Maximum Freq] x 10 = 100% Feedback. For example, with [Maximum Freq] = 60 Hz, a value of 600 sent over the network would represent 100% Feedback.



PID Set Up

F-5

Analog PID Reference Signals

Parameters A110 [Anlg In 0-10V Lo] and A111 [Anlg In 0-10V Hi] are used to scale or invert an analog PID Reference.

Important: Firmware version FRN 2.xx also allows PID Feedback scaling from an analog input.

Examples

Scale Function

For a 0-5 volt signal, the following parameter settings are used so that a 0 volt signal = 0% PID Reference and a 5 volt signal = 100% PID

Reference.

•

A110 [Anlg In 0-10V Lo] = 0.0%

•

A111 [Anlg In 0-10V Hi] = 50.0%

•

A132 [PID Ref Sel] = 0 “0-10V Input”

12

10

8

6

4

2

0 10 20 30 40 50 60 70 80 90 100

PID Reference (%)



F-6

PID Set Up

Invert Function

For a 4-20mA signal, the following parameter settings are used so that a

20mA signal = 0% PID Reference and a 4mA signal = 100% PID

Reference.

•

A112 [Anlg In 4-20mA Lo] = 100.0%

•

A113 [Anlg In 4-20mA Hi] = 0.0%

•

A132 [PID Ref Sel] = 3 “4-20mA Input”

24

20

16

12

8

4

0 10 20 30 40 50 60 70 80 90 100

PID Reference (%)

Alternatively, you can set the value of A167 [PID Invert Error] to 1 to

change the sign of the PID error. See A167

[PID Invert Error] in Chapter

3 for more details.

PID Deadband

Parameter A138 [PID Deadband] is used to set a range, in percent, of the

PID Reference that the drive will ignore.

Example

•

[PID Deadband] is set to 5.0

•

The PID Reference is 25.0%

•

The PID Regulator will not act on a PID Error that falls between 20.0 and 30.0%



PID Set Up

F-7

PID Preload

The value set in A139 [PID Preload], in Hertz, will be pre-loaded into the integral component of the PID at any start or enable. This will cause the drive’s frequency command to initially jump to that preload frequency, and the PID loop starts regulating from there.

PID Enabled

PID Pre-load Value

PID Output

Freq Cmd

PID Pre-load Value > 0

PID Limits

A130 [PID Trim Hi] and A131 [PID Trim Lo] are used to limit the PID output and are only used in trim mode. [PID Trim Hi] sets the maximum frequency for the PID output in trim mode. [PID Trim Lo] sets the reverse frequency limit for the PID output in trim mode. Note that when the PID reaches the Hi or Lo limit, the PID regulator stops integrating so that windup does not occur.



F-8

PID Set Up

PID Gains

The proportional, integral, and differential gains make up the PID regulator.

•

A134 [PID Prop Gain]

The proportional gain (unitless) affects how the regulator reacts to the magnitude of the error. The proportional component of the PID regulator outputs a speed command proportional to the PID error. For example, a proportional gain of 1 would output 100% of max frequency when the PID error is 100% of the analog input range. A larger value for [PID Prop Gain] makes the proportional component more responsive, and a smaller value makes it less responsive.

Setting [PID Prop Gain] to 0.00 disables the proportional component of the PID loop.

•

A135 [PID Integ Time]

The integral gain (units of seconds) affects how the regulator reacts to error over time and is used to get rid of steady state error. For example, with an integral gain of 2 seconds, the output of the integral gain component would integrate up to 100% of max frequency when the PID error is 100% for 2 seconds. A larger value for [PID Integ

Time] makes the integral component less responsive, and a smaller value makes it more responsive. Setting [PID Integ Time] to 0 disables the integral component of the PID loop.

•

A136 [PID Diff Rate]

The Differential gain (units of 1/seconds) affects the rate of change of the PID output. The differential gain is multiplied by the difference between the previous error and current error. Thus, with a large error the D has a large effect and with a small error the D has less of an effect. This parameter is scaled so that when it is set to

1.00, the process response is 0.1% of [Maximum Freq] when the process error is changing at 1% / second. A larger value for [PID Diff

Rate] makes the differential term have more of an effect and a small value makes it have less of an effect. In many applications, the D gain is not needed. Setting [PID Diff Rate] to 0.00 (factory default) disables the differential component of the PID loop.



PID Set Up

F-9

Guidelines for Adjusting the PID Gains

1. Adjust the proportional gain. During this step it may be desirable to disable the integral gain and differential gain by setting them to 0.

After a step change in the PID Feedback:

–

If the response is too slow increase A134 [PID Prop Gain].

–

If the response is too quick and/or unstable (see

Figure F.1

),

decrease A134 [PID Prop Gain].

–

Typically, A134 [PID Prop Gain] is set to some value below the point where the PID begins to go unstable.

2. Adjust the integral gain (leave the proportional gain set as in Step 1).

After a step change in the PID Feedback:

–

If the response is too slow (see

Figure F.2

), or the PID Feedback

does not become equal to the PID Reference, decrease A135

[PID Integ Time].

–

If there is a lot of oscillation in the PID Feedback before settling

out (see Figure F.3

), increase A135 [PID Integ Time].

3. At this point, the differential gain may not be needed. However, if after determining the values for A134 [PID Prop Gain] and A135

[PID Integ Time]:

–

Response is still slow after a step change, increase A136 [PID

Diff Rate].

–

Response is still unstable, decrease A136 [PID Diff Rate].



F-10

PID Set Up

The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains.

Figure F.1 Unstable

PID Reference

PID Feedback

Figure F.2 Slow Response – Over Damped

Time

PID Reference

PID Feedback

Time

Figure F.3 Oscillation – Under Damped

PID Reference

PID Feedback

Figure F.4 Good Response – Critically Damped

Time

PID Reference

PID Feedback

Time



Index

A

AC Supply

Ground, 1-7

Source, 1-5

Ungrounded, 1-5

Acceleration Rate, 1-24

Advanced Program Group

Parameters, 3-14

Ambient Temperatures, 1-3

Analog Input Loss Fault, F29, 4-3

Armored Cable, 1-10

Auto Rstrt Tries Fault, F33, 4-4

Auxiliary Input Fault, F2, 4-3

B

Before Applying Power, 2-1

Bus Capacitors, Discharging, P-3, 1-2

C

Cable Length, 1-15

Cable, Power, 1-10

Capacitors, Discharging, P-3, 1-2

Catalog Number Explanation, P-4

CE Conformity, 1-25

Checklist, Start-Up, 2-1

Circuit Breakers, 1-8

Comm Loss Fault, F81, 4-4

Command Sources for Start and

Speed, 1-23

Common Symptoms and Corrective

Action, 4-5

Contactors, 1-14

Control Wiring, 1-16

Control, 2 and 3 Wire, 1-18

Conventions, Manual, P-2

Cover, Opening, 1-1

Cross Reference, Parameter

by Name, 3-45

D

Data, Diagnostic, 2-7

Data, Saving, 2-7

Deceleration Rate, 1-24

Dimensions

Drive, B-7

Minimum Clearances, 1-3

Direction

of Drive, 2-2

of Motor, 1-13

Discharging Bus Capacitors, P-3, 1-2

Disconnecting Output Power, 1-12

Display, 2-4

Display Group Parameters, 3-3

Distribution Systems, Ungrounded,

1-5

Drive Frame Size, P-2, B-7

Drive Grounding, 1-7

Drive Overload Fault, F64, 4-4

Drive Ratings, P-4, A-1

DriveExecutive, 3-1

DriveExplorer, 3-1

E

Earthing, see Grounding

Edit Parameters, 2-5

EMC/RFI

Grounding, Filter, 1-8

Interference, 1-25

Enclosure Rating, Changing, 1-3

ESD, Static Discharge, P-3

F

Faults

Analog Input Loss, F29, 4-3

Auto Rstrt Tries, F33, 4-4

Auxiliary Input, F2, 4-3

Comm Loss, F81, 4-4

Drive Overload, F64, 4-4

Ground Fault, F13, 4-3

Heatsink OvrTmp, F8, 4-3

HW OverCurrent, F12, 4-3

I/O Board Fail, F122, 4-5

Motor Overload, F7, 4-3

Motor Stalled, F6, 4-3

Net Loss, F71, 4-4

OverVoltage, F5, 4-3

Parameter Checksum, F100, 4-5



Index-2

Params Defaulted, F48, 4-4

Phase Short, F41-F43, 4-4

Phase to Ground Short, F38-F40,

4-4

Power Loss, F3, 4-3

Power Unit, F70, 4-4

SVC Autotune, F80, 4-4

SW OverCurrent, F63, 4-4

File

UnderVoltage, F4, 4-3

Monitor, 3-3

Filter, RFI, 1-8

Frame Designations, P-2, A-1, B-7

Fuses

Minimum Recommendations, 1-8

Ratings, A-1

G

General Precautions, P-3

Ground Fault, F13, 4-3

Grounding

Filter, 1-8

General, 1-7

H

Heatsink OvrTmp Fault, F8, 4-3

HW OverCurrent Fault, F12, 4-3

I/O

I

Block Diagram, 1-16

Terminal Block, 1-15

Terminal Designations, 1-17

Wiring, 1-14

Wiring Examples, 1-18

Wiring Multiple Drives, 1-22

I/O Board Fail Fault, F122, 4-5

Input Contactor, 1-14

Input Fusing, 1-8

Input Potentiometer, 1-18

Input Power Conditioning, 1-6

Installation of Drive, 1-1

Integral Keypad, 2-4

Interference, EMC/RFI, 1-25

IP66 Installations, 1-14



K

Keypad, 2-4

L

LEDs, 2-4

M

Menu Structure, 2-6

Minimum Clearances, 1-3

Monitor File, 3-3

Motor

Cable Length, 1-12

Changing Forward Direction of,

1-13

Disconnect, 1-12

Motor Overload Fault, F7, 4-3

Motor Stalled Fault, F6, 4-3

Motor Starter, Bulletin 140M, 1-8

Mounting Options and Clearances,

1-3

MOV Jumper Location and Removal,

1-5

N

NEMA/UL Type 4X Installations, 1-14

Net Loss Fault, F71, 4-4

O

Opening the Drive Cover, 1-1

Operating Temperatures, 1-3

Operator Interface, 2-4

Output Disconnect, 1-12

OverVoltage Fault, F5, 4-3

P

Parameter

Descriptions, 3-1

Types, 3-1

Viewing and Editing, 2-5, 2-6

Parameter Checksum Fault, F100,

4-5

Parameter Cross Reference

by Name, 3-45

Parameters

Advanced Program Group, 3-14

Display Group, 3-3

Index-3

Program Group, 3-9

Params Defaulted Fault, F48, 4-4

PE Ground, 1-7

Phase Short Fault, F41-F43, 4-4

Phase to Ground Fault, F38-F40, 4-4

Potentiometer, Wiring, 1-18

Power Cables and Wiring, 1-10

Power Conditioning, 1-6

Power Loss Fault, F3, 4-3

Power Unit Fault, F70, 4-4

Powering Up the Drive, 2-1

Precautions, General, P-3

Preferences, Setting, 2-7

Product Selection, B-1

Program Group Parameters, 3-9

Programming, 3-1

PTC Analog Input Wiring, 1-18

R

Ratings, A-1

Reflective Wave Protection, 1-12

Removing Cover, 1-1

Repeated Start/Stop, 1-14

Repeated Start/Stop Precautions,

1-14

RFI, see EMC/RFI

RWR (Reflective Wave Reducer),

1-12

S

Safety Ground, 1-7

Saving Data, Viewing, 2-7

Setting Preferences, 2-7

Shielded Power Cables, 1-10

Short Circuit Protection, 1-8

Sink/Source, 1-17

Software, 3-1

Speed, Control of, 2-2

Start and Speed Reference Selection

and Control, 1-23

Start/Stop

Drive, 2-2

Motor, 1-14

Starting/Stopping, The Motor, 1-14

Start-Up Checklist, 2-1

Static Discharge, ESD, P-3

Status LEDs, 2-4

Supply Source, AC, 1-5

SVC Autotune Fault, F80, 4-4

SW OverCurrent Fault, F63, 4-4

System Grounding, 1-7

T

Terminal Block

I/O, 1-15

Power, 1-13

Three Wire Control, 1-18

Two Wire Control, 1-18

U

UnderVoltage Fault, F4, 4-3

Ungrounded Supply, 1-5

Unshielded Power Cables, 1-10

W

Watts Loss, A-5

Wiring, 1-1

Block Diagram, 1-16

Examples, 1-18

I/O Terminal Descriptions, 1-17

Potentiometer, 1-18

Power, 1-10

PTC Example, 1-18

Recommendations, 1-14



Index-4

Notes:



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

www.rockwellautomation.com

Power, Control and Information Solutions Headquarters

Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444

Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640

Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846

Publication 22B-UM001G-EN-E – August 2008

Supersedes April 2008 Copyright © 2008 Rockwell Automation, Inc. All rights reserved.