Quick Start

PowerFlex 4 Adjustable

Frequency AC Drive

FRN 6.xx

This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 4 Adjustable Frequency AC Drive.

The information provided Does Not replace the User Manual and is intended for qualified drive service personnel only.

For detailed PowerFlex 4 information including EMC instructions, application considerations and related precautions refer to the

PowerFlex 4 User Manual, Publication 22A-UM001… at

www.rockwellautomation.com/literature.

!

!

!

!

!

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: Equipment damage and/or personal injury may result if parameter A092 [Auto Rstrt Tries] or A094 [Start At PowerUp] is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines.

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.

English-2

Mounting Considerations

•

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

Min. Panel Thickness Screw Size Screw Torque DIN Rail

1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm

•

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

See page 12 for mounting dimensions.

120 mm

(4.7 in.)

120 mm

(4.7 in.)

25 mm

(1.0 in.)

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

120 mm

(4.7 in.)

120 mm

(4.7 in.)

Mounting Option A

No clearance required between drives.

Mounting Option B

Ambient Operating Temperatures

Ambient Temperature

Minimum Maximum

-10°C (14°F)

Enclosure Rating

40°C (104°F)

IP 20/Open Type

IP 30/NEMA 1/UL Type 1

(1)

50°C (122°F) IP 20/Open Type

(1)

Minimum Mounting

Clearances

Use Mounting Option A

Use Mounting Option B

Use Mounting Option B

Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.

General Grounding Requirements

Important: The MOV to ground jumper must be removed if the drive is installed on an ungrounded or resistive grounded distribution system.

Tighten screw after jumper removal.

Jumper

Location

R/L1

S/L2

T/L3

U/T1

V/T2

W/T3

SHLD

CE Conformity

Refer to the PowerFlex 4 User Manual for details on how to comply with the Low Voltage (LV) and Electromagnetic Compatibility (EMC)

Directives.

English-3

Specifications, Fuses and Circuit Breakers

Drive Ratings

Catalog

Number

Output

Ratings

Input Ratings Branch Circuit Protection

kW (HP) Amps

Voltage

Range kVA Amps Fuses

140M Motor

Protectors

(2) (3)

Contactors

Min. Enclosure

Volume

(4)

(in.

3

)

Power

Dissipation

IP20 Open

Watts

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

22A-V1P5N104 0.2 (0.25) 1.5

90-126 0.75 6.0

10 140M-C2E-C10 100-C09 1655

22A-V2P3N104 0.4 (0.5) 2.3

90-126 1.15 9.0

15 140M-C2E-C16 100-C12 1655

32

40

55

80

22A-V4P5N104 0.75 (1.0) 4.5

90-126 2.25 18.0

30 140M-D8E-C20 100-C23 1655

22A-V6P0N104 1.1 (1.5) 6.0

90-126 3.0

24.0

40

200 - 240V AC (±10%) – 1-Phase

(1)

140M-F8E-C32 100-C37 1655

Input, 0 - 230V 3-Phase Output, NO BRAKE

22A-A1P4N103 0.2 (0.25) 1.4

180-265 0.7

3.2

6 140M-C2E-B40 100-C09 1655

22A-A2P1N103 0.4 (0.5) 2.1

180-265 1.05 5.3

10 140M-C2E-B63 100-C09 1655

22A-A3P6N103 0.75 (1.0) 3.6

180-265 1.8

9.2

15

22A-A6P8N103 1.5 (2.0) 6.8

180-265 3.4

14.2

25

140M-C2E-C16 100-C12 1655

140M-C2E-C16 100-C16 1655

22A-A9P6N103 2.2 (3.0) 9.6

180-265 4.8

19.6

30 140M-D8E-C25 100-C23 1655

200 - 240V AC (±10%) – 1-Phase

(1)

Input, 0 - 230V 3-Phase Output

22A-A1P5N104 0.2 (0.25) 1.5

180-265 0.75 5.0

10

22A-A2P3N104 0.4 (0.5) 2.3

180-265 1.15 6.0

10

22A-A4P5N104 0.75 (1.0) 4.5

180-265 2.25 10.0

15

22A-A8P0N104 1.5 (2.0) 8.0

180-265 4.0

18.0

30

140M-C2E-B63 100-C09 1655

140M-C2E-B63 100-C09 1655

140M-C2E-C16 100-C12 1655

140M-D8E-C20 100-C23 1655

200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output

22A-B1P5N104 0.2 (0.25) 1.5

180-265 0.75 1.8

3 140M-C2E-B25 100-C09 1655

32

40

55

85

125

32

40

55

85

32

22A-B2P3N104 0.4 (0.5) 2.3

180-265 1.15 2.5

6

22A-B4P5N104 0.75 (1.0) 4.5

180-265 2.25 5.2

10

22A-B8P0N104 1.5 (2.0) 8.0

180-265 4.0

9.5

15

22A-B012N104 2.2 (3.0) 12.0

180-265 5.5

15.5

25

22A-B017N104 3.7 (5.0) 17.5

180-265 8.6

21.0

30

140M-C2E-B40 100-C09 1655

140M-C2E-C10 100-C09 1655

140M-C2E-C16 100-C12 1655

140M-C2E-C16 100-C16 1655

140M-F8E-C25 100-C23 1655

380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output

22A-D1P4N104 0.4 (0.5) 1.4

340-528 1.4

1.8

3

22A-D2P3N104 0.75 (1.0) 2.3

340-528 2.3

3.2

6

22A-D4P0N104 1.5 (2.0) 4.0

340-528 4.0

5.7

10

22A-D6P0N104 2.2 (3.0) 6.0

340-528 5.9

7.5

15

22A-D8P7N104 3.7 (5.0) 8.7

340-528 8.6

9.0

15

Input/Output Ratings

Approvals

Output Frequency: 0-240 Hz (Programmable)

Efficiency: 97.5% (Typical)

C US

UL508C

CSA 22.2

No. 14

140M-C2E-B25 100-C09 1655

140M-C2E-B40 100-C09 1655

140M-C2E-B63 100-C09 1655

140M-C2E-C10 100-C09 1655

140M-C2E-C16 100-C16 1655

EMC Directive 89/336/EEC, LV Dir. 73/23/EEC

LV: EN

EMC:

50178

EN

35

50

70

100

150

Digital Control Inputs (Input Current = 6mA) Analog Control Inputs

SRC (Source) Mode:

18-24V = ON

0-6V = OFF

SNK (Sink) Mode:

0-6V = ON

18-24V = OFF

4-20mA Analog: 250 ohm input impedance

0-10V DC Analog: 100k ohm input impedance

External Pot: 1-10k ohms, 2 Watt minimum

40

55

85

125

180

Control Output (Programmable Output, form C relay)

Resistive Rating: 3.0A at 30V DC, 125V AC and 240V AC Inductive Rating: 0.5A at 30V DC, 125V AC, and 240V AC

Recommended Fuses and Circuit Breakers

Fuse: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. Circuit Breakers: HMCP or Bulletin 140U or equivalent.

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)

200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)

380-460V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)

Under Voltage:

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

200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line)

380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)

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

Faultless Power Ride Through: 100 milliseconds

Dynamic Braking

Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 4 User Manual for

DB resistor ordering information.

(1)

200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N103 to N113 and N104 to N114.

English-4

(2)

(3)

(4)

The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection

Circuit Breakers Application Ratings .

Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/

277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems.

When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure.

Power Wiring

Power Wire Rating Recommended Copper Wire

Unshielded 600V, 75°C (167°F) THHN/THWN

Shielded 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2

15 Mils insulated, dry location

Belden 29501-29507 or equivalent

Shielded Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Shawflex 2ACD/3ACD or equivalent

Power Terminal Block (A Frame Shown)

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

Terminal

R/L1, S/L2

R/L1, S/L2, T/L3

U/T1

V/T2

W/T3

BR+, BR-

Description

1-Phase Input

3-Phase Input

To Motor U/T1

BR+ BR-

To Motor V/T2

To Motor W/T3

=

Switch any two motor leads to change forward direction.

Dynamic Brake Resistor Connection [0.75 kW (1 HP) ratings and higher]

Safety Ground - PE

Frame

A

B

(1)

Power Terminal Block Specifications

Maximum Wire Size

(1)

3.3 mm

2

(12 AWG)

5.3 mm

2

(10 AWG)

Minimum Wire Size

(1)

0.8 mm

2

(18 AWG)

1.3 mm

2

(16 AWG)

Torque

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

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

Input Power Conditions

Input Power Condition

Low Line Impedance (less than 1% line reactance)

Greater than 120 kVA supply transformer

Line has power factor correction capacitors

Line has frequent power interruptions

Line has intermittent noise spikes in excess of 6000V (lightning)

Phase to ground voltage exceeds 125% of normal line to line voltage

Corrective Action

•

Install Line Reactor

(2)

• or Isolation Transformer

Ungrounded Distribution System

(2)

•

Remove MOV jumper to ground.

• or Install Isolation Transformer with grounded secondary if necessary.

Refer to Appendix B of the PowerFlex 4 User Manual for accessory ordering information.

I/O Wiring Recommendations

(3)

Wire Type(s)

Belden 8760/9460

(or equiv.)

Belden 8770

(or equiv.)

(3)

Description

0.8 mm

2

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

0.8 mm

2

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

Minimum Insulation Rating

300V

60 degrees C

(140 degrees F)

If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

I/O Terminal Block Specifications

Maximum Wire Size

(4)

Minimum Wire Size

(4)

1.3 mm

2

(16 AWG) 0.13 mm

2

(26 AWG)

(4)

Torque

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

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

English-5

Refer to the PowerFlex 4 User Manual for recommendations on maximum power and control cable length.

Control Terminal Block

(1)

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

“3-Wire” control. In three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode]. All other stop sources are controlled by P037

[Stop Mode].

P036

[Start Source]

Keypad

3-Wire

2-Wire

RS485 Port

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 on I/O Terminal 02 to command a start. Use a maintained input for I/O Terminal 03 to change direction.

Relay N.O.

Relay Common

Relay N.C.

SNK

R1

R2

R3

SRC

Stop

Per P037

Per P037

Per P037

Per P037

+24V

+10V

I/O Terminal 01

Stop

Coast

Per P037

Coast

Coast

Refer to the PowerFlex 4

User Manual for more information.

01

02

03

04

05

06

11

12

13

14

15

16

Stop

(1)

Start/Run FWD

(2)

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

+24V DC

+10V DC

0-10V In

Analog Common

4-20mA In

RS485 Shield

Typical

SRC Wiring

Typical

SNK Wiring

Potentiometer must be

1-10k ohm

2 Watt Min.

01 02 03 04 05 06

30V DC 125V AC 240V AC

Resistive 3.0A

3.0A

3.0A

Inductive 0.5A

0.5A

0.5A

No.

Signal

R1 Relay N.O.

R2 Relay Common

R3 Relay N.C.

Sink/Source DIP Switch Source (SRC)

01 Stop

(1)

02 Start/Run FWD

Coast

Not Active

03 Direction/Run REV Not Active

04 Digital Common

05 Digital Input 1

06 Digital Input 2

11 +24V DC

12 +10V DC

13 0-10V In

(3)

14 Analog Common

Default

Fault

–

Fault

–

Preset Freq

Preset Freq

–

–

–

R1 R2 R3

Not Active

SNK 11 12 13 14 15 16

RS485

(DSI)

8 1

SRC

(1)

Description

Normally open contact for output relay.

Common for output relay.

Normally closed contact for output relay.

Param.

A055

A055

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

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

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.

Program with A051 [Digital In1 Sel].

Program with A052 [Digital In2 Sel].

Drive supplied power for digital inputs.

Maximum output current is 100mA.

Drive supplied power for 0-10V external potentiometer.

Maximum output current is 15mA.

A051

A052

P038

For external 0-10V input supply

(input impedance = 100k ohm) or potentiometer wiper.

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

P038

English-6

No.

Signal

15 4-20mA In

(3)

Default

Not Active

16 RS485 (DSI) Shield –

(3)

Description Param.

For external 4-20mA input supply

(input impedance = 250 ohm).

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

P038

Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an undetermined frequency reference will result.

Prepare For Drive Start-Up

!

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.

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 page 5 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.

Applying Power to the Drive

❏

6. Apply AC power and control voltages to the drive.

❏

7. Familiarize yourself with the integral keypad features (see next page) before setting any Program Group parameters.

Start, Stop, Direction and Speed Control

Factory default parameter values allow the drive to be controlled from the integral keypad. No programming is required to start, stop, change direction and control speed directly from the integral keypad.

Important: To disable reverse operation, see A095 [Reverse Disable].

If a fault appears on power up, refer to page 11 for an explanation of the

fault code. For complete troubleshooting information, refer to the

PowerFlex 4 User Manual.

English-7

➏

Integral Keypad

➊

RUN

FWD

REV

➋

➍

PROGRAM

➎

FAULT

➌

VOLTS

AMPS

HERTZ

➐

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

➋ Alphanumeric

Display

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.

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.

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

Enter Advance one step in programming menu.

Save a change to a parameter value.

Potentiometer Used to control speed of drive. Default is active.

Controlled by parameter P038.

Start

Reverse

Stop

Used to start the drive. Default is active.

Controlled by parameter P036.

Used to reverse direction of the drive. Default is active.

Controlled by parameters P036 and A095.

Used to stop the drive or clear a fault.

This key is always active.

Controlled by parameter P037.

English-8

See the PowerFlex 4 User Manual for more information on parameters.

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.

or or or or

PROGRAM FAULT

PROGRAM FAULT

PROGRAM FAULT

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

VOLTS

AMPS

HERTZ

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

PROGRAM FAULT

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

See the PowerFlex 4 User Manual for more information on parameters.

English-9

Display Group Parameters

No.

Parameter Min/Max Display/Options

d001 [Output Freq] d002 [Commanded Freq] d003 [Output Current] d004 [Output Voltage] d005 [DC Bus Voltage] d006 [Drive Status] d007d009

[Fault x Code] d010 [Process Display] d012 [Control Source] d013 [Contrl In Status] d014 [Dig In Status] d015 [Comm Status]

0.0/[Maximum Freq]

0.0/[Maximum Freq]

0.00/(Drive Amps

×

2)

0/Drive Rated Volts

0.1 Hz

0.1 Hz

0.01 Amps

1 VAC

Based on Drive Rating 1 VDC

0/1 (1 = Condition True) Bit 3

Decelerating

F2/F122 F1

Bit 2

Accelerating

Bit 1

Forward

Bit 0

Running

0.00/9999

0/9

0.01 – 1

Digit 1 = Speed Command

(See P038; 9 = “Jog Freq”)

0/1 (1 = Input Present) Bit 3

Reserved

Bit 2

Stop Input

Digit 0 = Start Command

(See P036; 9 = “Jog”)

Bit 1

Dir/Run REV

Bit 0

Start/Run FWD

0/1 (1 = Input Present) Bit 3

Reserved

Bit 2

Reserved

Bit 1

0/1 (1 = Condition True) Bit 3 Bit 2 Bit 1

Fault Occurred RS485 Option Transmitting

Bit 0

Digital In2 Sel Digital In1 Sel

Bit 0

Receiving d016 [Control SW Ver] d017 [Drive Type]

1.00/99.99

1001/9999 d018 [Elapsed Run Time] 0/9999 Hrs d019 [Testpoint Data] 0/FFFF d020 [Analog In 0-10V] d021 [Analog In 4-20mA] d024 [Drive Temp]

0.0/100.0%

0.0/100.0%

0/120 degC

0.01

1

1 = 10 Hrs

1 Hex

0.1%

0.1%

1 degC

Smart Start-Up with Basic Program Group Parameters

= Stop drive before changing this parameter.

No.

Parameter Min/Max Display/Options Default

P031 [Motor NP Volts] 20/Drive Rated Volts

Set to the motor nameplate rated volts.

P032 [Motor NP Hertz] 10/240 Hz

1 VAC

1 Hz

Set to the motor nameplate rated frequency.

P033 [Motor OL Current] 0.0/(Drive Rated Amps

×

2) 0.1 Amps

Set to the maximum allowable motor current.

P034 [Minimum Freq] 0.0/240.0 Hz 0.1 Hz

Based on Drive Rating

60 Hz

Based on Drive Rating

0.0 Hz

Sets the lowest frequency the drive will output continuously.

P035 [Maximum Freq] 0/240 Hz 1 Hz 60 Hz

Sets the highest frequency the drive will output.

P036 [Start Source] 0/5

Sets the control scheme used to start the drive.

0 = “Keypad”

1 = “3-Wire”

2 = “2-Wire”

(1)

3 = “2-W Lvl Sens”

4 = “2-W Hi Speed”

5 = “Comm Port”

(1)

When active, the Reverse key is also active unless disabled by A095 [Reverse Disable].

P037 [Stop Mode] 0/7

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.

0 = “Ramp, CF”

(1)

1 = “Coast, CF”

(1)

2 = “DC Brake, CF”

(1)

3 = “DCBrkAuto,CF”

(1)

4 = “Ramp”

5 = “Coast”

6 = “DC Brake”

7 = “DC BrakeAuto”

0

0

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].

(1)

Stop input also clears active fault.

P038 [Speed Reference] 0/5

Sets the source of the speed reference to the drive.

0 = “Drive Pot”

1 = “InternalFreq”

2 = “0-10V Input”

3 = “4-20mA Input”

4 = “Preset Freq”

5 = “Comm Port”

0

Important: When A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5, 6, 13 or 14, and the digital input is active, A051 or A052 will override the speed reference commanded by this parameter. Refer to Chapter 1 of the PowerFlex 4 User

Manual for details.

P039 [Accel Time 1] 0.0/600.0 Secs 0.1 Secs 10.0 Secs

Sets the rate of accel for all speed increases.

P040 [Decel Time 1] 0.1/600.0 Secs 0.1 Secs 10.0 Secs

Sets the rate of decel for all speed decreases.

P041 [Reset To Defalts] 0/1

Resets all parameter values to factory defaults.

0 = “Idle State”

1 = “Reset Defaults”

P043 [Motor OL Ret] 0/1 0 = “Disabled”

Enables/disables the Motor Overload Retention function.

1 = “Enabled”

0

0

English-10

See the PowerFlex 4 User Manual for more information on parameters.

Advanced Group Parameters

No.

Parameter

A051

A052

[Digital In1 Sel]

I/O Terminal 05

[Digital In2 Sel]

I/O Terminal 06

A055 [Relay Out Sel]

Min/Max

0/26

0/21

Display/Options

0 = “Not Used”

1 = “Acc 2 & Dec 2”

2 = “Jog”

3 = “Aux Fault”

4 = “Preset Freq”

5 = “Local”

6 = “Comm Port”

7 = “Clear Fault”

0 = “Ready/Fault”

1 = “At Frequency”

2 = “MotorRunning”

3 = “Reverse”

4 = “Motor Overld”

5 = “Ramp Reg”

8 = “RampStop,CF”

9 = “CoastStop,CF”

10 = “DCInjStop,CF”

11 = “Jog Forward”

12 = “Jog Reverse”

13 = “10V In Ctrl”

14 = “20mA In Ctrl”

26 = “Anlg Invert”

6 = “Above Freq”

7 = “Above Cur”

8 = “Above DCVolt”

9 = “Retries Exst”

10 = “Above Anlg V”

20 = “ParamControl”

21 = “NonRec Fault”

Default

4

0

A056 [Relay Out Level]

A067 [Accel Time 2]

0.0/9999

0.0/600.0 Secs

0.1

0.1 Secs

A068 [Decel Time 2] 0.1/600.0 Secs 0.1 Secs

A069 [Internal Freq]

A070

A071

A072

A073

[Preset Freq 0]

(1)

[Preset Freq 1]

[Preset Freq 2]

[Preset Freq 3]

0.0/240.0 Hz

0.0/240.0 Hz

0.1 Hz

0.1 Hz

(1)

To activate [Preset Freq 0] set P038 [Speed Reference] to option 4.

0.0

20.0 Secs

20.0 Secs

60.0 Hz

0.0 Hz

5.0 Hz

10.0 Hz

20.0 Hz

Input State of Digital In 1

(I/O Terminal 05)

0

1

0

1

Input State of Digital In 2

(I/O Terminal 06)

0

0

1

1

Frequency Source

[Preset Freq 0]

[Preset Freq 1]

[Preset Freq 2]

[Preset Freq 3]

Accel / Decel Parameter Used

(2)

[Accel Time 1] / [Decel Time 1]

[Accel Time 1] / [Decel Time 1]

[Accel Time 2] / [Decel Time 2]

[Accel Time 2] / [Decel Time 2]

(2)

When a Digital Input is set to “Accel 2 & Decel 2”, and the input is active, that input overrides the settings in this table.

A078 [Jog Frequency]

A079 [Jog Accel/Decel]

A080 [DC Brake Time]

A081 [DC Brake Level]

A082 [DB Resistor Sel]

0.0/[Maximum Freq] 0.1 Hz

0.1/600.0 Secs 0.1 Secs

0.0/90.0 Secs 0.1 Secs

0.0/(Drive Amps

×

1.8) 0.1 Amps

0/99 0 = Disabled

1 = Normal RA Res

2 = NoProtection

3-99 = % of Duty Cycle

10.0 Hz

10.0 Secs

0.0 Secs

Amps

×

0.05

0

A083 [S Curve %]

A084 [Start Boost]

0/100%

1/14

1%

Settings in % of base voltage.

Variable Torque Constant Torque

1 = “30.0, VT” 5 = “0.0, no IR”

2 = “35.0, VT”

3 = “40.0, VT”

4 = “45.0, VT”

6 = “0.0”

7 = “2.5, CT”

8 = “5.0, CT”

9 = “7.5, CT”

A088 [Maximum Voltage] 20/Rated Volts

A089 [Current Limit]

1 VAC

0/(Drive Amps

×

1.8) 0.1 Amps

A090 [Motor OL Select] 0/2 0 = “No Derate”

10 = “10.0, CT”

11 = “12.5, CT”

12 = “15.0, CT”

13 = “17.5, CT”

14 = “20.0, CT”

1 = “Min Derate”

2 = “Max Derate”

0% (Disabled)

8

7 (5 HP Drives)

Rated Volts

Amps

×

1.5

0

A091 [PWM Frequency]

A092 [Auto Rstrt Tries]

2.0/16.0 kHz

0/9

A093 [Auto Rstrt Delay] 0.0/300.0 Secs

A094 [Start At PowerUp] 0/1

0.1 kHz

1

0.1 Secs

0 = “Disabled” 1 = “Enabled”

4.0 kHz

0

1.0 Secs

0

A095 [Reverse Disable]

A096 [Flying Start En]

A097 [Compensation]

A098 [SW Current Trip]

A099 [Process Factor]

A100 [Fault Clear]

A101 [Program Lock]

A102 [Testpoint Sel]

0/1 0 = “Rev Enabled”

0/1 0 = “Disabled”

0/3 0 = “Disabled”

1 = “Electrical”

0.0/(Drive Amps

×

2) 0.1 Amps

0.1/999.9

0.1

0/2 0 = “Ready/Idle”

0/1

0/FFFF

0 = “Unlocked”

1 Hex

1 = “Rev Disabled”

1 = “Enabled”

2 = “Mechanical”

3 = “Both”

1 = “Reset Fault”

2 = “Clear Buffer”

1 = “Locked”

0

0

1

0.0 (Disabled)

30.0

0

0

400

See the PowerFlex 4 User Manual for more information on parameters.

English-11

No.

Parameter

A103 [Comm Data Rate]

(3)

Min/Max

0/5

A104 [Comm Node Addr]

(3)

1/247

A105 [Comm Loss Action] 0/3

A106 [Comm Loss Time] 0.1/60.0

A107 [Comm Format]

(3)

0/5

Display/Options

0 = “1200”

1 = “2400”

2 = “4800”

1

0 = “Fault”

1 = “Coast to Stop”

0.1

0 = “RTU 8-N-1”

1 = “RTU 8-E-1”

2 = “RTU 8-O-1”

0.1% A110 [Anlg In 0-10V Lo] 0.0/100.0%

A111 [Anlg In 0-10V Hi] 0.0/100.0%

A112 [Anlg In4-20mA Lo] 0.0/100.0%

A113 [Anlg In4-20mA Hi] 0.0/100.0%

A114 [Slip Hertz @ FLA] 0.0/10.0 Hz

0.1%

0.1%

0.1%

0.1 Hz

A115 [Process Time Lo]

A116 [Process Time Hi]

0.00/99.99

0.00/99.99

0.01

0.01

A117 [Bus Reg Mode] 0/1 0 = “Disabled”

A118 [Comm Write Mode] 0/1 0 = “Save”

(3)

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

3 = “9600”

4 = “19.2K”

5 = “38.4K”

2 = “Stop”

3 = “Continu Last”

3 = “RTU 8-N-2”

4 = “RTU 8-E-2”

5 = “RTU 8-O-2”

1 = “Enabled”

1 = “RAM Only”

Default

3

100

0

5.0

0

0.0%

100.0%

0.0%

100.0%

2.0 Hz

1

0

0.00

0.00

(1)

Fault Codes

To clear a fault, press the Stop key, cycle power or set A100 [Fault Clear] to 1 or 2.

No.

Fault

F2 Auxiliary Input

(1)

Description

Check remote wiring.

F3

F4

F5

F6

F7

F8

Power Loss

UnderVoltage

OverVoltage

(1)

(1)

Motor Stalled

(1)

Motor Overload

(1)

Heatsink OvrTmp

(1)

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

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

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

Increase [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A089 [Current Limit].

An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current].

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

40

°

C (104

°

F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for Open type installations.

Check fan.

F12 HW OverCurrent

(1)

F13 Ground 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

F64

F70 Power Unit

F71 Net Loss

F81

SW OverCurrent

Drive Overload

Comm Loss

(1)

Check programming. Check for excess load, improper DC boost 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.

Correct the cause of the fault and manually clear.

Check the wiring between the drive and motor. Check motor for grounded phase.

Replace drive if fault cannot be cleared.

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

Replace drive if fault cannot be cleared.

The drive was commanded to write default values to EEPROM. Clear the fault or cycle power to the drive. Program the drive parameters as needed.

Check load requirements and A098 [SW Current Trip] setting.

Reduce load or extend Accel Time.

Cycle power. Replace drive if fault cannot be cleared.

The communication network has faulted.

If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required. Check connection. An adapter was intentionally disconnected. Turn off using A105 [Comm Loss Action].

F100 Parameter Checksum Restore factory defaults.

F122 I/O Board Fail Cycle power. Replace drive if fault cannot be cleared.

Auto-Reset/Run type fault. Configure with parameters A092 and A093.

English-12

Drive Dimensions

PowerFlex 4 Panel Mount Drives – Ratings are in kW and (HP)

120V AC – 1-Phase

240V AC – 1-Phase

No Brake

240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase

A 0.2 (0.25)

0.37(0.5)

B 0.75(1.0)

1.1 (1.5)

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

PowerFlex 4 Panel Mount Drives

(1)

– Dimensions are in millimeters and (inches).

Weights are in kilograms and (pounds).

a d c f g e b

5.5 (0.22)

A

B

Frame a b

(2)

c d

80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64)

100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43)

e

(3)

f g

Shipping

Weight

152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1)

180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9)

(1) Flange Mount drives are also available. Refer to the PowerFlex 4 User Manual for more information.

(2) Overall height of drive with IP 30/NEMA 1/UL Type 1 option kit installed.

(3) Overall height of standard IP 20/Open Type drive.

IP 30/NEMA 1/UL Type 1 Option Kit – Dimensions are in millimeters and (inches)

20.7

(0.81)

40.0

(1.57)

59.2

(2.33)

∅

22.2

(0.87)

25.6

(1.01)

40.6

(1.60)

64.1

(2.52)

79.1

(3.11)

∅

22.2

(0.87)

109.3

(4.30)

75.3

(2.96)

109.9

(4.33)

74.3

(2.93)

Frame A - 22-JBAA Frame B - 22-JBAB

U.S. Allen-Bradley Drives Technical Support

Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

Publication 22A-QS001I-EN-P – June 2013

Supersedes Publication 22A-QS001H-EN-P – October 2009 Copyright © 2013 Rockwell Automation, Inc. All rights reserved.