null  User manual

www.abpowerflex.com

Adjustable

Frequency AC

Drive

FRN 1.xx - 2.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.

PowerFlex is a registered trademark of Rockwell Automation, Inc.

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

PLC is a registered trademark of Rockwell Automation, Inc.

Summary of Changes

Manual Updates

The information below summarizes the changes to the PowerFlex 40P

User Manual since the March 2006 release.

Description of New or Updated Information

Voltage Range DIP Switch location and note added

I/O Terminal 03 default value is Not Active

Catalog Number for Encoder Terminal Cover corrected

DriveGuard Safe-Off Option (Series B)

User Manual

publication number corrected to PFLEX-UM003

Display resolution corrected to 0.01 for b001 [Output Freq]

Display resolution corrected to 0.01 for b002 [Commanded Freq]

Description of I/O Terminal 03 function added to options 1, 2, 3 & 4

See Page(s)

1-15 ,

1-16

1-17

1-19

P-1

,

1-21

,

1-29

3-3

3-3

3-10

3-25

Position Source added to table for A070-A077 [Preset Freq x], when

P038 [Speed Reference] = 9 “Positioning”

Important statement about saving parameter settings to drive non-volatile memory added at E207 [Comm Write Mode]

E248 [Enh Control Word] descriptions for options 7 & 8 clarified

Corrective Action added for an F91 Encoder Loss fault when in

Positioning mode

3-52

3-60

4-5

RS485 (DSI) Network Wiring practices clarified

Logic Command Word and Logic Status Word now have selectable

Velocity and Position Bit definitions

Positioning Mode option 1 “Preset Input” description clarified

C-1

C-4 …

C-6

F-5

Parameter Updates

The following parameters have been added or updated with Firmware

Revision Number (FRN) 2.xx.

Parameter

Cmd Stat Select

Drive Status 2

Number

E249 d301

Description

New Parameter

Bit 0 renamed “Dir Positive”

Page

3-61

3-62

soc-2

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 . . . . . . . . . . . . . 1-2

Plate Drive Installation . . . . . . . . . . . . . . . 1-3

AC Supply Source Considerations . . . . . . 1-4

General Grounding Requirements . . . . . . 1-6

Fuses and Circuit Breakers . . . . . . . . . . . . 1-7

Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-9

Common Bus/Precharge Notes . . . . . . . . 1-13

I/O Wiring Recommendations . . . . . . . . 1-13

Start and Speed Reference Control . . . . . 1-27

EMC Instructions . . . . . . . . . . . . . . . . . . 1-29

Start Up

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

Display/Fault Reset . . . . . . . . . . . . . . . . . . 2-3

Drive Programming Tools . . . . . . . . . . . . . 2-3

Programming and Parameters

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

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

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

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

Advanced Program Group. . . . . . . . . . . . 3-15

Enhanced Program Group . . . . . . . . . . . . 3-49

Advanced Display Group . . . . . . . . . . . . 3-62

Parameter Cross Reference – by Name. . 3-64

Troubleshooting

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

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

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

Common Symptoms and

Corrective Actions . . . . . . . . . . . . . . . . . 4-6

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

Appendix G

Appendix H

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-6

Reading (03) Feedback . . . . . . . . . . . . . . . C-7

Reading (03) Drive Error Codes . . . . . . . . C-7

Reading (03) and Writing (06) Drive

Parameters . . . . . . . . . . . . . . . . . . . . . . . C-8

Additional Information . . . . . . . . . . . . . . . C-8

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

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

Velocity StepLogic Using Timed Steps . . . E-2

Velocity StepLogic Using Basic Logic

Functions . . . . . . . . . . . . . . . . . . . . . . . . E-3

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

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

Encoder Usage and Position StepLogic Application

Encoder Usage . . . . . . . . . . . . . . . . . . . . . . F-1

Wiring Notes . . . . . . . . . . . . . . . . . . . . . . . F-2

Positioning Overview . . . . . . . . . . . . . . . . F-2

Common Guidelines for All Applications. F-3

Positioning Operation . . . . . . . . . . . . . . . . F-5

Homing Routine . . . . . . . . . . . . . . . . . . . . F-8

Encoder and Position Feedback. . . . . . . . . F-9

Use Over Communications . . . . . . . . . . . F-10

Setup Notes . . . . . . . . . . . . . . . . . . . . . . . F-11

PID Set Up

PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

PID Reference and Feedback . . . . . . . . . . G-4

Analog PID Reference Signals . . . . . . . . . G-5

Plate Drive Installation Instructions

Introduction . . . . . . . . . . . . . . . . . . . . . . . . H-1

General Requirements . . . . . . . . . . . . . . . . H-1

Heatsink Thermal Capacity . . . . . . . . . . . . H-2

Heatsink Surface and

Flatness Requirements . . . . . . . . . . . . . . H-3

Mounting Dimensions and Requirements . H-4

Verification . . . . . . . . . . . . . . . . . . . . . . . . H-4

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 40P

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

DriveGuard® Safe-Off Option

(Series B) for PowerFlex AC

Drives

Publication

DRIVES-IN001…

DRIVES-TD001…

SGI-1.1

100-2.10

8000-4.5.2

PFLEX-UM003…

Available Online at … www.rockwellautomation.com/ literature

P-2

Overview

Manual Conventions

In this manual we refer to the PowerFlex 40P Adjustable Frequency

AC Drive as; drive, PowerFlex 40P or PowerFlex 40P Drive.

Parameter numbers and names are shown in this format:

P031 [Motor NP Volts]

Name

Number

Group b = Basic Display Group

P = Basic Program Group

A = Advanced Program Group

E = Enhanced Program Group d = Advanced Display 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 40P 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.

ATTENTION:

Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis.

P-4

Overview

Catalog Number Explanation

1-3 4

22D -

Drive Dash

5

B

Voltage Rating

6-8

2P3

Rating

9

N

10

1

11

0

12

4

Enclosure HIM Emission Class Version

13-14

AA

Optional

Code

22D PowerFlex 40P

Code Version

4 Standard

Code EMC Filter

0 Not Filter

Code Voltage

B

Ph.

240V AC 3

D

E

480V AC 3

600V AC 3

Code HIM Version

1 Display/Fault Reset Only

2 Display/Fault Reset Only (Plate Drive)

Code Purpose

AA Reserved for thru

ZZ custom firmware

Code Enclosure

N Panel Mount - IP 20 (NEMA Type Open)

F

H

Flange Mount - IP 20 (NEMA Type Open)

Plate Drive - IP 20 (NEMA Type Open)

Output Current @ 200-240V Input

Code Amps kW (HP)

2P3

5P0

2.3

5.0

0.4 (0.5)

0.75 (1.0)

8P0

012

017

024

033

8.0

12

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 @ 380-480V Input

Code Amps kW (HP)

1P4

2P3

1.4

2.3

0.4 (0.5)

0.75 (1.0)

4P0

6P0

010

012

017

024

4.0

6.0

10.5

12

17

24

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

Output Current @ 460-600V Input

Code Amps kW (HP)

1P7

3P0

1.7

3.0

0.75 (1.0)

1.5 (2.0)

4P2

6P6

9P9

012

019

4.2

6.6

9.9

12

19

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10)

11 (15)

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 40P Drive.

For information on…

Opening the Cover

Mounting Considerations

See page

1-1

1-2

AC Supply Source Considerations 1-4

For information on… See page

Fuses and Circuit Breakers 1-7

Power Wiring 1-9

1-13 I/O Wiring

Recommendations

EMC Instructions 1-29

General Grounding Requirements 1-6

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

1.

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

2.

Pull the cover out and up to release.

1-2

Installation/Wiring

Mounting Considerations

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

Frame

B

C

Screw Size

M4 (#8-32)

M5 (#10-24)

Screw Torque

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

2.45-2.94 N-m (22-26 lb.-in.)

DIN Rail

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

Refer to Appendix B for mounting dimensions.

RUN

REV

FAULT

RUN

REV

FAULT

120 mm

(4.7 in.)

120 mm

(4.7 in.)

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

RUN

REV

FAULT

120 mm

(4.7 in.)

120 mm

(4.7 in.)

25 mm

(1.0 in.)

RUN

REV

FAULT

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

40°C (104°F)

IP 20/Open Type

IP 30/NEMA 1/UL Type 1

(1)

50°C (122°F) IP 20/Open Type

Minimum Mounting

Clearances

Use Mounting Option A

Use Mounting Option B

Use Mounting Option B

(1)

Rating requires installation of the PowerFlex 40P IP 30/NEMA 1/UL Type 1 option kit.

Installation/Wiring

1-3

Debris Protection

A plastic top panel is included with the drive. Install the panel to prevent debris from falling through the vents of the drive housing during installation. Remove the panel for IP 20/Open Type applications.

Storage

Store within an ambient temperature range of -40° to +85°C.

Store within a relative humidity range of 0% to 95%, non-condensing.

Do not expose to a corrosive atmosphere.

Plate Drive Installation

For Plate drive installation instructions, refer to Appendix H .

1-4

Installation/Wiring

!

AC Supply Source Considerations

Ungrounded Distribution Systems

ATTENTION:

PowerFlex 40P 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)

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

Installation/Wiring

1-5

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

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

Corrective Action

Install Line Reactor

(2) or Isolation Transformer or Bus Inductor – 5.5 & 11 kW

(7.5 & 15 HP) drives only

Install Line Reactor 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.

Install Line Reactor

(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.

1-6

Installation/Wiring

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

RUN

REV

FAULT

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.

Installation/Wiring

1-7

RFI Filter Grounding

Using 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 40P 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.

Fusing

The ratings in the table that follows are the 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.

1-8

Installation/Wiring

Table 1.C Recommended Branch Circuit Protective Devices

Voltage

Rating

240V AC –

3-Phase

480V AC –

3-Phase

600V AC –

3-Phase

Drive Rating

kW (HP)

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)

Fuse Rating

Amps

20

25

30

50

3

6

10

15

25

30

40

60

6

10

15

20

25

40

6

6

10

15

(1)

140M Motor

Protectors

Catalog No.

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-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-C07

100-C09

100-C12

100-C23

100-C23

100-C37

100-C60

(1)

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

Installation/Wiring

1-9

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.

1-10

Installation/Wiring

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 Description

600V, 90°C (194°F)

XHHW2/RHW-2

Anixter

B209500-B209507,

Belden 29501-29507, or equivalent

Tray rated 600V, 90°C

(194°F) RHH/RHW-2

Anixter OLF-7xxxxx or

• equivalent

Tray rated 600V, 90°C

(194°F) RHH/RHW-2

Anixter 7V-7xxxx-3G or equivalent

Four tinned copper conductors with XLPE insulation.

Copper braid/aluminum foil combination shield and tinned copper drain wire.

PVC jacket.

Three tinned copper conductors with XLPE insulation.

5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield.

PVC jacket.

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

Black sunlight resistant PVC jacket overall.

Three copper grounds on #10 AWG and smaller.

Installation/Wiring

1-11

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)

170 meters (558 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.

1-12

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)

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

DC- DC+ BR+ BRDC- DC+ BR+ BR-

Terminal

(1)

R/L1, S/L2

Description

1-Phase Input

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

(2)

U/T1

V/T2

W/T3

To Motor U/T1

To Motor V/T2

To Motor W/T3

=

Switch any two motor leads to change forward direction.

DC Bus Inductor Connection (C Frame drives only.)

P2, P1

DC+, DC-

BR+, BR-

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)

(2)

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.

Single-phase operation requires a 65% derate of drive rated current.

Table 1.E Power Terminal Block Specifications

Frame

B

C

Maximum Wire Size

(1)

5.3 mm

2

(10 AWG)

8.4 mm

2

(8 AWG)

Minimum Wire Size

1.3 mm

1.3 mm

2

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.

Installation/Wiring

1-13

Common Bus/Precharge Notes

If drives with internal precharge are used with a disconnect switch to the common bus, then an auxiliary contact on the disconnect must be connected to a digital input of the drive. The corresponding input

(parameter A051-A054) must be set to option 29, “Precharge Enable.”

This provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus.

!

!

I/O Wiring Recommendations

Motor Start/Stop Precautions

ATTENTION:

A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur.

ATTENTION:

The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present - the motor will coast to a stop. An auxiliary braking method may be required.

Important points to remember about I/O wiring:

Always use copper wire.

Wire with an insulation rating of 600V or greater is recommended.

Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).

Important:

I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to greatly reduce common mode interference.

!

ATTENTION:

Driving the 4-20mA analog input from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.

1-14

Installation/Wiring

Signal and Control Wire Types

Table 1.F Recommended Signal Wire

Signal Type/

Where Used

Analog I/O & PTC

Remote Pot

Encoder/Pulse I/O

Belden Wire Type(s)

(1)

(or equivalent)

8760/9460

8770

89730

(2)

Description

0.750 mm

2

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

(3)

0.750 mm

2

(18AWG), 3 cond., shielded

0.196 mm

2

(24AWG), individually shielded pairs

Min. Insulation

Rating

300V,

75-90

°

C

(167-194

°

F)

(1)

(2)

(3)

Stranded or solid wire.

9728 or 9730 are equivalent and may be used but may not fit in the drive wire channel.

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.

Table 1.G Recommended Control Wire for Digital I/O

Type

Shielded

Wire Type(s)

Unshielded Per US NEC or applicable national or local code

Multi-conductor shielded cable such as Belden

8770(or equiv.)

Description

0.750 mm

2

(18AWG), 3 conductor, shielded.

Minimum

Insulation Rating

300V,

60 degrees C

(140 degrees F)

I/O Terminal Block

Table 1.H I/O Terminal Block Specifications

Frame

B & C

Maximum Wire Size

(1)

Minimum Wire Size

(1)

Torque

1.3 mm

2

(16 AWG) 0.2 mm

2

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

(1)

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 may be connected to ground terminal/protective earth. If using the RS485 (DSI) port, I/O Terminal 19 should also be connected to ground terminal/protective earth.

Installation/Wiring

1-15

Figure 1.5 Control Wiring Block Diagram

Enable Jumper

(6)

Relay N.O.

R1

Relay Common

R2

Relay N.C.

R3

SNK SRC

30V DC

50mA

Non-inductive

+24V

+10V

0-10V

0/4-20mA

08

09

06

07

04

05

01

02

03

Stop

(1)(6)

Start/Run FWD

(2)

Direction/Run REV

(3)

Typical

SRC Wiring

Digital Common

Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

Opto Common

18

19

15

16

12

13

14

11

+24V DC

+10V DC

0-10V (or ±10V) Input

(4)

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

(5)

24V

0-10V

0-20mA

R1 R2 R3

SNK

SRC

Analog Output Select

+/-10V

10V

(4)

01 02 03 04 05

Voltage Range Select

ENBL

Enable

(6)

Jumper

06 07 08 09

RS485

(DSI)

1

(1)

11 12 13 14 15 16 17 18 19

Resistive

Inductive

30V DC

3.0A

0.5A

125V AC

3.0A

0.5A

240V AC

3.0A

0.5A

See Control Wiring Block Diagram Notes on next page.

1-16

Installation/Wiring

Control Wiring Block Diagram Notes

(1)

Important:

I/O Terminal 01 is always a coast to stop input except when P036 [Start

Source] is set to “3-Wire”, “2-W Lvl Sens” 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] Stop

3-Wire Per P037

2-Wire Per P037

2-W Lvl Sens

2-W Hi Speed

RS485 Port

Momt FWD/REV

Per P037

Per P037

Per P037

Per P037

I/O Terminal 01 Stop

Per P037

(6)

Coast

Per P037

(6)

Coast

Coast

Per P037

(6)

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

Terminal 02 to command a start. Use a maintained input change direction.

on I/O

for I/O Terminal 03 to

(3)

The function of I/O Terminal 03 is fully programmable. Program with E202 [Digital

Term 3].

(4)

Match the Voltage Range Select DIP Switch setting with the control scheme for proper

Uni-Polar or Bipolar analog input operation.

(5)

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.

(6)

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

No. Signal Default

R1

R2

R3

Relay N.O.

Relay Common

Relay N.C.

Fault

Fault

Analog Output Select DIP

Switch

0-10V

Sink/Source DIP Switch Source (SRC)

01

02

03

04

05

06

07

08

09

11

12

13

14

15

16

17

18

19

Stop

(1)

Table 1.I Control I/O Terminal Designations

Start/Run FWD

Digital Term 3

Digital Common

Digital Input 1

Digital Input 2

Digital Input 3

Digital Input 4

Opto Common

+24V DC

+10V DC

±10V In

(2)

Analog Common

4-20mA In

(2)

Analog Output

Opto Output 1

Opto Output 2

Coast

Not Active

Not Active

Preset Freq

Preset Freq

Local

Jog Forward

Not Active

Not Active

OutFreq 0-10

MotorRunning

At Frequency

RS485 (DSI) Shield –

Description Param.

Normally open contact for output relay.

A055

Common for output relay.

Normally closed contact for output relay.

A055

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.

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

P036

(1)

P036

,

P037

I/O Terminal 03 is fully programmable. Program with

E202 [Digital Term 3]. To disable reverse operation, see A095 [Reverse Disable].

P036

A095

,

,

P037

E202

,

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

Program with A051 [Digital In1 Sel].

Program with A052 [Digital In2 Sel].

Program with A053 [Digital In3 Sel].

Program with A054 [Digital In4 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).

P038

A051

A132

-

,

A054

,

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)

Program with A058 [Opto Out1 Sel]

A065

,

A066

A058

A064

,

A059 ,

Program with A061 [Opto Out2 Sel]

A061

,

A062 ,

A064

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

(1)

(2)

See Footnotes (1) and (6) 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

Encoder Interface

The PowerFlex 40P Encoder Interface can source 5 or12 volt power and accept 5, 12 or 24 volt single ended or differential inputs.

12V

5V

+V Cm B- B A- A

Table 1.J Terminal Description

No. Signal

+V

Cm Power Return

BEncoder B (NOT)

B

A-

A

5V-12V Power

(1)

Encoder B

Encoder A (NOT)

Encoder A

Description

Internal power source 250 mA (isolated).

Quadrature B input.

Single channel, pulse train, or quadrature A input.

Output DIP switch selects 12 or 5 volt power supplied at terminals “+V” and “Cm” for the encoder.

(1)

When using 12V Encoder power, 24V I/O power, maximum output current at I/O

Terminal 11 is 50 mA.

Important:

A quadrature encoder provides rotor speed and direction.

Therefore, the encoder must be wired such that the forward direction matches the motor forward direction. If the drive is reading encoder speed but the position regulator or other encoder function is not working properly, remove power to the drive and swap the A and B encoder channels or swap any two motor leads. Drives using FRN 2.xx and greater

will fault when an encoder is incorrectly wired and E216

[Motor Fdbk Type] is set to option 5 “Quad Check”.

Installation/Wiring

Figure 1.6 Sample Encoder Wiring

I/O

Encoder

Power –

Internal Drive

Power

Internal (drive)

12V DC,

250mA

Encoder

Signal –

Single-Ended,

Dual Channel

Connection Example

B

A-

A

+V

Cm

B-

+V

Cm

B-

B

A-

A

+12V DC

(250 mA)

Common

B NOT

B

A NOT

A to SHLD to Power Supply

Common to SHLD

I/O

Encoder

Power –

External

Power

Source

Connection Example

Encoder

Signal –

Differential,

Dual

Channel

+V

Cm

B-

B

A-

A

External

Power

Supply to

SHLD to SHLD

B NOT

B

A NOT

A

Figure 1.7 Encoder Wire Routing Options

IP20/Open Type

1-19

SK-U1-DCVR4-EN

IP30/NEMA 1/UL Type 1

SK-U1-DCVR4-EN

1-20

Installation/Wiring

Hardware Enable Circuitry

I/O Terminal 01 is always a stop input. The status of this input is

interpreted by drive software

. If the application requires the drive to be disabled

without

software interpretation, a hardware enable configuration can be utilized. This is done by removing the ENBL enable jumper and wiring the enable input to I/O Terminal 1 (see below).

1.

Remove drive cover as

described on page 1-1

.

2.

Locate and remove the Enable

Jumper on the Main Control Board

(see diagram).

3.

Wire Enable to I/O Terminal 1

(see

Table 1.I

). The drive will always coast to a stop regardless of the settings of

P036

[Start Source]

and P037

[Stop Mode].

4.

If I/O Terminal 01 is used as hardware enable and 3-wire control is needed, program one of the digital inputs for the desired stop mode.

Installation/Wiring

User Installed DriveGuard Safe-Off Option (Series B)

1-21

4

3

2

1

The DriveGuard Safe-Off Option (Series B) board, when used with suitable safety components, provides protection according to EN

954-1:1997; Category 3 for safe off and protection against restart. The

PowerFlex safe off option is just one safety control system. All components in the system must be chosen and applied correctly to achieve the desired level of operator safeguarding. Refer to the

DriveGuard Safe-Off Option (Series B)

User Manual

, publication

PFLEX-UM003… for detailed installation information.

!

ATTENTION:

Hazard of injury exists due to electric shock. Only install a Series B or greater DriveGuard Safe-Off Option in a PowerFlex

40P Drive.

Important:

When using the DriveGuard Safe-Off Option (Series B) with the drive in an IP30/NEMA 1/UL Type 1 installation, only use low voltage Class 2 circuits.

Table 1.K Safe-Off Option Terminal Description

No. Signal

4

3

2

1

24V Common

+24V DC

Common - N.C.

Monitor - N.C.

Description

Connections for user supplied power to energize coil.

Normally closed contacts for monitoring relay status.

Maximum Resistive Load: 250V AC / 30V DC / 50 VA / 60 Watts

Maximum Inductive Load: 250V AC / 30V DC / 25 VA / 30 Watts

1-22

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

1-23

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

Connection Example

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.

2 Wire SRC Control -

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.

2 Wire SNK Control -

Run FWD/Run REV

Internal Supply (SRC)

Stop-Run

Forward

Stop-Run

Reverse

11

Internal Supply (SNK)

01

02

03

Stop-Run

Forward

Stop-Run

Reverse

01

02

03

04

External Supply (SRC)

+24V

Stop-Run

Forward

Stop-Run

Reverse

Common

Each digital input draws 6 mA.

01

02

03

04

1-24

Installation/Wiring

Input/Output

3 Wire SRC Control -

Non-Reversing

P036

[Start Source] = 1

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

P037

[Stop Mode].

Connection Example

Internal Supply (SRC)

Stop

Start

11

01

02

External Supply (SRC)

Stop

Start

01

02

04

+24V Common

Each digital input draws 6 mA.

3 Wire SNK Control -

Non-Reversing

Internal Supply (SNK)

Stop

Start

01

02

03

04

3 Wire SRC Control -

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.

Internal Supply (SRC)

Stop

Start

Direction

11

01

02

03

3 Wire SNK Control -

Reversing

Internal Supply (SNK)

Stop

Start

Direction

01

02

03

04

External Supply (SRC)

Stop

+24V

Start

Direction

Common

Each digital input draws 6 mA.

01

02

03

04

Installation/Wiring

1-25

Input/Output

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.

Connection Example

Opto-Output 1

17

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

+24V

CR

Each Opto-Output is rated

30V DC 50 mA (Non-inductive).

Common

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

+

1-26

Installation/Wiring

Typical Multiple Drive Connection Examples

Input/Output

Multiple Digital

Input Connections

Customer Inputs can be wired per

External Supply

(SRC).

Connection Example

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:

I/O Common terminals 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

1-27

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

Comm Select Input

Enabled and Active:

[Digital Inx Sel] = 6

Yes

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

No

0-10V Override

Enabled and Active:

[Digital Inx Sel] = 13

Yes

Speed commands come from

0-10V or -10-10V.

Start and Direction follows P036 [Start Source] or

Bi-Polar input when enabled.

No

4-20mA Override

Enabled and Active:

[Digital Inx Sel] = 14

Yes

Speed commands come from 4-20mA.

Start and Direction follows P036 [Start Source].

No

P038 [Speed Reference]

= 4 or 5

Yes

Run as specified by

P038 [Speed Reference].

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].

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

No

PID Enabled:

A132 [PID Ref Sel]

0

Yes

Run as specified by

A132 [PID Ref Sel].

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

No

Run as specified by

P038 [Speed Reference].

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

All Results

Encoder Enabled

P038 = 8 or

A132 = 9

No

Yes

No change in control.

Run according to Priority Checklist.

Encoder Type Selected:

A216 [Motor Fdbk Type]

0

Yes

No

No change in control.

Speed Commands as defined.

Encoder provides trim.

No change in direction control.

1-28

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]

Direction comes from

I/O Terminal 03 Dir/Run REV

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

Speed is controlled by [Preset Freq x]

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

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

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 or

Pos Logic

Yes

Either

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

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

Step Logic parameters A140-A147 or

Position Logic parameters E230-E245

No

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

Installation/Wiring

1-29

EMC Instructions

CE Conformity

(1)

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 encoder cover is not intact, 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.

If the DriveGuard Safe-Off Option (Series B) is installed, use only low voltage Class 2 circuits.

When using the DriveGuard Safe-Off Option (Series B), the installation must meet all the requirements listed in the DriveGuard

Safe-Off Option (Series B)

User Manual

, publication

PFLEX-UM003.

In CE installations, input power must be a Balanced Wye with Center

Ground configuration.

(1)

600 Volt class drives are not CE Certified.

1-30

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 1.8

. Refer to

page 1-7 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.L

is not exceeded.

Table 1.L Allowable Cable Length

Filter Type

External - S Type

(1)

External - L Type

(1)

EN61800-3 First Environment

Restricted Distribution or

Second Environment

(2)

10 meters (33 feet)

100 meters (328 feet)

EN61800-3 First Environment

Unrestricted Distribution

1 meter (3 feet)

5 meters (16 feet)

(3)

(1)

Refer to

Appendix B for details on optional external filters.

(2)

Equivalent to EN55011 Class A.

(3)

Equivalent to EN55011 Class B. To meet radiated emissions requirements for

EN61800-3 First Environment Unrestricted Distribution when communications is used, ferrite cores need to be added to the communication lines. The recommended core is

Fair-Rite part number 0446176451 or Erocore part number FH29.7x13x25.9/FH1300 or an equivalent core. The communication line must be wrapped a total of three times around the core. Two cores may be needed depending on the thickness of the wire and the core chosen. Both recommended cores are split-type and can be added to an existing installation.

Figure 1.8 Connections and Grounding

Shielded Enclosure

(1)

IP 30/NEMA 1/UL Type 1

Option Kit

EMI Fittings and Metal Conduit

L1

L2

L3

EMI Filter

L1'

L2'

L3'

R/L1

S/L2

T/L3

Enclosure Ground Connection Shielded Motor Cable

U/T1

V/T2

W/T3

Building Structure Steel

(1)

First Environment Unrestricted Distribution installations require a shielded enclosure.

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

Installation/Wiring

1-31

EN61000-3-2

0.75 kW (1 HP) 240V 3-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.

1-32

Notes:

Installation/Wiring

Chapter

2

Start Up

This chapter describes how to start up the PowerFlex 40P 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 1-15 for

location.

Important:

The default control scheme is Source (SRC). The Stop terminal is jumpered to allow starting from comms. 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.

Start, Stop, Direction and Speed Control

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

Important:

To disable reverse operation, see

A095 [Reverse Disable].

If a fault appears on power up, refer to

Fault Descriptions on page 4-3

for an explanation of the fault code.

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”.

Start Up

2-3

Display/Fault Reset

RUN

REV

FAULT

Menu Description

Basic Display Group (View Only)

Commonly viewed drive operating conditions.

Advanced Display Group (View Only)

Consists of advanced drive operating conditions.

Fault Designator

Consists of list of codes for specific fault conditions. Displayed only when fault is present.

No. LED

Run Status

Fault Status

LED State

Steady Red

Flashing Red

Direction Status Steady Red

Flashing Red

Flashing Red

Description

Indicates drive is running.

Drive has been commanded to change direction.

Indicates drive is running in reverse direction.

Drive has been commanded to change direction and motor is decelerating to zero.

Indicates drive is faulted.

No. Key

Name

Up Arrow

Description

Scroll:

Press and release to scroll through user-selectable display parameters. Refer to

E201 [LED Display Opt] for options.

Reset:

Press and hold for three seconds to clear active fault.

Drive Programming Tools

For additional drive programming and control, a DSI remote HIM or PC programming tools (DriveExplorer or DriveTools SP) should be used.

Description

Serial Converter Module

DriveExplorer Software

(1)

DriveTools SP Software

(1)

Remote Panel Mount, LCD Display

Remote Handheld, LCD Display

(1)

Requires a Serial Converter Module.

Catalog Number

22-SCM-232

9306-4EXP02ENE

9303-4DTS01ENE

22-HIM-C2S

22-HIM-A3

2-4

Start Up

Notes:

Chapter

3

Programming and Parameters

Chapter 3 provides a complete listing and description of the PowerFlex

40P parameters. Parameters are programmed (viewed/edited) using either a DSI Remote HIM or PC programming tools (DriveExplorer™ or

DriveTools SP™ software), a personal computer and a serial converter

module. Refer to Appendix B for catalog numbers.

For information on…

About Parameters

Parameter Organization

Basic Display Group

Basic Program Group

Advanced Program Group

Enhanced Program Group

Advanced Display Group

Parameter Cross Reference – by Name

See page…

3-1

3-2

3-3

3-9

3-15

3-49

3-62

3-64

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 3-64 for an alphabetical listing of parameters.

Basic Display Group

Output Freq

Commanded Freq

Output Current

Basic Program Group

b001 b002 b003

Output Voltage

DC Bus Voltage

Drive Status

Fault 1 Code

Fault 2 Code

Fault 3 Code

Process Display

Control Source

Motor NP Volts

Motor NP Hertz

Motor OL Current b004 b005 b006 b007 b008 b009 b010 b012

P031

P032

P033

Advanced Program Group

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

A051

A052

A053

A054

A055

A056

A058

A059

A061

A062

A064

A065

A066

A067

A068

A069

A070

A071

A072

A073

A074

A075

A076

A077

Enhanced Program Group

LED Display Opt

Digital Term 3

Accel Time 3

Decel Time 3

Accel Time 4

Decel Time 4

E201

E202

E203

E204

E205

E206

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

A102

A103

Comm Node Addr A104

Comm Loss Action A105

Comm Loss Time

Comm Format

Language

A106

A107

A108

A094

A095

A096

A097

A098

A099

A100

A101

A086

A087

A088

A089

A090

A091

A092

A093

A078

A079

A080

A081

A082

A083

A084

A085

Comm Write Mode E207

Power Loss Mode E208

Half Bus Enable

Max Traverse

E209

E210

Traverse Inc

Traverse Dec

P Jump

Sync Time

Speed Ratio

E211

E212

E213

E214

E215

Advanced Display Group

Drive Status 2

Fibers Status d301 d302 b013 b014 b015 b016 b017 b018 b019 b020

P034

P035

P036

P037

P038

A133

A134

A135

A136

A137

A138

A139

A125

A126

A127

A128

A129

A130

A131

A132

A117

A118

A119

A120

A121

A122

A123

A124

A109

A110

A111

A112

A113

A114

A115

A116

E216

E217

E218

E219

E220

E221

E222

E223

E224

E225

E226

Contrl In Status

Dig In Status

Comm Status

Control SW Ver

Drive Type

Elapsed Run Time

Testpoint Data

Analog In 0-10V

Minimum Freq

Maximum Freq

Start Source

Stop Mode

Speed Reference

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

PID Setpoint

PID Deadband

PID Preload

Motor Fdbk Type

Motor NP Poles

Encoder PPR

Pulse In Scale

Ki Speed Loop

Kp Speed Loop

Positioning Mode

Find Home Freq

Find Home Dir

Encoder Pos Tol

Counts Per Unit

Slip Hz Meter

Speed Feedback

Encoder Speed d303 d304 d306 b021 b022 b023 b024 b025 b026 b028 b029

P039

P040

P041

P042

P043

A150

A151

A152

A153

A154

A155

A156

A157

A140

A141

A142

A143

A144

A145

A146

A147

A160

A161

A162

A163

Analog In 4-20mA

Output Power

Output Powr Fctr

Drive Temp

Counter Status

Timer Status

Stp Logic Status

Torque Current

Accel Time 1

Decel Time 1

Reset To Defalts

Voltage Class

Motor OL Ret

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

Step Units 0

Step Units 1

Step Units 2

Step Units 3

Step Units 4

Step Units 5

Step Units 6

Step Units 7

Pos Reg Filter

Pos Reg Gain

Enh Control Word

Cmd Stat Select

Units Traveled H

Units Traveled L

E230

E232

E234

E236

E238

E240

E242

E244

E246

E247

E248

E249 d308 d309

Programming and Parameters

3-3

Basic Display Group

b001 [Output Freq]

Related Parameter(s): b002

, b010

,

P034 , P035

,

P038

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

Values

Default:

Min/Max:

Display:

Read Only

0.00/

P035 [Maximum Freq]

0.01 Hz

b002 [Commanded Freq]

Related Parameter(s): b001

, b013

,

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 1-27

for details.

Values

Default: Read Only

Min/Max: 0.00/

P035 [Maximum Freq]

Display: 0.01 Hz

b003 [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

b004 [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

b005 [DC Bus Voltage]

Present DC bus voltage level.

Values

Default:

Min/Max:

Display:

Read Only

Based on Drive Rating

1 VDC

3-4

Programming and Parameters

Basic Display Group

(continued)

b006 [Drive Status]

Present operating condition of the drive.

Related Parameter(s):

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

b007 [Fault 1 Code] b008 [Fault 2 Code] b009 [Fault 3 Code]

A code that represents a drive fault. The codes will appear in these parameters in the order they occur

( b007

[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

b010 [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

Related Parameter(s): b001

,

A099

Programming and Parameters

3-5

Basic Display Group

(continued)

b012 [Control Source]

Related Parameter(s):

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

1-27

and 1-28

for details.

Values

Default:

Min/Max:

Display:

Start Command

1 = Terminal Block

2 = Communications

9 = Jogging

Digit 1

Speed Command

01 = A069 [Internal Freq]

02 = 0-10V Input/Remote Potentiometer

Digit 3 & 2

03 = 4-20mA Input

04 =

A070 A077

[Preset Freq x]

( A051 - A053

[Digital Inx Sel] must be set to 4)

05 = RS485 (DSI) Port

06 = StepLogic Control (Parameters

A140

-

A147 )

07 = Analog Input Multiply

08 = PID Control

09 = Jogging

10 = Encoder or Pulse Train Reference

11 = Positioning Control

Reserved Digit 4

Read Only

0/112

1

b013 [Contrl In Status]

Related Parameter(s):

b002 ,

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

Programming and Parameters

Basic Display Group

(continued)

b014 [Dig In Status]

Status of the control terminal block digital inputs.

Related Parameter(s): A051

-

A054

1 = Input Present, 0 = Input Not Present

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

Digital In2 Sel (I/O Terminal 06)

Digital In3 Sel (I/O Terminal 07)

Digital In4 Sel (I/O Terminal 08)

Bit 1

Bit 2

Bit 3

Values

Default:

Min/Max:

Display:

b015 [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

b016 [Control SW Ver]

Main Control Board software version.

Values

Default:

Min/Max:

Display:

Read Only

1.00/99.99

0.01

b017 [Drive Type]

Used by Rockwell Automation field service personnel.

Values

Default: Read Only

Min/Max: 1001/9999

Display: 1

Related Parameter(s): A103

-

A107

Programming and Parameters

3-7

Basic Display Group

(continued)

b018 [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

b019 [Testpoint Data]

The present value of the function selected in A102

[Testpoint Sel].

Values

Default: Read Only

Min/Max: 0/FFFF

Display: 1 Hex

Related Parameter(s):

A102

b020 [Analog In 0-10V]

Related Parameter(s): A110

,

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%

b021 [Analog In 4-20mA]

Related Parameter(s): A112

,

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%

b022 [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

b023 [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

Programming and Parameters

Basic Display Group

(continued)

b024 [Drive Temp]

Present operating temperature of the drive power section.

Values

Default: Read Only

Min/Max:

Display:

0/120 degC

1 degC

b025 [Counter Status]

The current value of the counter when counter is enabled.

Values

Default: Read only

Min/Max: 0/9999

Display: 1

b026 [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

b028 [Stp Logic Status]

When P038

[Speed Reference] is set to 6 “Stp Logic” or 9 “Positioning”, this parameter will display the

current step of the Step Logic profile as defined by parameters A140 A147

[Stp Logic x].

Values

Default: Read Only

Min/Max: 0/8

Display: 1

b029 [Torque Current]

The current value of the motor torque current.

Values

Default:

Min/Max:

Read Only

0.00/(Drive Rated Amps

×

2)

Display: 0.01 Amps

Programming and Parameters

3-9

Basic Program Group

P031 [Motor NP Volts]

Related Parameter(s): b004

, 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]

Related Parameter(s):

A084 ,

A085

,

A086 , A087

,

A090

Stop drive before changing this parameter.

Set to the motor nameplate rated frequency.

Values

Default: 60 Hz

Min/Max: 15/500 Hz

Display: 1 Hz

P033 [Motor OL Current]

Related Parameter(s): A055

,

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:

Based on Drive Rating

0.0/(Drive Rated Amps

×

2)

Display: 0.1 Amps

P034 [Minimum Freq]

Related Parameter(s): b001

,

b002 ,

b013

,

P035

,

A085 ,

A086

,

A087

, A110

,

A112

Sets the lowest frequency the drive will output continuously.

Values

Default: 0.00 Hz

Min/Max:

Display:

0.00/500.0 Hz

0.01 Hz

P035 [Maximum Freq]

Related Parameter(s): b001

,

b002 ,

b013

,

P034

,

A065 ,

A078 ,

A085 , A086

,

A087 ,

A111

,

A113

Stop drive before changing this parameter.

Sets the highest frequency the drive will output.

Values

Default: 60.00 Hz

Min/Max: 0.00/500.0 Hz

Display: 0.01 Hz

3-10

Programming and Parameters

Basic Program Group

(continued)

P036 [Start Source]

Related Parameter(s): b012

,

P037

Stop drive before changing this parameter.

Sets the control scheme used to start the drive and controls the behavior of I/O Terminals 01, 02, and

03. However, I/O Terminal 03 is fully programmable via E202

[Digital Term 3].

Refer to Start and Speed Reference Control on page 1-27 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.

Important:

I/O Terminal 01 is always a stop and must be active for the drive to run regardless of stop source.

Options 1

“3-Wire”

(1)

I/O Terminal 01 “Stop” = stop according to the value set in

P037 [Stop Mode].

I/O Terminal 03 “Direction”

2

“2-Wire”

3

“2-W Lvl Sens”

I/O Terminal 01 “Stop” = coast to stop.

I/O Terminal 03 “Run REV”

I/O Terminal 01 “Stop” = coast to stop. Drive will restart after a

“Stop” command when:

Stop is removed

• and

Start is held active

I/O Terminal 03 “Run REV”

!

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

5

6

“2-W Hi Speed”

“Comm Port” (Default)

“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.

I/O Terminal 01 “Stop” = coast to stop.

I/O Terminal 03 “Run REV”

Remote communications. Refer to Appendix C for details.

I/O Terminal 01 “Stop” = coast to stop.

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).

I/O Terminal 01 “Stop” = stop according to the value set in

P037 [Stop Mode].

(1)

If I/O Terminal 01 is used as hardware enable and 3-wire control is needed, program one of the digital inputs for the desired stop mode.

Programming and Parameters

3-11

Basic Program Group

(continued)

P037 [Stop Mode]

Related Parameter(s): P036 ,

A080 , A081

,

A082

, A105

,

A160

Active stop mode for all stop sources [e.g. 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, I/O Terminal 01 will always cause the drive to

coast to a stop regardless of the settings of P036

[Start Source] and P037

[Stop Mode].

DriveGuard Safe-Off Option (Series B)

The addition of the DriveGuard Safe-Off Option (Series B) board, when used with suitable safety components, provides protection according to EN 954-1:1997; Category 3 for safe-off and protection against restart.

Options 0

“Ramp, CF”

(1)

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

1

2

“Coast, CF”

(1)

“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

Brake Time].

A080 [DC

OR

Drive shuts off if the drive detects that the motor is stopped.

“Stop” command clears active fault.

6

7

4

5

8

“Ramp”

“Coast”

“DC Brake”

“DC BrakeAuto”

“Ramp+EM B,CF”

Ramp to Stop.

Coast to Stop.

DC Injection Braking Stop.

DC Injection Braking Stop with Auto Shutoff.

Standard DC Injection Braking for value set in

Brake Time].

A080 [DC

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

Programming and Parameters

Basic Program Group

(continued)

P038 [Speed Reference]

Related Parameter(s):

b001

,

b002 ,

b012

,

b020

,

b021

, P039

,

P040 ,

A051 A054 ,

A069 ,

A070 A077

,

A110

,

A111 ,

A112 ,

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 1-27 for more information on speed reference control priority.

Options 1

2

3

4

5

“InternalFreq”

“0-10V Input”

“4-20mA Input”

“Preset Freq”

“Comm Port” (Default)

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

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.

External frequency command from the communications port.

Refer to Appendix C for details.

6

“Stp Logic”

7

8

9

“Anlg In Mult”

“Encoder”

“Positioning”

External frequency command as defined by

A070 - A077

[Preset Freq x] and

A140 - A147

[Stp Logic x]. If Step

Logic-based positioning control is desired, select option 9

“Positioning” and adjust E222 [Positioning Mode].

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

b020 [Analog In 0-10V] and b021

[Analog In 4-20mA]).

[Analog In 0-10V]

×

[Analog In 4-20mA] = Speed Command

Example: 100%

×

50% = 50%

External frequency command directly from encoder or pulse train input. Use

E216

[Motor Fdbk Type] to select encoder type.

External position as defined by E222 and E230 -

E245 . Refer

to

Appendix F

for detailed information on positioning.

Programming and Parameters

3-13

Basic Program Group

(continued)

P039 [Accel Time 1]

Sets the rate of acceleration for all speed increases.

Maximum Freq

Accel Time

=

Accel Rate

Related Parameter(s):

P038 ,

P040

,

A051 A054 ,

A067

,

A070 A077 ,

A140

-

A147

Values

Default:

Min/Max:

Display:

P035 [Maximum Freq]

10.0 Secs

0.0/600.0 Secs

0.1 Secs

Deceleration

Speed

Acceleration

0

0

P039, A067,

E203 or E205

[Accel Time x]

Time

P040, A068,

E204 or E206

[Decel Time x]

P040 [Decel Time 1]

Sets the rate of deceleration for all speed decreases.

Maximum Freq

Decel Time

=

Decel Rate

Related Parameter(s):

P038 ,

P039

,

A051 A054 ,

A068

,

A070 A077 ,

A140

-

A147

Values

Default:

Min/Max:

Display:

P035 [Maximum Freq]

10.0 Secs

0.0/600.0 Secs

0.1 Secs

Deceleration

Speed

Acceleration

0

0

P039, A067,

E203 or E205

[Accel Time x]

Time

P040, A068,

E204 or E206

[Decel Time x]

P041 [Reset To Defalts]

Stop drive before changing this parameter.

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.

3-14

Programming and Parameters

Basic Program Group

(continued)

P042 [Voltage Class]

Stop drive before changing this parameter.

Sets the voltage class of 600V drives.

Options 2

“Low Voltage” 480V

3

“High Voltage” (Default) 600V

P043 [Motor OL Ret]

Related Parameter(s):

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

1

“Disabled” (Default)

“Enabled”

Programming and Parameters

3-15

Advanced Program Group

A051 [Digital In1 Sel]

(I/O Terminal 05)

A052 [Digital In2 Sel]

(I/O Terminal 06)

A053 [Digital In3 Sel]

(I/O Terminal 07)

A054 [Digital In4 Sel]

(I/O Terminal 08)

Related Parameter(s): b012

,

b014 ,

P038

,

P039

,

P040 ,

A067 , A068 ,

A070

-

A077 , A078

,

A079 ,

A118 ,

A140

-

A147

Stop drive before changing this parameter.

Selects the function for the digital inputs. I/O Terminal 03 is fully programmable via E202 [Digital Term

3]. Refer to the flowchart on page 1-27 for more information on speed reference control priority.

Options 0

“Not Used”

1

2

3

4

“Acc/Dec Sel1”

“Jog”

“Aux Fault”

“Preset Freq”

(A051 & A052 Default)

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

b014 [Dig In Status].

If active, can determine which Accel/Decel time will be used for all ramp rates except jog. Can be applied to one input only. Refer to

A067 [Accel Time 2] for details. Can be used

with option 28 “Acc/Dec Sel2” for additional Accel/Decel times.

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.

In Velocity mode (P038

9) selects a preset frequency.

Refer to A070 - A077 [Preset Freq x].

In Positioning mode (P038 = 9) selects a preset frequency and position. Refer to E230 - E244 [Step Units x].

Important:

Digital Inputs have priority for frequency and position control when programmed as Preset Speed and are

active. Refer to the flowchart on page 1-27 for more

information on speed reference control priority.

5

6

“Reserved”

“Comm Port”

7

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

Can only be tied to one input.

When active, clears an active fault.

8

“Clear Fault”

(A053 Default)

“RampStop,CF”

9

“CoastStop,CF”

10

“DCInjStop,CF”

11

“Jog Forward”

(A054 Default)

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.

3-16

Programming and Parameters

A051 -

A054

Options

(Cont.)

12

“Jog Reverse”

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”

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.

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 a rate of 2 Hz per second. Default for A069 is 60 Hz.

Decreases the value of A069 [Internal Freq] at a rate of 2 Hz per second. Default for A069 is 60 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 Step Logic

parameters A140

-

A147 [Stp Logic x]. Logically ORed with

E248 [Enh Control Word] bit 6 “Logic In 1”.

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 Step Logic

parameters A140

-

A147 [Stp Logic x]. Logically ORed with

E248 [Enh Control Word] bit 7 “Logic In 2”.

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.

Refer to A160

[EM Brk Off Delay] for additional information.

ATTENTION:

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

!

28

“Acc/Dec Sel2” If active, can determine which

Accel/Decel time will be used for all ramp rates except jog. Can be applied to one input only. Used with option 1 “Acc/Dec Sel1” for the Accel/Decel times listed in this table.

1

1

0

0

Option

28 1

0

1

0

1

Description

Acc/Dec 1

Acc/Dec 2

Acc/Dec 3

Acc/Dec 4

A051 -

A054

Options

(Cont.)

29

“Precharge En”

30

“Inertia Dcel”

31

“Sync Enable”

32

“Traverse Dis”

33

“Home Limit”

34

“Find Home”

35

“Hold Step”

36

“Pos Redefine”

Programming and Parameters

3-17

Forces drive into precharge state. Typically controlled by auxiliary contact on the disconnect at the DC input to the drive. If this input is assigned, it must be energized for the pre-charge relay to close and for the drive to run. If it is de-energized, the pre-charge relay will open and the drive will coast to a stop.

Forces drive into Inertia Ride-Through state. The drive will attempt to regulate the DC bus at the current level.

Must be used in order to hold the existing frequency when

Sync Time is set to enable speed synchronization. When this input is released the drive will accelerate to the commanded frequency in E214 [Sync Time].

When an input is programmed the traverse function will be

disabled while this input is active. Refer to E210

[Max

Traverse].

In Positioning mode, this indicates the drive is at the home position. Refer to

Appendix F

for detailed information on positioning.

In Positioning mode this causes the drive to return to the

Home position when a start is issued. It does this by using the

[Find Home Freq] and [Find Home Direction] until the “Home

Limit” input is activated. If it passes this point, it then runs in the reverse direction at 1/10th the frequency of [Find Home

Freq] until the “Home Limit” is activated again. As long as this input is active, any start command will cause the drive to enter the homing routing. Only functions if in Positioning mode. Once the Find Home routine has finished, the drive will stop. Refer to

Appendix F for detailed information on

positioning.

In Positioning mode, this input over-rides other inputs and causes the drive to remain at its current step (running at zero speed once it reaches its position) until released. While in

“Hold”, the drive will ignore any input command which would normally result in a move to a new step. Timers continue to run. Therefore, when the Hold is removed, the drive must see any required digital inputs transition (even if they already transitioned during the hold), but it does not reset any timer.

Refer to Appendix F for detailed information on positioning.

In Positioning mode, this input resets the home position to the

current position of the machine. Refer to Appendix F for

detailed information on positioning.

3-18

Programming and Parameters

Advanced Program Group

(continued)

A055 [Relay Out Sel]

Related Parameter(s):

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

2

“At Frequency”

“MotorRunning”

Drive reaches commanded frequency.

Motor is receiving power from the drive.

3

4

5

“Reverse”

“Motor Overld”

“Ramp Reg”

6

7

8

“Above Freq”

“Above Cur”

“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].

Use A056 to set threshold.

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].

Use A056 to set threshold.

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.

Use A056 to set threshold.

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

An input is programmed as “Logic In 2” 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 Step Logic step with Digit 3 of Command Word

( A140 - A147 ) set to enable Step Logic output.

Timer has reached value set in

Use A056 to set threshold.

Use A056 to set threshold.

A056

Counter has reached value set in

[Relay Out Level].

A056 [Relay Out Level].

Power Factor angle has exceeded the value set in

[Relay Out Level].

Use A056 to set threshold.

A056

Programming and Parameters

3-19

A055

Options

(Cont.)

19

“Anlg In Loss”

20

“ParamControl”

21

“NonRec Fault”

22

“EM Brk Cntrl”

23

“At Position”

24

“At Home”

25

“Safe-Off”

Analog input loss has occurred. Program A122 [Analog In

Loss] for desired action when input loss occurs.

Enables the output to be controlled over network communications by writing to

A056 [Relay Out Level].

(0 = Off, 1 = On.)

Value set in

A092

A092

[Auto Rstrt Tries] is exceeded.

[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 drive is in Positioning mode and has reached the

commanded position. Tolerance is adjusted with E225

[Encoder Pos Tol].

The drive is in Positioning mode and has reached the home

position. Tolerance is adjusted with E225

[Encoder Pos Tol].

The DriveGuard Safe Off option is installed and both safe-off inputs are active.

A056 [Relay Out Level]

32

32 bit parameter.

Related Parameter(s):

A055 ,

A058

,

A061

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.

A055 Setting

16

17

18

20

6

7

8

10

A056 Min/Max

0/500 Hz

0/180%

0/815 Volts

0/100%

0.1/9999 Secs

1/9999 Counts

1/180 degs

0/1

Values

Default:

Min/Max:

Display:

0.0

0.0/9999

0.1

3-20

Programming and Parameters

Advanced Program Group

(continued)

A058 [Opto Out1 Sel]

A061 [Opto Out2 Sel]

Related Parameter(s): P033

,

A056 ,

A092

,

A140 A147 ,

A150

-

A157

Determines the operation of the programmable opto outputs.

Options 0

“Ready/Fault”

1

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.

2

3

“At Frequency”

(A061 Default)

“MotorRunning”

(A058 Default)

“Reverse”

Motor is receiving power from the drive.

Drive is commanded to run in reverse direction.

4

5

“Motor Overld”

“Ramp Reg”

6

7

8

“Above Freq”

“Above Cur”

“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

A062 [Opto Outx Level].

Use A059 or A062 to set threshold.

A059

or

Drive exceeds the current (% Amps) value set in

A062 [Opto Outx Level].

Use A059 or A062 to set threshold.

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

A062 [Opto Outx Level].

Use A059 or A062 to set threshold.

Value set in A092

[Auto Rstrt Tries] is exceeded.

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.

Use A059 or A062 to set threshold.

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

An input is programmed as “Logic In 2” 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 Step Logic step with Digit 3 of Command Word

( A140 - A147 ) set to enable Step Logic output.

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

Level].

Use A059 or A062 to set threshold.

Counter has reached value set in

A059

Outx Level].

Use A059 or A062 to set threshold.

or A062 [Opto

A058,

A061

Options

(Cont.)

18

“Above PF Ang”

19

“Anlg In Loss”

20

“ParamControl”

21

“NonRec Fault”

22

“EM Brk Cntrl”

23

“At Position”

24

“At Home”

25

“Safe-Off”

Programming and Parameters

3-21

Power Factor angle has exceeded the value set in A059

or

A062 [Opto Outx Level].

Use A059 or A062 to set threshold.

Analog input loss has occurred. Program A122 [Analog In

Loss] for desired action when input loss occurs.

Enables the output to be controlled over network communications by writing to

A059 or A062 [Opto Outx

Level].

(0 = Off, 1 = On.)

Value set in

A092

A092

[Auto Rstrt Tries] is exceeded.

[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 drive is in Positioning mode and has reached the

commanded position. Tolerance is adjusted with E225

[Encoder Pos Tol].

The drive is in Positioning mode and has reached the home

position. Tolerance is adjusted with E225

[Encoder Pos Tol].

The DriveGuard Safe Off option is installed and both safe-off inputs are active.

A059 [Opto Out1 Level]

A062 [Opto Out2 Level]

32

32 bit parameter.

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.

A058 & A061 Setting

6

7

8

10

16

17

18

20

A059 & A062 Min/Max

0/500 Hz

0/180%

0/815 Volts

0/100%

0.1/9999 Secs

1/9999 Counts

1/180 degs

0/1

Values

Default:

Min/Max:

Display:

0.0

0.0/9999

0.1

3-22

Programming and Parameters

Advanced Program Group

(continued)

A064 [Opto Out Logic]

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

A064 Option

2

3

0

1

Opto Out1 Logic

NO (Normally Open)

NC (Normally Closed)

NO (Normally Open)

NC (Normally Closed)

Opto Out2 Logic

NO (Normally Open)

NO (Normally Open)

NC (Normally Closed)

NC (Normally Closed)

Values

Default:

Min/Max:

Display:

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

0 “OutFreq 0-10”

1 “OutCurr 0-10”

2 “OutVolt 0-10”

3 “OutPowr 0-10”

4 “TstData 0-10”

5 “OutFreq 0-20”

6 “OutCurr 0-20”

7 “OutVolt 0-20”

8 “OutPowr 0-20”

9 “TstData 0-20”

10 “OutFreq 4-20”

11 “OutCurr 4-20”

12 “OutVolt 4-20”

Output

Range

0-10V

0-10V

0-10V

0-10V

0-10V

0-20mA

0-20mA

0-20mA

0-20mA

0-20mA

4-20mA

4-20mA

4-20mA

13 “OutPowr 4-20” 4-20mA

14 “TstData 4-20”

15 “OutTorq 0-10”

4-20mA

0-10V

16 “OutTorq 0-20”

17 “OutTorq 4-20”

18 “Setpnt 0-10”

19 “Setpnt 0-20”

20 “Setpnt 4-20”

0-20 mA

4-20 mA

0-10V

0-20 mA

4-20 mA

Minimum Output

Value

0V = 0 Hz

0V = 0 Amps

0V = 0 Volts

0V = 0 kW

0V = 0000

0 mA = 0 Hz

0 mA = 0 Amps

0 mA = 0 Volts

0 mA = 0 kW

0 mA = 0000

4 mA = 0 Hz

4 mA = 0 Amps

4 mA = 0 Volts

4 mA = 0 kW

4 mA = 0000

0V = 0 Amps

0 mA = 0 Amps

4 mA = 0 Amps

0V = 0%

0 mA = 0%

4 mA = 0%

Maximum Output Value

A066 [Analog Out High]

P035 [Maximum Freq]

200% Drive Rated Output Current

120% Drive Rated Output Volts

200% Drive Rated Power

65535 (Hex FFFF)

P035 [Maximum Freq]

200% Drive Rated Output Current

120% Drive Rated Output Volts

200% Drive Rated Power

65535 (Hex FFFF)

P035 [Maximum Freq]

200% Drive Rated Output Current

120% Drive Rated Output Volts

200% Drive Rated Power

65535 (Hex FFFF)

200% Drive Rated FLA

200% Drive Rated FLA

200% Drive Rated FLA

100.0% Setpoint Setting

100.0% Setpoint Setting

100.0% Setpoint Setting

0-20mA

0-20mA

0-20mA

0-20mA

0-20mA

0-20mA

0-20mA

0-20mA

DIP Switch

Position

0-10V

0-10V

0-10V

0-10V

0-10V

0-20mA

0-20mA

0-10V

0-20 mA

0-20 mA

0-10V

0-20 mA

0-20 mA

b019

b029 b029 b029

A109

A109

A109

b003 b004

b022 b019

b001 b003 b004

b022

Related

Parameter

b001 b003 b004

b022 b019

b001

Values

Default:

Min/Max:

Display:

0

0/20

1

Programming and Parameters

3-23

Advanced Program Group

(continued)

A066 [Analog Out High]

Related Parameter(s):

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]

Related Parameter(s): P039

,

A051 A054 ,

A070

-

A077

A140 A147

, E203

-

E206

When active, sets the rate of acceleration for all speed increases except jog.

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]

Deceleration

Speed

Acceleration

0

0

P039, A067,

E203 or E205

[Accel Time x]

Time

P040, A068,

E204 or E206

[Decel Time x]

1

1

0

0

Option

28 1

0

1

0

1

Description

Acc/Dec 1

Acc/Dec 2

Acc/Dec 3

Acc/Dec 4

A068 [Decel Time 2]

Related Parameter(s):

P040 ,

A051

-

A054 ,

A067

, A070

-

A077

A140 A147 ,

E203

-

E206

When active, sets the rate of deceleration for all speed decreases except jog. Refer to graphic at A067

[Accel Time 2].

Maximum Freq

Decel Time

=

Decel Rate

Values

Default:

Min/Max:

Display:

20.0 Secs

0.0/600.0 Secs

0.1 Secs

3-24

Programming and Parameters

Advanced Program Group

(continued)

A069 [Internal Freq]

Related Parameter(s): P038

, A162

Provides the frequency command to the drive when P038

[Speed Reference] is set to 1 “InternalFreq”.

When enabled, this parameter will change the frequency command in “real time”.

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: 60.00 Hz

Min/Max: 0.00/600.0 Hz

Display: 0.01 Hz

Programming and Parameters

3-25

Advanced Program Group

(continued)

A070 [Preset Freq 0]

(1)

A071 [Preset Freq 1]

A072 [Preset Freq 2]

A073 [Preset Freq 3]

A074 [Preset Freq 4]

A075 [Preset Freq 5]

A076 [Preset Freq 6]

A077 [Preset Freq 7]

Values

A070 Default:

(1)

A071 Default:

A072 Default:

A073 Default:

A074 Default:

A075 Default:

A076 Default:

A077 Default:

Min/Max:

Display:

Related Parameter(s): P038

,

P039 , P040

,

A051 A053 ,

A067 , A068

,

A140 A147 ,

A150

-

A157

0.00 Hz

5.00 Hz

10.00 Hz

20.00 Hz

30.00 Hz

40.00 Hz

50.00 Hz

60.00 Hz

0.00/500.0 Hz

0.01 Hz

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

Freq”.

An active preset input will override speed command as shown in the flowchart on page 1-27

.

(1)

To activate A070-A077 in Velocity mode, set

P038 [Speed Reference] to option 4 “Preset Freq”.

In Positioning mode, set P038 [Speed Reference] to option 9 “Positioning” and

E222 [Positioning

Mode] to option 1 “Preset Input”.

Input State of Digital In 1

(I/O Terminal 05 when A051 = 4)

0

1

0

1

0

1

0

1

(2)

Input State of Digital In 2

(I/O Terminal 06 when A052 = 4)

0

0

1

1

0

0

1

1

Input State of Digital In 3

(I/O Terminal 07 when A053 = 4)

0

0

0

0

1

1

1

1

Freq

Source

A070

A071

A072

A073

A074

A075

A076

A077

Position

Source

(when

P038 = 9) Accel / Decel Parameter Used

E230

E232

E234

E236

E238

E240

E242

E244

(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]

[Accel Time 1] / [Decel Time 1]

[Accel Time 1] / [Decel Time 1]

[Accel Time 2] / [Decel Time 2]

[Accel Time 2] / [Decel Time 2]

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

A078 [Jog Frequency]

Related Parameter(s):

P035 ,

A051 A054

,

A079

Sets the output frequency when a jog command is issued.

Values

Default:

Min/Max:

Display:

10.00 Hz

0.00/[Maximum Freq]

0.01 Hz

3-26

Programming and Parameters

Advanced Program Group

(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]

Related Parameter(s):

P037 ,

A051 A054

,

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]

Related Parameter(s):

P037 ,

A080 ,

A051

-

A054

Defines the maximum DC brake current, in amps, applied to the motor when

P037 [Stop Mode] is set

to either option 4 “Ramp” or 6 “DC Brake”.

Values

Default: Drive Rated Amps

×

0.05

Min/Max: 0.0/(Drive Rated Amps

×

1.8)

Display: 0.1 Amps

Ramp-to-Stop Mode 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.

Programming and Parameters

3-27

Advanced Program Group

(continued)

A082 [DB Resistor Sel]

Stop drive before changing this parameter.

Enables/disables external dynamic braking.

Related Parameter(s):

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.

For more information on external dynamic brake kits, refer to the External Dynamic Brake Kit

Installation Instructions

, publication RA-IN004.

!

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.7 on page B-12 , 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

3-28

Programming and Parameters

Advanced Program Group

(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”

Related Parameter(s):

b004 ,

P031

,

P032

,

A085 ,

A086 , A087

,

A125

5

6

7

3

4

1

2

“30.0, VT”

“35.0, VT”

“40.0, VT”

“45.0, VT”

“0.0 no IR”

“0.0”

“2.5, CT”

[Default for

4.0, 5.5, 7.5 & 11 kW

(5.0, 7.5, 10 & 15 HP)

Drives]

8

9

“5.0, CT” (Default)

“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

Programming and Parameters

3-29

Advanced Program Group

(continued)

A085 [Start Boost]

Related Parameter(s):

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

A084 [Boost Select] = 5 “0.0 no IR”.

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%

Related Parameter(s):

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: 0.0/500.0 Hz

Related Parameter(s):

P031 , P032

,

P034

,

P035 ,

A084 ,

A085

,

A086 ,

A088

,

A125

Display: 0.1 Hz

3-30

Programming and Parameters

Advanced Program Group

(continued)

A088 [Maximum Voltage]

Sets the highest voltage the drive will output.

Values

Default:

Min/Max:

Display:

Related Parameter(s): b004

,

A085 , A086

,

A087

Drive Rated Volts

20/Drive Rated Volts

1 VAC

A089 [Current Limit 1]

Related Parameter(s): P033

,

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]

Related Parameter(s): P032

,

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

2

“Min Derate”

“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

Programming and Parameters

3-31

Advanced Program Group

(continued)

A091 [PWM Frequency]

Related Parameter(s):

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:

Display:

2.0/16.0 kHz

0.1 kHz

76

72

68

64

60

56

52

100

96

92

88

84

80

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

A092 [Auto Rstrt Tries]

Related Parameter(s): A055

,

A058 , A061

,

A093

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

For information on faults and fault codes refer to

Chapter 4

.

Clear a Type 1 fault and restart the drive.

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

2. Set

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

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

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

2. Set

A093 [Auto Rstrt Delay] to “0”.

Values

!

ATTENTION:

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

Default:

Min/Max:

Display:

0

0/9

1

A093 [Auto Rstrt Delay]

Related Parameter(s):

A092

Sets the time between restart attempts when

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

Values

Default: 1.0 Secs

Min/Max:

Display:

0.0/120.0 Secs

0.1 Secs

3-32

Programming and Parameters

Advanced Program Group

(continued)

A094 [Start At PowerUp]

Stop drive before changing this parameter.

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 0

1

“Disabled” (Default)

“Enabled”

A095 [Reverse Disable]

Stop drive before changing this parameter.

Related Parameter(s):

b006

Enables/disables the function that allows the direction of motor rotation to be changed. The reverse command may come from a digital command 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.

Important:

Do not use this feature with permanent magnet motors.

Options 0

“Disabled” (Default)

1

“Enabled”

A097 [Compensation]

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

Options 0

“Disabled”

1

2

“Electrical” (Default)

“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”

Programming and Parameters

3-33

Advanced Program Group

(continued)

A098 [SW Current Trip]

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

Values

Default:

Min/Max:

Display:

0.0 (Disabled)

0.0/(Drive Rated Amps

×

2)

0.1 Amps

Related Parameter(s):

P033

A099 [Process Factor]

Scales the output frequency value displayed by b010

[Process Display].

Output

Freq x

Process

Factor

=

Process

Display

Related Parameter(s):

b010

Values

Default:

Min/Max:

Display:

30.0

0.1/999.9

0.1

A100 [Fault Clear]

Stop drive before changing this parameter.

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

Options 0

“Ready/Idle” (Default)

1

2

“Reset Fault”

“Clear Buffer”

(Parameters b007 b009

[Fault x Code])

A101 [Program Lock]

Protects parameters against change by unauthorized personnel with a 4-digit password.

Options 0

“Unlocked” (Default)

1

“Locked”

A102 [Testpoint Sel]

Used by Rockwell Automation field service personnel.

Values

Default: 400

Min/Max:

Display:

400/FFFF

1 Hex

Related Parameter(s):

b019

3-34

Programming and Parameters

Advanced Program Group

(continued)

A103 [Comm Data Rate]

Related Parameter(s):

b015

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”

3

4

1

2

5

“2400”

“4800”

“9600” (Default)

“19.2K”

“38.4K”

A104 [Comm Node Addr]

Related Parameter(s):

b015

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

Important:

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

Values

Default: 100

Min/Max:

Display:

1/247

1

A105 [Comm Loss Action]

Related Parameter(s):

b015

, 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” Stops drive via coast to stop.

2

3

“Stop”

“Continu Last”

Stops drive via

P037 [Stop Mode] setting.

Drive continues operating at communication commanded speed saved in RAM.

A106 [Comm Loss Time]

Related Parameter(s): b015

,

A105

Sets the time that the drive will remain in communication loss before implementing the option selected

in A105

[Comm Loss Action].

Values

Default: 5.0 Secs

Min/Max: 0.1/60.0 Secs

Display: 0.1 Secs

Programming and Parameters

3-35

Advanced Program Group

(continued)

A107 [Comm Format]

Related Parameter(s):

b015

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.

Important:

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

Options 0

“RTU 8-N-1” (Default)

3

4

1

2

5

“RTU 8-E-1”

“RTU 8-O-1”

“RTU 8-N-2”

“RTU 8-E-2”

“RTU 8-O-2”

A108 [Language]

Selects the language displayed by the remote communications option.

Options 1

“English” (Default)

4

5

2

3

“Français”

“Español”

“Italiano”

“Deutsch”

8

9

6

7

“Reserved”

“Português”

“Reserved”

“Reserved”

10

“Nederlands”

A109 [Anlg Out Setpt]

Related Parameter(s):

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: 0.0/100.0%

Display: 0.1%

3-36

Programming and Parameters

Advanced Program Group

(continued)

A110 [Anlg In 0-10V Lo]

Related Parameter(s): b020 ,

P034

,

P038 ,

A122

,

A123

Stop drive before changing this parameter.

Sets the analog input level that corresponds to P034

[Minimum Freq] if a 0-10V input is used by P038

[Speed Reference].

When A123

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

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): b020 ,

P035

,

P038 ,

A122

,

A123

Stop drive before changing this parameter.

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]

Related Parameter(s):

b021 ,

P034

,

P038

Stop drive before changing this parameter.

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

P038 [Speed Reference].

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%

Programming and Parameters

3-37

Advanced Program Group

(continued)

A113 [Anlg In4-20mA Hi]

Related Parameter(s):

b021 ,

P035

,

P038

Stop drive before changing this parameter.

Sets the analog input level that corresponds to P035

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

P038 [Speed Reference].

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]

Related Parameter(s): P033

,

E216

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

Values

Default: 2.0 Hz

Min/Max:

Display:

0.0/10.0 Hz

0.1 Hz

A115 [Process Time Lo]

Related Parameter(s): b010

,

P034

Scales the time value when the drive is running at P034 [Minimum Freq]. When set to a value other

than zero,

b010 [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]

Related Parameter(s): b010

,

P035

Scales the time value when the drive is running at P035 [Maximum Freq]. When set to a value other

than zero,

b010 [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

1

“Disabled”

“Enabled” (Default)

A118 [Current Limit 2]

Related Parameter(s):

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

0.1/(Drive Rated Amps

×

1.8)

0.1 Amps

3-38

Programming and Parameters

Advanced Program Group

(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:

0/500 Hz

1 Hz

Related Parameter(s):

A120

A120 [Skip Freq Band]

Related Parameter(s):

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”

4

5

2

3

“240 Seconds”

“360 Seconds”

“480 Seconds”

“Flt Disabled”

Programming and Parameters

3-39

Advanced Program Group

(continued)

A122 [Analog In Loss]

Related Parameter(s):

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). Ensure that the Voltage Range Select DIP Switch is set to 10V.

Options 0

“Disabled” (Default)

1

“Fault (F29)” F29 Analog Input Loss

4

5

2

3

6

“Stop”

“Zero Ref”

“Min Freq Ref”

“Max Freq Ref”

“Int Freq Ref”

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]

Related Parameter(s): P038

,

A111

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

Ensure that the Voltage Range Select DIP Switch setting matches the selected control scheme. Refer to

Figure 1.5 on page 1-15 .

Options 0

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

1

“Bi-Polar In” ±10V

A124 [Var PWM Disable]

Related Parameter(s):

A091

Stop drive before changing this parameter.

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]

Related Parameter(s):

A084

, A085

,

A086 , A087

,

A127

Stop drive before changing this parameter.

Enables/disables sensorless vector control operation.

Options 0

“V/Hz”

1

“Sensrls Vect” (Default)

3-40

Programming and Parameters

Advanced Program Group

(continued)

A126 [Motor NP FLA]

Set to the motor nameplate rated full load amps.

Values

Default:

Min/Max:

Drive Rated Amps

0.1/(Drive Rated Amps

×

2)

Display: 0.1 Amps

Related Parameter(s):

A127

A127 [Autotune]

Related Parameter(s): A125

, A126 ,

A128

, A129

Stop drive before changing this parameter.

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 0

“Ready/Idle” (Default)

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/Idle” (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

Related Parameter(s):

A127

Programming and Parameters

3-41

Advanced Program Group

(continued)

A129 [Flux Current Ref]

Value of amps for full motor flux.

Values

Default:

Min/Max:

Display:

Based on Drive Rating

0.00/[Motor NP FLA]

0.01 Amps

Related Parameter(s):

A127

A130 [PID Trim Hi]

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

Values

Default: 60.0 Hz

Min/Max:

Display:

0.0/500.0 Hz

0.1 Hz

A131 [PID Trim Lo]

Sets the minimum positive value that is added to a PID reference when PID trim is used.

Values

Default: 0.0 Hz

Min/Max: 0.0/500.0 Hz

Display: 0.1 Hz

A132 [PID Ref Sel]

Related Parameter(s): P038

,

A122

Stop drive before changing this parameter.

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

Appendix F for

details.

Options 0

1

“PID Disabled”

(Default)

“PID Setpoint”

4

5

2

3

“0-10V Input”

“4-20mA Input”

“Comm Port”

“Encoder”

8

9

6

7

“Setpnt, Trim”

“0-10V, Trim”

“4-20mA, Trim”

“Comm, Trim”

10

“Encoder,Trim”

Encoder or Pulse Train

Encoder or Pulse Train

3-42

Programming and Parameters

Advanced Program Group

(continued)

A133 [PID Feedback Sel]

Select the source of the PID feedback. Refer to

Appendix F

for details.

!

ATTENTION:

The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against possible unintended speed or motion.

Options 0

1

2

3

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

“4-20mA Input”

“Comm Port”

“Encoder” Encoder or Pulse Train

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

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: 2.0 Secs

Min/Max:

Display:

0.0/999.9 Secs

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: 0.00 (1/Secs)

Min/Max: 0.00/99.99 (1/Secs)

Display: 0.01 (1/Secs)

Programming and Parameters

3-43

Advanced Program Group

(continued)

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:

Display:

0.0/500.0 Hz

0.1 Hz

3-44

Programming and Parameters

Step

0

1

2

3

4

5

6

7

Advanced Program Group

(continued)

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 Parameter(s): P038

,

P039 , P040

,

A051 A054 ,

A055 ,

A058

,

A061 ,

A067

,

A068 ,

A070 A077

,

A150 A157 ,

E248

Stop drive before changing this parameter.

Values

Default:

Min/Max:

00F1

0001/FAFF

Display: 4 Digits

For detailed information on applying Step Logic and Position StepLogic refer to Appendix E and

Appendix F .

Parameters A140-A147 are only active if

P038

[Speed Reference] is set to 6 “Stp Logic” or 9

“Positioning”.

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” or by using Bits 6 and 7 of E248 [Enh Control Word].

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

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)

A070 [Preset Freq 0]

A071 [Preset Freq 1]

A072 [Preset Freq 2]

A073 [Preset Freq 3]

A074 [Preset Freq 4]

A075 [Preset Freq 5]

A076 [Preset Freq 6]

A077 [Preset Freq 7]

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]

A151 [Stp Logic Time 1]

A152 [Stp Logic Time 2]

A153 [Stp Logic Time 3]

A154 [Stp Logic Time 4]

A155 [Stp Logic Time 5]

A156 [Stp Logic Time 6]

A157 [Stp Logic Time 7]

The position for any step is programmed using parameters E230 -

E245

[Step Units x].

5

6

7

Step

0

1

2

3

4

StepLogic Position Parameters

E230 [Step Units 0] & E231 [Step Units F 0]

E232 [Step Units 1] & E233 [Step Units F 1]

E234 [Step Units 2] & E235 [Step Units F 2]

E236 [Step Units 3] & E237 [Step Units F 3]

E238 [Step Units 4] & E239 [Step Units F 4]

E240 [Step Units 5] & E241 [Step Units F 5]

E242 [Step Units 6] & E243 [Step Units F 6]

E244 [Step Units 7] & E245 [Step Units F 7]

Programming and Parameters

3-45

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.

Digit 3: Step Settings

This digit defines additional characteristics of each step.

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.

3-46

Programming and Parameters

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

Velocity Control Settings (Digit 3)

Required

Setting

Accel/Decel

Param. Used

6

7

4

5

2

3

0

1

A b

8

9

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

StepLogic

Output State

On

On

Off

Off

Off

Off

Off

On

Off

On

On

On

Positioning Settings (Digit 3)

Required

Setting

Accel/Decel

Param. Used

E

F

C d

A b

8

9

6

7

4

5

2

3

0

1

Accel/Decel 1

Accel/Decel 1

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

Accel/Decel 2

Accel/Decel 2

Settings (Digit 2)

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

Commanded

Direction

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

FWD

REV

No Output

StepLogic

Output State

On

On

On

On

Off

Off

Off

Off

On

On

On

On

Off

Off

Off

Off

Direction

From Home

FWD

FWD

REV

REV

FWD

FWD

REV

REV

FWD

FWD

REV

REV

FWD

FWD

REV

REV

Type Of

Command

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Settings (Digit 1 and Digit 0)

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

Programming and Parameters

3-47

Advanced Program Group

(continued)

A150 [Stp Logic Time 0]

A151 [Stp Logic Time 1]

A152 [Stp Logic Time 2]

A153 [Stp Logic Time 3]

A154 [Stp Logic Time 4]

A155 [Stp Logic Time 5]

A156 [Stp Logic Time 6]

A157 [Stp Logic Time 7]

Related Parameter(s):

P038 ,

A055

,

A058

,

A061 ,

A070

-

A077 ,

A140 A147

, E222

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

Time” or if using E222 [Positioning Mode] set to 0.

Values

Default: 30.0 Secs

Min/Max: 0.0/999.9 Secs

Display: 0.1 Secs

A160 [EM Brk Off Delay]

Related Parameter(s):

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

3-48

Programming and Parameters

Advanced Program Group

(continued)

A161 [EM Brk On Delay]

Related Parameter(s):

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]

Related Parameter(s): A069

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]

Related Parameter(s): P037

,

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”.

Programming and Parameters

Enhanced Program Group

E201 [LED Display Opt]

Selects which parameters can be viewed by the drive’s LED interface.

E201 Option

2

3

0

1

Parameter Set

All Basic Display (Group b) and Advanced Display (Group d) parameters

All Basic Display Group (b001-b029) parameters

Basic Display Group parameters b001-b007 and b010

Basic Display Group parameter b001-b004

Values

Default:

Min/Max:

Display:

2

0/3

1

3-49

E202 [Digital Term 3]

Stop drive before changing this parameter.

Sets the function of I/O Terminal 03.

Options 0

“Start Source” (Default) Input functions as defined by P036 [Start Source].

1

2

3

4

“Acc/Dec Sel1”

“Jog”

“Aux Fault”

“Preset Freq”

If active, can determine which Accel/Decel time will be used for all ramp rates except jog. Can be applied to one input only. Refer to

A067 [Accel Time 2] for details.

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 1-27 for more information on speed

reference control priority.

5

6

“Reserved”

“Comm Port”

7

8

9

“Clear Fault”

“RampStop,CF”

“CoastStop,CF”

10

“DCInjStop,CF”

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.

3-50

Programming and Parameters

E202

Options

(Cont.)

11

“Jog Forward”

12

“Jog Reverse”

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”

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.

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 a rate of 2 Hz per second. Default for A069 is 60 Hz.

Decreases the value of A069 [Internal Freq] at a rate of 2 Hz per second. Default for A069 is 60 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]. Logically ORed with

E248 [Enh Control Word] bit 6 “Logic In 1”.

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]. Logically ORed with

E248 [Enh Control Word] bit 7 “Logic In 2”.

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.

Refer to A160

[EM Brk Off Delay] for additional information.

!

ATTENTION:

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

E202

Options

(Cont.)

28

“Acc/Dec Sel2”

29

“Precharge En”

30

“Inertia Dcel”

31

“Sync Enable”

32

“Traverse Dis”

33

“Home Limit”

34

“Find Home”

35

“Hold Step”

36

“Pos Redefine”

Programming and Parameters

3-51

If active, can determine which

Accel/Decel time will be used for all ramp rates except jog. Can be applied to one input only.

1

1

0

0

Option

28 1

0

1

0

1

Description

Acc/Dec 1

Acc/Dec 2

Acc/Dec 3

Acc/Dec 4

Forces drive into precharge state. Typically controlled by auxiliary contact on the disconnect at the DC input to the drive. If this input is assigned, it must be energized for the pre-charge relay to close and for the drive to run. If it is de-energized, the pre-charge relay will open and the drive will coast to a stop.

Forces drive into Inertia Ride-Through state. The drive will attempt to regulate the DC bus at the current level.

Must be used in order to hold the existing frequency when

Sync Time is set to enable speed synchronization. When this input is released the drive will accelerate to the commanded frequency in E214 [Sync Time].

When an input is programmed the traverse function will be

disabled while this input is active. Refer to E210

[Max

Traverse]

In Positioning mode, this indicates the drive is at the home position. Refer to

Appendix F

for detailed information on positioning.

In Positioning mode this causes the drive to return to the

Home position when a start is issued. It does this by using the [Find Home Freq] and [Find Home Direction] until the

“Home Limit” input is activated. If it passes this point, it then runs in the reverse direction at 1/10th the frequency of [Find

Home Freq] until the “Home Limit” is activated again. As long as this input is active, any start command will cause the drive to enter the homing routing. However, it only functions if in

Positioning mode. Once the Find Home routine has finished, the drive will stop. Refer to

Appendix F

for detailed information on positioning.

In Positioning mode, this input over-rides other inputs and causes the drive to remain at it’s current step (running at zero speed once it reaches its position) until released. While in

“Hold”, the drive will ignore any digital input command which would normally result in a move to a new step. However, timers continue to run. Therefore, when the Hold is removed, the drive must see any required digital inputs transition (even if they already transitioned during the hold), but it does not

reset any timer. Refer to Appendix F for detailed information

on positioning.

In Positioning mode, this input resets the home position to the

current position of the machine. Refer to Appendix F for

detailed information on positioning.

3-52

Programming and Parameters

Enhanced Program Group

(continued)

E203 [Accel Time 3]

E205 [Accel Time 4]

Related Parameter(s):

A067

Sets the rate of acceleration for all speed increases when selected by digital inputs. Refer to graphic at

A067 [Accel Time 2].

Maximum Freq

Accel Time

=

Accel Rate

Values

Default:

Min/Max:

Display:

5.0 Secs (E203)

30.0 Secs (E205)

0.0/600.0 Secs

0.1 Secs

E204 [Decel Time 3]

E206 [Decel Time 4]

Related Parameter(s):

A067

Sets the rate of deceleration for all speed decreases when selected by digital inputs. Refer to graphic at

A067 [Accel Time 2].

Maximum Freq

Decel Time

=

Decel Rate

Values

Default:

Min/Max:

Display:

5.0 Secs (E204)

30.0 Secs (E206)

0.0/600.0 Secs

0.1 Secs

E207 [Comm Write Mode]

Saves parameter values in active drive memory (RAM) or in drive non-volatile memory (EEPROM).

Important:

Parameter values set prior to selecting option 1 “RAM only” will be saved in drive non-volatile memory (EEPROM).

Options 0

“EEPROM” (Default)

1

“RAM only”

E208 [Power Loss Mode]

Sets the reaction to a loss of input power.

Options 0

“Coast” (Default) Drive will fault and motor will coast to stop.

1

“Decel” Drive will decelerate and attempt to keep the DC Bus voltage above the undervoltage level.

Programming and Parameters

Enhanced Program Group

(continued)

E209 [Half Bus Enable]

Enables/disables the power ride through function which allows the drive to maintain power to the motor at 50% drive input voltage during short-term power sag conditions.

Options 0

“Disabled” (Default)

1

“Enabled”

3-53

!

ATTENTION:

To guard against drive damage, a minimum line impedance must be provided to limit inrush current when the power line recovers. The input impedance should be equal or greater than the equivalent of a 5% transformer with a VA rating 6 times the drive’s input VA rating.

E210 [Max Traverse]

Sets the amplitude of triangle wave speed modulation.

Values

Default: 0.00 Hz (Disabled)

Min/Max:

Display:

0.00/300.0 Hz

0.01 Hz

Related Parameter(s):

E211 ,

E212 , E213

212 [Traverse Dec] 211 [Traverse Inc]

Hertz

E210 [Max Traverse]

E213 [P Jump]

E213 [P Jump] b001 [Output Freq]

Traverse Bit

Seconds

d302 [Fiber Status]

Traverse Enable Bit

E211 [Traverse Inc]

Related Parameter(s):

E210

Sets time required for the Traverse function to accelerate from the minimum to the maximum traverse frequency. Refer to the diagram at

E210

[Max Traverse].

Values

Default: 0.00 Secs

Min/Max:

Display:

0.00/30.00 Secs

0.01 Secs

3-54

Programming and Parameters

Enhanced Program Group

(continued)

E212 [Traverse Dec]

Related Parameter(s):

E210

Sets time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency. Refer to the diagram at

E210

[Max Traverse].

Values

Default: 0.00 Secs

Min/Max:

Display:

0.00/30.00 Secs

0.01 Secs

E213 [P Jump]

Related Parameter(s):

E210

Sets the frequency amplitude that is added to or subtracted from the commanded frequency. Refer to

the diagram at E210

[Max Traverse].

Values

Default: 0.00 Hz

Min/Max: 0.00/300.0 Hz

Display: 0.01 Hz

E214 [Sync Time]

Related Parameter(s): A051 A054

,

d302

Enables the function that holds the drive at the current frequency even if the commanded frequency

changes. Used with A051

-

A054 [Digital Inx Sel] option 31 “Sync Enable”.

Values

Default: 0.0 Secs (Disabled)

Min/Max:

Display:

0.0/3200.0 Secs

0.1 Secs

214 [Sync Time]

New Drive #2 Reference

Hertz

New Drive #1 Reference

Change Ref's

Speed Sync Bit

Time

d302 [Fiber Status]

Drive #1 and #2 Sync Enable Input

E215 [Speed Ratio]

Stop drive before changing this parameter.

Enables the function that scales the drive speed command.

Values

Default: 1.00

Min/Max: 0.01/99.99

Display: 0.01

Programming and Parameters

Enhanced Program Group

(continued)

E216 [Motor Fdbk Type]

Stop drive before changing this parameter.

Selects the encoder type. For additional information refer to

Appendix F

.

E216 Option

3

4

5

0

1

2

Encoder

None

Pulse Train

Single Chan

Single Check

Quadrature

Quad Check

3-55

!

ATTENTION:

The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against possible unintended speed or motion.

Values

Default:

Min/Max:

Display:

0

0/5

1

E217 [Motor NP Poles]

Defines the number of poles in the motor.

Values

Default: 4

Min/Max:

Display:

2/40

1

E218 [Encoder PPR]

Specifies the encoder pulses per revolution when an encoder is used. For additional information refer to

Appendix F .

Values

Default: 1024

Min/Max: 1/20000

Display: 1

E219 [Pulse In Scale]

Sets the scale factor/gain for the Pulse Input when E216 [Motor Fdbk Type] is set to 1 “Pulse Train”.

For additional information refer to

Appendix F .

Input Pulse Rate

Desired Command

=

Speed Command

Values

Default:

Min/Max:

Display:

64

1/20000

1

3-56

Programming and Parameters

Enhanced Program Group

(continued)

E220 [Ki Speed Loop]

Sets the I-Gain used in the PI calculation of the speed loop.

Values

Default: 2.0

Min/Max:

Display:

0.0/400.0

0.1

E221 [Kp Speed Loop]

Sets the P-Gain used in the PI calculation of the speed loop.

Values

Default: 0.5

Min/Max:

Display:

0.0/200.0

0.1

E222 [Positioning Mode]

Stop drive before changing this parameter.

Defines the positioning transition mode used for the position steps. For additional information refer to

Appendix F .

E222 Option

2

3

0

1

4

Values

Default:

Min/Max:

Display:

Transition Mode

Time Steps

Preset Input

Step Logic

Preset StpL

StpLogic-Lst

Description

Steps based on time.

Preset inputs directly command a given step.

Use Step Logic commands. Always start from Step 0.

Use Preset inputs to determine starting step then Step Logic commands.

Use Step Logic commands from last StepLogic step at last drive stop.

0

0/4

1

E223 [Find Home Freq]

Sets the maximum frequency the drive uses when “Find Home” is issued. For additional information refer to

Appendix F

.

Values

Default: 10.0 Hz

Min/Max:

Display:

0.1/500.0 Hz

0.1 Hz

Programming and Parameters

Enhanced Program Group

(continued)

3-57

E224 [Find Home Dir]

Stop drive before changing this parameter.

Sets the direction the drive commands when “Find Home” is issued. For additional information refer to

Appendix F .

Options 0

“Forward” (Default)

1

“Reverse”

E225 [Encoder Pos Tol]

Sets the “At Position” and the “At Home” tolerance around the encoder count. The value is added to and subtracted from the target encoder unit value to create the tolerance range. For additional

information refer to Appendix F .

Values

Default: 100

Min/Max:

Display:

1/50000

1

E226 [Counts Per Unit]

Related Parameter(s): E230 -

E245

Sets the number of encoder counts equal to one user-defined unit. For additional information refer to

Appendix F .

Values

Default: 4096

Min/Max: 1/32000

Display: 1

3-58

Programming and Parameters

Enhanced Program Group

(continued)

E230 [Step Units 0]

E232 [Step Units 1]

E234 [Step Units 2]

E236 [Step Units 3]

E238 [Step Units 4]

E240 [Step Units 5]

E242 [Step Units 6]

E244 [Step Units 7]

32

32 bit parameter.

Related Parameter(s):

E226

Sets the position in whole number user-defined units the drive must reach at each step. For additional

information refer to Appendix F .

Values

Default: 0

Min/Max: 0/64000

Display: 1

Input State of Digital In 1

(I/O Terminal 05 when A051 = 4)

0

1

0

1

0

1

0

1

(2)

Input State of Digital In 2

(I/O Terminal 06 when A052 = 4)

0

0

1

1

0

0

1

1

Input State of Digital In 3

(I/O Terminal 07 when A053 = 4)

0

0

0

0

1

1

1

1

Position

Source

E230

E232

E234

E236

E238

E240

E242

E244

Freq

Source

A070

A071

A072

A073

A074

A075

A076

A077

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]

[Accel Time 1] / [Decel Time 1]

[Accel Time 1] / [Decel Time 1]

[Accel Time 2] / [Decel Time 2]

[Accel Time 2] / [Decel Time 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.

E231 [Step Units F 0]

E233 [Step Units F 1]

E235 [Step Units F 2]

E237 [Step Units F 3]

E239 [Step Units F 4]

E241 [Step Units F 5]

E243 [Step Units F 6]

E245 [Step Units F 7]

32

32 bit parameter.

Related Parameter(s):

E226

Sets the position in fractional user-defined units the drive must reach at each step. For additional

information refer to Appendix F .

Values

Default: 0.00

Min/Max: 0.00/0.99

Display: 0.01

Programming and Parameters

Enhanced Program Group

(continued)

E246 [Pos Reg Filter]

Sets the error signal filter in the position regulator. For additional information refer to Appendix F .

Values

Default: 8

Min/Max:

Display:

0/15

1

3-59

E247 [Pos Reg Gain]

Sets the gain adjustment for the position regulator. For additional information refer to

Appendix F

.

Values

Default: 3.0

Min/Max:

Display:

0.0/200.0

0.1

3-60

Programming and Parameters

Enhanced Program Group

(continued)

E248 [Enh Control Word]

Allows control of positioning and other functions via parameter control for use over comms. The functions replicate the digital input options and function in the same way. For additional information refer to

Appendix F

.

Important:

The Find Home and Position Redefine bits must be returned to 0 following the homing routine and before starting the drive.

Values

Bit

Default:

Min/Max:

Display:

0

1

2

“Home Limit”

“Find Home”

“Hold Step”

3

“Pos Redefine”

4

5

6

7

“Sync Enable”

“Traverse Disable”

“Logic In 1”

“Logic In 2”

Home Limit

Find Home

Hold Step

Pos Redefine

Sync Enable

Traverse Disable

Logic In 1

Logic In 2

1 = Input Present, 0 = Input Not Present

Bit 0

Bit 1

Bit 2

Bit 3

Bit 4

Bit 5

Bit 6

Bit 7

0

0/1

1

In Positioning mode, this indicates the drive is at the home position.

When set, the next start command causes the drive to find home. Set this bit to 0 after completing the homing routine.

In Positioning mode, this input over-rides other inputs and causes the drive to remain at its current step (running at zero speed once it reaches its position) until released.

In Positioning mode, this input resets the home position to the current position of the machine. Set this bit to 0 after completing the homing routine.

Must be used in order to hold the existing frequency when

Sync Time is set to enable speed synchronization. When this bit is reset to zero the drive will accelerate to the new commanded frequency based on E214 [Sync Time] setting.

When set the traverse function will be disabled.

This provides an identical function as the “Logic In1” Digital

Input option. This bit is logically ORed with a digital input

A051 - A054

set to option 23 “Logic In1”. It can be used to move through the Step-Logic functions (speed or position) via comms control without requiring actual digital input transitions.

This provides and identical function as the “Logic In2” Digital

Input option. This bit is logically ORed with a digital input

A051 - A054

set to option 24 “Logic In2”. It can be used to move through the Step-Logic functions (speed or position) via comms control without requiring actual digital input transitions.

Programming and Parameters

3-61

Enhanced Program Group

(continued)

E249 [Cmd Stat Select]

Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use

over a communication network. For additional information refer to Appendix C

.

Options 0

“Velocity” (Default)

1

“Position”

3-62

Programming and Parameters

Advanced Display Group

d301 [Drive Status 2]

Present operating condition of the drive.

When in Positioning mode, Bit 10 indicates positive or negative position in relation to Home.

Values

Default:

Min/Max:

Display:

Dir Positive

At Position

At Home

Drive Homed

1 = Condition True, 0 = Condition False

Bit 0

Bit 1

Bit 2

Bit 3

Read Only

0/1

1

d302 [Fibers Status]

Present status of the Fibers features.

Values

Default:

Min/Max:

Display:

Sync Hold

Sync Ramp

Traverse On

Traverse Dec

1 = Condition True, 0 = Condition False

Digit 1

Digit 2

Digit 3

Digit 4

Read Only

0/1

1

d303 [Slip Hz Meter]

Displays the current amount of slip being applied to the motor frequency.

Values

Default: Read Only

Min/Max:

Display:

0.0/25.0 Hz

0.1 Hz

d304 [Speed Feedback]

32

32 bit parameter.

Related Parameter(s): E218

,

d305

Displays the value of the actual motor speed (whole number portion) whether measured by encoder/ pulse train feedback or estimated.

Values

Default: Read Only

Min/Max: 0/64000 RPM

Display: 1 RPM

Programming and Parameters

3-63

Advanced Display Group

(continued)

d305 [Speed Feedback F]

Related Parameter(s):

d304

Displays the value of the actual motor speed (fractional portion) whether measured by encoder/pulse train feedback or estimated.

Values

Default: Read Only

Min/Max: 0.0/0.9

Display: 0.1

d306 [Encoder Speed]

32

32 bit parameter.

Related Parameter(s):

d307

Provides a monitoring point that reflects the speed (whole number portion) measured from the feedback device. This shows the encoder or pulse train speed even if this is not used directly to control the motor speed.

Values

Default: Read Only

Min/Max:

Display:

0/64000

1

d307 [Encoder Speed F]

Related Parameter(s):

d306

Provides a monitoring point that reflects the speed (fractional portion) measured from the feedback device. This shows the encoder or pulse train speed even if this is not used directly to control the motor speed.

Values

Default: Read Only

Min/Max:

Display:

0.0/0.9

0.1

d308 [Units Traveled H]

32

32 bit parameter.

Related Parameter(s): d309

,

E226

Displays the number of user-defined units (whole number portion) traveled from the home position.

Values

Default: Read Only

Min/Max:

Display:

0/64000

1

d309 [Units Traveled L]

Related Parameter(s): d308

,

E226

Displays the number of user-defined units (fractional portion) traveled from the home position.

Values

Default: Read Only

Min/Max:

Display:

0.00/0.99

0.01

3-64

Programming and Parameters

No.

A123

Group

Advanced Program

A087

A086

A117

E249

A103

A107

A105

A106

A110

A113

A112

A109

A093

A092

A127

A084

P039

A067

E203

E205 b020 b021

A122

A066

A065

A111

A104 b015

E207 b002

A097 b013 b012 b016

Advanced Program

Display

Enhanced Program

Display

Advanced Program

Display

Display

Display b025

E226

Display

Enhanced Program

A089, A118 Advanced Program

A082

A163

A081

A080 b005

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Display d301 b024 b017 b018

A160

A161

E225

P040

A068

E204

Basic Program

Advanced Program

Enhanced Program

E206 b014

Enhanced Program

Display

A051-A054 Advanced Program

E202 b006

Enhanced Program

Display

Advanced Display

Display

Display

Display

Advanced Program

Advanced Program

Enhanced Program

Basic Program

Advanced Program

Enhanced Program

Enhanced 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

Enhanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Parameter Cross Reference – by Name

Parameter Name

10V Bipolar Enbl

Comm Node Addr

Comm Status

Comm Write Mode

Commanded Freq

Compensation

Contrl In Status

Control Source

Control SW Ver

Counter Status

Counts Per Unit

Current Limit x

DB Resistor Sel

DB Threshold

DC Brake Level

DC Brake Time

DC Bus Voltage

Decel Time 1

Decel Time 2

Decel Time 3

Decel Time 4

Dig In Status

Digital Inx Sel

Digital Term 3

Drive Status

Drive Status 2

Drive Temp

Drive Type

Elapsed Run Time

EM Brk Off Delay

EM Brk On Delay

Encoder Pos Tol

Accel Time 1

Accel Time 2

Accel Time 3

Accel Time 4

Analog In 0-10V

Analog In 4-20mA

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 Out Setpt

Auto Rstrt Delay

Auto Rstrt Tries

Autotune

Boost Select

Break Frequency

Break Voltage

Bus Reg Mode

Cmd Stat Select

Comm Data Rate

Comm Format

Comm Loss Action

Comm Loss Time

Parameter Name

Encoder PPR

Encoder Speed

Motor NP Poles

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

P Jump

PID Deadband

PID Diff Rate

PID Feedback Sel

PID Integ Time

PID Preload

PID Prop Gain

PID Ref Sel

PID Setpoint

PID Trim Hi

PID Trim Lo

Pos Reg Filter

Pos Reg Gain

Positioning Mode

Power Loss Mode

Preset Freq x

Process Display

Encoder Speed F

Enh Control Word

Fault Clear

Fault x Code

Fibers Status

Find Home Dir

Find Home Freq

Flux Current Ref

Flying Start En

Half Bus Enable

Internal Freq

IR Voltage Drop

Jog Accel/Decel

Jog Frequency

Ki Speed Loop

Kp Speed Loop

Language

LED Display Opt

Max Traverse

Maximum Freq

Maximum Voltage

Minimum Freq

MOP Reset Sel

Motor Fdbk Type

Motor NP FLA

Motor NP Hertz

No.

E218 d306

Group

Enhanced Program

Advanced Display

E210

P035

A088

P034

A162

E216

A126

P032

A069

A128

A079

A078

E220

E221

A108

E201 d307

E248

Advanced Display

Enhanced Program

A100 Advanced Program b007-b009 Display d302 Advanced Display

E224

E223

A129

A096

E209

Enhanced Program

Enhanced Program

Advanced Program

Advanced Program

Enhanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Enhanced Program

Enhanced Program

Advanced Program

Enhanced Program

Enhanced Program

Basic Program

Advanced Program

Basic Program

Advanced Program

Enhanced Program

Advanced Program

Basic Program b003 b001 b022 b023 b004

E213

A138

A136

E217

P031

P033

P043

A090

A064

Enhanced Program

Basic Program

Basic Program

Basic Program

Advanced Program

Advanced Program

A059, A062 Advanced Program

A058, A061 Advanced Program

Display

Display

Display

Display

Display

Enhanced Program

Advanced Program

Advanced Program

A133

A135

A139

A134

A132

A137

A130

A131

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

E246

E247

E222

Enhanced Program

Enhanced Program

Enhanced Program

E208 Enhanced Program

A070-A077 Advanced Program b010 Display

Parameter Name

Process Factor

Step Units 7

Step Units F 0

Step Units F 1

Step Units F 2

Step Units F 3

Step Units F 4

Step Units F 5

Step Units F 6

Step Units F 7

Stop Mode

Stp Logic Status

Stp Logic Time x

Stp Logic x

SW Current Trip

Sync Time

Testpoint Data

Testpoint Sel

Timer Status

Torque Current

Torque Perf Mode

Traverse Dec

Traverse Inc

Units Traveled H

Units Traveled L

Var PWM Disable

Voltage Class

Process Time Hi

Process Time Lo

Program Lock

Pulse In Scale

PWM Frequency

Relay Out Level

Relay Out Sel

Reset To Defalts

Reverse Disable

S Curve %

Skip Freq Band

Skip Frequency

Slip Hertz @ FLA

Slip Hertz Meter

Speed Feedback

Speed Feedback F

Speed Ratio

Speed Reference

Stall Fault Time

Start At PowerUp

Start Boost

Start Source

Step Units 0

Step Units 1

Step Units 2

Step Units 3

Step Units 4

Step Units 5

Step Units 6

No.

A099

Group

Advanced Program

P036

E230

E232

E234

E236

E238

E240

E242 d303 d304 d305

E215

P038

A121

A094

A085

A116

A115

A101

E219

A091

A056

A055

P041

A095

A083

A120

A119

A114

A102 b026 b029

A125

E212

E211 d308 d309

A124

P042

E244

E231

E233

E235

E237

E239

E241

E243

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

E245

P037 b028

Enhanced Program

Basic Program

Display

A150-A157 Advanced Program

A140-A147 Advanced Program

A098 Advanced Program

E214 b019

Enhanced Program

Display

Advanced Program

Display

Display

Advanced Program

Enhanced Program

Enhanced Program

Advanced Display

Advanced Display

Advanced Program

Basic Program

Advanced Program

Advanced Program

Advanced Program

Enhanced Program

Advanced Program

Advanced Program

Advanced Program

Basic Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Program

Advanced Display

Advanced Display

Advanced Display

Enhanced Program

Basic Program

Advanced Program

Advanced Program

Advanced Program

Basic Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Enhanced Program

Programming and Parameters

3-65

3-66

Notes:

Programming and Parameters

Chapter

4

Troubleshooting

Chapter 4 provides information to guide you in troubleshooting the

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

(with possible solutions, when applicable).

For information on…

Drive Status

Faults

See page… For information on…

4-1

Fault Descriptions

4-1

Common Symptoms and

Corrective Actions

See page…

4-3

4-6

!

ATTENTION:

Risk of injury or equipment damage exists. Drive does not contain user-serviceable components. Do not disassemble drive chassis.

Drive Status

The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral LED display.

LED Indications

See

page 2-3

for information on drive status indicators and controls.

Faults

A fault is a condition that stops the drive. There are two fault types.

Table 4.A Fault Types

Type Fault Description

Auto-Reset/Run

Non-Resetable

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.

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 LED display provides visual notification of a fault condition by displaying the following.

Flashing fault number

Flashing fault indicator

Press the Up Arrow key to regain control of the display.

Display

RUN

REV

FAULT

Manually Clearing Faults

Step

1. Address the condition that caused the fault.

The cause must be corrected before the fault can be cleared.

See Table 4.B

.

2. After corrective action has been taken, clear the fault by one of these methods.

Press and hold the Up Arrow key for three seconds.

Cycle drive power.

Set

A100 [Fault Clear] to “1” or “2”.

Cycle digital input if

“Clear Fault”.

A051 A054 [Digital Inx Sel] is set to option 7

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. Fault types are listed in Table 4.A

. Refer to

Table 4.B

for fault descriptions.

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.B Fault Types, Descriptions and Actions

No.

F2

F3

F4

F5

F6

F7

F8

F12

F13

F29

Fault

Auxiliary Input

Power Loss

UnderVoltage

OverVoltage

Motor Stalled

Motor Overload

Heatsink

OvrTmp

HW OverCurrent

Ground Fault

Analog Input

Loss

Description

Auxiliary input interlock is open.

DC bus voltage remained below

85% of nominal or single phase operation detected.

DC bus voltage fell below the minimum value.

DC bus voltage exceeded maximum value.

Drive is unable to accelerate motor.

Internal electronic overload trip.

Action

1. Check remote wiring.

2. Verify communications programming for intentional fault.

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

2. Check input fuses.

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 P039

-

A067 [Accel Time x]

or reduce load so drive output current does not exceed the current

set by parameter A089

[Current Limit

1].

1. An excessive motor load exists.

Reduce load so drive output current does not exceed the current set by parameter

P033

[Motor OL Current].

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 IP 30/NEMA 1/UL

Type 1 installations or 50°C (122°F) for

IP20/Open type installations.

The drive output current has exceeded the hardware current limit.

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

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.

(1)

See page 4-1

for a description of fault types.

4-4

Troubleshooting

No.

F33

F38

F39

F40

F41

F42

F43

F48

F63

F64

F70

F71

F80

F81

Fault

Auto Rstrt Tries

Phase U to Gnd

Phase V to Gnd

Phase W to Gnd

Phase UV Short

Phase UW Short

Phase VW Short

Params

Defaulted

SW OverCurrent

Drive Overload

Power Unit

Net Loss

SVC Autotune

Comm Loss

Description

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

number of A092

[Auto Rstrt

Tries].

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

Action

Correct the cause of the fault and manually clear.

1. Check the wiring between the drive and motor.

2. Check motor for grounded phase.

Excessive current has been detected between these two output terminals.

The drive was commanded to write default values to EEPROM.

Programmed

A098 [SW Current

Trip] has been exceeded.

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

Failure has been detected in the drive power section.

The communication network has faulted.

3. Replace drive if fault cannot be cleared.

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

2. Replace drive if fault cannot be cleared.

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.

1. Cycle power.

2. Replace drive if fault cannot be cleared.

1. Cycle power.

2. Check communications cabling.

3. Check network adapter setting.

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

RS485 (DSI) port stopped communicating.

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].

5. Connecting I/O Terminal 04 to ground may improve noise immunity.

Troubleshooting

4-5

No.

F91

Fault

Encoder Loss

F100 Parameter

Checksum

F111 Enable

Hardware

F122 I/O Board Fail

Description

Requires differential encoder.

One of the 2 encoder channel signals is missing.

Action

1. Check Wiring.

2. If P038 [Speed Reference] = 9

“Positioning” and E216 [Motor

Fdbk Type] = 5 “Quad Check” swap the Encoder channel inputs

(see page 1-18

) or swap any two motor leads.

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

DriveGuard Safe-Off Option

(Series B) board is installed and the ENBL enable jumper has not been removed.

DriveGuard Safe-Off Option

(Series B) board has failed.

3. Replace encoder.

Set

P041 [Reset To Defalts] to

option 1 “Reset Defaults”.

1. Remove the ENBL enable jumper.

2. Cycle power.

1. Remove power to the drive.

2. Replace DriveGuard Safe-Off

Option (Series B) board.

Replace drive.

Hardware Enable circuitry has failed.

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

1. Cycle power.

2. Replace drive if fault cannot be cleared.

(1)

See page 4-1

for a description of fault types.

4-6

Troubleshooting

Common Symptoms and Corrective Actions

Motor does not Start.

Cause(s)

No output voltage to the motor.

Indication

None

Improper boost setting at initial start-up.

Drive is Faulted

None

Flashing red status light

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.

If using the DriveGuard Safe-Off

Option (Series B) board, verify that inputs are active.

Set A084

[Boost Select] to option 2

“35.0, VT”.

Clear fault.

Press and hold Up Arrow key for

3 seconds.

Cycle power

Set A100 [Fault Clear] to option 1

“Clear Faults”.

Cycle digital input if

A051 - A054

[Digital Inx Sel] is set to option 7

“Clear Fault”.

Troubleshooting

4-7

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

Cause(s)

Drive is Faulted

Indication

Flashing red status light

Corrective Action

Clear fault.

Press and hold Up Arrow key for

3 seconds.

Cycle power

Set A100 [Fault Clear] to option 1

“Clear Faults”.

Cycle digital input if

A051 - A054

[Digital Inx Sel] is set to option 7

“Clear Fault”.

Check parameter settings.

Incorrect programming.

P036

[Start Source] is set to option 5 “Comm Port”.

Incorrect input wiring.

See 1-22 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

None

Wire inputs correctly and/or install jumper.

If using the DriveGuard Safe-Off

Option (Series B) board, verify that inputs are active.

Set switch to match wiring scheme.

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 b012

[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 b002

[Commanded Freq] to verify correct command.

Check b012

[Control Source] for correct source.

Check b014

[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 1-27

.

4-8

Troubleshooting

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.

None

Torque performance does not match motor characteristics.

None

Corrective Action

Reprogram

P039

[Accel Time 1] or

A067 [Accel Time 2].

Compare b003

[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

b002 [Commanded Freq].

Check b012 [Control Source] for the

proper Speed Command.

Check P035

[Maximum Freq] to insure that speed is not limited by programming.

Verify programming of E215

[Speed

Ratio].

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”.

Troubleshooting

4-9

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 3-15)

. 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.

4-10

Notes:

Troubleshooting

Appendix

A

Supplemental Drive Information

For information on…

Drive, Fuse & Circuit Breaker Ratings

Specifications

See page…

A-1

A-2

Drive, Fuse & Circuit Breaker Ratings

The tables on the following pages provide drive ratings and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 degree

C and the U.S. N.E.C. Other country, state or local codes may require different ratings.

Fusing

If fuses are chosen as the desired protection method

, refer to the recommended types listed below. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen.

IEC – BS88 (British Standard) Parts 1 & 2

(1)

, EN60269-1, Parts 1 &

2, type gG or equivalent should be used.

UL – UL Class CC, T or J must be used.

(2)

Circuit Breakers

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

Table A.A Drive Ratings

Catalog

Number

(1)

Output Ratings

kW (HP) Amps

Input Ratings

Voltage

Range kVA Amps

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

22D-B2P3

22D-B5P0

22D-B8P0

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

2.45

4.0

2.5

5.7

9.5

22D-B012

22D-B017

2.2 (3.0)

3.7 (5.0)

12.0

17.5

180-264

180-264

5.5

8.6

15.5

21.0

22D-B024

22D-B033

5.5 (7.5)

7.5 (10.0)

24.0

33.0

180-264

180-264

11.8

16.3

26.1

34.6

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

22D-D1P4 0.4 (0.5) 1.4

342-528 1.4

1.8

22D-D2P3

22D-D4P0

22D-D6P0

22D-D010

22D-D012

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

2.3

4.0

6.0

10.5

12.0

342-528

342-528

342-528

342-528

342-528

2.3

4.0

5.9

10.3

11.8

22D-D017

22D-D024

7.5 (10.0)

11.0 (15.0)

17.0

24.0

342-528

342-528

16.8

23.4

18.4

26.0

460 - 600V AC (±10%) – 3-Phase Input, 0 - 575V 3-Phase Output

3.2

5.7

7.5

13.0

14.2

22D-E1P7

22D-E3P0

22D-E4P2

22D-E6P6

22D-E9P9

22D-E012

22D-E019

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

4.0 (5.0)

5.5 (7.5)

7.5 (10.0)

11.0 (15.0)

1.7

3.0

4.2

6.6

9.9

12.2

19.0

414-660

414-660

414-660

414-660

414-660

414-660

414-660

2.1

3.65

5.2

8.1

12.1

14.9

23.1

2.3

3.8

5.3

8.3

11.2

13.7

24.1

(1)

15

20

25

30

50

3

6

10

25

30

40

60

6

10

15

15

20

25

6

6

10

40

Branch Circuit Protection

Fuses

140M Motor

Protectors

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

Contactors

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

Ratings apply to all drive types; Panel Mount (N104), Flange Mount (F104), and Plate Drive

(H204).

Supplemental Drive Information

A-3

Category

Agency

Certification

Table A.B Specifications

Specification

C US

Listed to UL508C and CAN/CSA-22.2

Certified to AS/NZS, 1997 Group 1, Class A

Protection

Environment

.

.

Product Safety

E

W

C

Production inspected

Marked for all applicable European Directives

EMC Directive (89/336)

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

Low Voltage Directive (73/23/EEC)

EN 50178, EN 60204

Certified to EN 954-1, Category 3.

Meets Functional Safety (FS) when used with the

DriveGuard Safe-Off Option (Series B).

EN 50178

Bauart geprüft

Functional

.

.

TUV

Rheinland

Safety

Type approved

The drive is also designed to meet the appropriate portions of the following specifications:

NFPA 70 - US National Electrical Code

NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and

Operation of Adjustable Speed Drive Systems.

IEC 146 - International Electrical Code.

Bus Overvoltage Trip

200-240V AC Input:

380-460V AC Input:

460-600V AC Input:

405V DC bus (equivalent to 290V AC incoming line)

810V DC bus (equivalent to 575V AC incoming line)

1005V DC bus (equivalent to 711V AC incoming line)

Bus Undervoltage Trip

200-240V AC Input:

380-480V AC Input:

460-600V AC Input

P042 = 3 “High Voltage”:

P042 = 2 “Low Voltage”:

Power Ride-Thru:

Logic Control Ride-Thru:

Electronic Motor Overload Protection:

210V DC bus (equivalent to 150V AC incoming line)

390V DC bus (equivalent to 275V AC incoming line)

487V DC bus (equivalent to 344V AC incoming line)

390V DC bus (equivalent to 275V AC incoming line)

100 milliseconds

I

0.5 seconds minimum, 2 seconds typical

2 t protection - 150% for 60 seconds, 200% for 3 seconds (Provides Class 10 protection)

200% hardware limit, 300% instantaneous fault Overcurrent:

Ground Fault Trip:

Short Circuit Trip:

Altitude:

Phase-to-ground on drive output

Phase-to-phase on drive output

1000 m (3300 ft) max. without derating. Above 1000 m

(3300 ft) derate 3% for every 305 m (1000 ft).

Maximum Surrounding Air Temperature without derating:

IP20, Open Type:

IP30, NEMA Type 1, UL Type 1:

Flange and Plate Mount:

–10 to 50° C (14 to 122° F)

–10 to 40° C (14 to 104° F)

Heatsink:

Drive:

–10 to 40° C (14 to 104° F)

–10 to 50° C (14 to 122° F)

Cooling Method

Convection:

Fan:

Storage Temperature:

Atmosphere:

0.4 kW (0.5 HP) drives and all Flange and Plate drives

All other drive ratings

–40 to 85 degrees C (–40 to 185 degrees F)

Relative Humidity:

Shock (operating):

Vibration (operating):

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 (

±

1.0 ms)

1G peak, 5 to 2000 Hz

A-4

Supplemental Drive Information

Category

Electrical

Control

Control Inputs

Encoder

Specification

Voltage Tolerance:

Frequency Tolerance:

Input Phases:

Displacement Power Factor:

Maximum Short Circuit Rating:

Actual Short Circuit Rating:

Transistor Type:

Method:

Carrier Frequency

Frequency Accuracy

Digital Input:

Analog Input:

Analog Output:

Speed Regulation

Open Loop with Slip Compensation:

With Encoder:

Output Frequency:

Efficiency:

Stop Modes:

Accel/Decel:

Intermittent Overload:

Electronic Motor Overload Protection

Digital: Bandwidth:

Quantity:

Analog:

Type:

Supply:

Quadrature:

Duty Cycle:

Requirements:

Current:

Type

Source Mode (SRC):

Sink Mode (SNK):

Quantity:

Specification

Resolution:

0 to 10V DC Analog:

4-20mA Analog:

External Pot:

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

Isolated Gate Bipolar (IGBT)

Sinusoidal PWM, Volts/Hertz, and Sensorless Vector

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 80:1 speed range

±0.3% of base speed across a 80:1 speed range

±0.05% of base speed across a 20:1 speed range

0-500 Hz (programmable)

97.5% (typical)

Multiple programmable stop modes including - Ramp,

Coast, DC-Brake, and Ramp-to-Stop

Four 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 selectable speed sensitive response and power-down overload retention function when enabled.

10 Rad/Secs for open and closed loop

(2) Dedicated for start and stop

(5) Programmable

6 mA

18-24V = ON, 0-6V = OFF

0-6V = ON, 18-24V = OFF

(2) Isolated, –10 to 10V and 4-20mA

10-bit

100k ohm input impedance

250 ohm input impedance

1-10k ohm, 2 Watt minimum

Incremental, dual channel

12V, 250 mA. 12V, 10 mA minimum inputs isolated with differential transmitter, 250 kHz maximum.

90°, ±27 degrees at 25 degrees C.

50%, +10%

Encoders must be line driver type, quadrature (dual channel) or pulse (single channel), 3.5-26V DC output, single-ended or differential and capable of supplying a minimum of 10 mA per channel. Allowable input is DC up to a maximum frequency of 250 kHz. The encoder

I/O automatically scales to allow 5V, 12V and 24V DC nominal voltages.

Supplemental Drive Information

Category

Control Outputs

Specification

Relay:

Opto:

Quantity:

Specification

Resistive Rating:

Inductive Rating:

Quantity:

Analog:

Specification:

Quantity:

Specification

Resolution:

0 to 10V DC Analog:

4-20mA Analog:

(1) Programmable Form C

3.0A at 30V DC, 3.0A at 125V, 3.0A at 240V AC

0.5A at 30V DC, 0.5A at 125V, 0.5A at 240V AC

(2) Programmable

30V DC, 50mA Non-inductive

(1) Non-Isolated 0-10V or 4-20mA

10-bit

1k ohm minimum

525 ohm maximum

A-5

Table A.C PowerFlex 40P Estimated Watts Loss (Rated Load, Speed & PWM)

Voltage

200–240V

380–480V

460–600V kW (HP)

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)

30

48

75

135

140

175

260

17

30

48

75

135

140

175

260

External Watts

22

40

63

100

150

200

265

20

22

25

25

35

35

40

18

20

22

25

25

35

35

40

Internal Watts

18

20

22

25

30

35

40

50

70

100

160

175

210

300

35

50

70

100

160

175

210

300

Total Watts Loss

40

60

85

125

180

235

305

A-6

Notes:

Supplemental Drive Information

Appendix

B

Accessories and Dimensions

Product Selection

Table B.A Catalog Number Description

22D -

Drive

B

Voltage Rating

2P3

Rating

N

Enclosure

1

HIM

0

Emission Class

4

Version

Table B.B PowerFlex 40P Drives

Input Voltage

240V 50/60 Hz

3-Phase

No Filter

(1)

(2)

Drive Ratings

480V 50/60 Hz

3-Phase

No Filter

600V 50/60 Hz

3-Phase

No Filter

1.5

2.2

3.7

5.5

kW HP

0.4

0.5

0.75 1.0

2.0

3.0

5.0

7.5

2.2

4.0

5.5

7.5

7.5

0.4

10.0 33.0A

0.5

0.75 1.0

1.5

2.0

1.4A

2.3A

4.0A

3.0

5.0

6.0A

10.5A

7.5

12.0A

10.0 17.0A

IP20/NEMA Type Open

Output

Current Catalog Number

IP20 Flange

Mount

(1)

Frame

Size Catalog Number

2.3A

5.0A

22D-B2P3N104

22D-B5P0N104

B

B

22D-B2P3F104

22D-B5P0F104

8.0A

12.0A

17.5A

24.0A

22D-B8P0N104

22D-B012N104

22D-B017N104

22D-B024N104

B

B

B

C

22D-B8P0F104

22D-B012F104

22D-B017F104

22D-B024F104

11.0 15.0 24.0A

0.75 1.0

1.5

2.2

2.0

3.0

1.7A

3.0A

4.2A

4.0

5.5

5.0

7.5

6.6A

9.9A

7.5

10.0 12.0A

11.0 15.0 19.0A

22D-B033N104

22D-D1P4N104

22D-D2P3N104

22D-D4P0N104

22D-D6P0N104

22D-D010N104

22D-D012N104

22D-D017N104

22D-D024N104

22D-E1P7N104

22D-E3P0N104

22D-E4P2N104

22D-E6P6N104

22D-E9P9N104

22D-E012N104

22D-E019N104

C

B

B

B

B

B

C

C

C

B

B

B

B

C

C

C

22D-B033F104

22D-D1P4F104

22D-D2P3F104

22D-D4P0F104

22D-D6P0F104

22D-D010F104

22D-D012F104

22D-D017F104

22D-D024F104

(2)

22D-E1P7F104

22D-E3P0F104

22D-E4P2F104

22D-E6P6F104

22D-E9P9F104

22D-E012F104

22D-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.

Plate Drive

Catalog Number

22D-B2P3H204

22D-B5P0H204

22D-B8P0H204

22D-B012H204

22D-B017H204

22D-B024H204

22D-B033H204

22D-D1P4H204

22D-D2P3H204

22D-D4P0H204

22D-D6P0H204

22D-D010H204

22D-D012H204

22D-D017H204

22D-D024H204

(2)

22D-E1P7H204

22D-E3P0H204

22D-E4P2H204

22D-E6P6H204

22D-E9P9H204

22D-E012H204

22D-E019H204

B-2

Accessories and Dimensions

Table B.C Dynamic Brake Modules

Drive Ratings

Input Voltage

240V 50/60 Hz

3-Phase

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

4.0

5.5

7.5

11.0

0.4

0.75

1.5

2.2

2.2

3.7

5.5

7.5

kW

0.4

0.75

1.5

0.75

1.5

2.2

4.0

5.5

7.5

11.0

5.0

7.5

10.0

15.0

0.5

1.0

2.0

3.0

3.0

5.0

7.5

10.0

HP

0.5

1.0

2.0

1.0

2.0

3.0

5.0

7.5

10.0

15.0

51

51

51

120

120

82

82

77

55

39

24

97

97

97

97

48

48

32

19

13

10

Minimum

Resistance

Ω

48

Catalog Number

(1) (2)

AK-R2-091P500

AK-R2-091P500

AK-R2-091P500

AK-R2-047P500

AK-R2-047P500

AK-R2-030P1K2

AK-R2-030P1K2

AK-R2-360P500

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

AK-R2-120P1K2

AK-R2-120P1K2

(3)

(1)

(2)

(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 P

owerFlex Dynamic Braking

Resistor Calculator

, publication PFLEX-AT001.

Requires two resistors wired in parallel.

Accessories and Dimensions

B-3

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

Input Voltage

240V 50/60 Hz

3-Phase

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

2.2

4.0

5.5

7.5

7.5

0.4

0.75

1.5

1.5

2.2

3.7

5.5

kW

0.4

0.75

4.0

5.5

7.5

11.0

11.0

0.75

1.5

2.2

3.0

5.0

7.5

10.0

10.0

0.5

1.0

2.0

2.0

3.0

5.0

7.5

HP

0.5

1.0

5.0

7.5

10.0

15.0

15.0

1.0

2.0

3.0

8

12

12

18

4

4

25

2

8

12

12

18

4

4

35

2

Fundamental

Amps

Maximum

Continuous

Amps

Inductance mh

Watts

Loss

4

8

8

12

18

25

6

12

12

18

27

37.5

12.0

3.0

1.5

1.25

0.8

0.5

21 W

29 W

19.5 W

26 W

36 W

48 W

52.5

3

6

6

12

18

18

27

0.4

20.0

9.0

6.5

5.0

2.5

2.5

1.5

49 W

11.3 W

20 W

20 W

25.3 W

31 W

31 W

43 W

12

18

18

27

6

6

37.5

3

5.0

2.5

2.5

1.5

1.2

20.0

6.5

6.5

52 W

11.3 W

20 W

20 W

25.3 W

31 W

31 W

43 W

Catalog

Number

(1)

1321-3R4-D

1321-3R8-B

1321-3R8-A

1321-3R12-A

1321-3R18-A

1321-3R25-A

1321-3R35-A

1321-3R2-B

1321-3R4-C

1321-3R4-B

1321-3R8-C

1321-3R12-B

1321-3R12-B

1321-3R18-B

1321-3R25-B

1321-3R2-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

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

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

Catalog Number

1321-DC32-1

1321-DC40-2

1321-DC18-4

1321-DC25-4

1321-DC32-3

1321-DC12-2

1321-DC18-4

1321-DC25-4

B-4

Accessories and Dimensions

Table B.F EMC Line Filters

Drive Ratings

Input Voltage

240V 50/60 Hz

3-Phase

480V 50/60 Hz

3-Phase

600V 50/60 Hz

3-Phase

7.5

11.0

0.75

1.5

1.5

2.2

4.0

5.5

2.2

4.0

5.5

7.5

11.0

5.5

7.5

0.4

0.75

kW

0.4

0.75

1.5

2.2

3.7

10.0

15.0

1.0

2.0

2.0

3.0

5.0

7.5

3.0

5.0

7.5

10.0

15.0

7.5

10.0

0.5

1.0

HP

0.5

1.0

2.0

3.0

5.0

S Type Filter

Catalog Number

(1)

22-RF021-BS

22-RF021-BS

22-RF021-BS

22-RF021-BS

22-RF021-BS

22-RF034-CS

22-RF034-CS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF012-BS

22-RF018-CS

(3)

22-RF018-CS

(3)

22-RF026-CS

(3)

L Type Filter

Catalog Number

(2)

22-RF021-BL

(3)

22-RF021-BL

(3)

22-RF021-BL

(3)

22-RF021-BL

(3)

22-RF021-BL

(3)

22-RF034-CL

22-RF034-CL

22-RF012-BL

22-RF012-BL

22-RF012-BL

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

(1)

(2)

(3)

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.

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.

Filter must be Series C or later.

Accessories and Dimensions

B-5

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

Item

DSI HIM Cable

(DSI HIM to RJ45 cable)

Description

LCD Display, Remote Panel

Mount

Digital speed control

CopyCat capable

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

Includes 2.9 meter cable

LCD Display, Remote Handheld Digital speed control

Full numeric keypad

CopyCat capable

IP30 (NEMA Type 1)

Includes 1.0 meter cable

Panel mount with optional Bezel Kit

Bezel Kit 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-A3

22-HIM-B1

22-HIM-H10

22-HIM-H30

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

Item Description

IP30/NEMA 1/UL Type 1

Kit

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

Table B.I Other Options

Item

DriveGuard® Safe-Off Option

Board

Description Catalog Number

When used with suitable safety components, provides protection according to EN

954-1:1997; Category 3 for safe off and protection against restart.

20A-DG01

B-6

Accessories and Dimensions

Table B.J 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

(Ordered Separately).

ControlNet™

DeviceNet™

EtherNet/IP™

LonWorks™

PROFIBUS™ DP

External mounting kit for 22-COMM cards.

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

Universal Serial Bus™

(USB) Converter Module

Cover that houses the Communication Adapter.

B Frame Drive

C Frame Drive

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

2m USB cable (1)

20-HIM-H10 cable (1)

22-HIM-H10 cable (1)

Catalog Number

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

22D-CCB

22D-CCC

1203-USB

Serial Converter Module

(RS485 to RS232)

Remote Handheld HIM

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

DSI to RS232 serial converter (1)

1203-SFC serial cable (1)

22-RJ45CBL-C20 cable (1)

DriveExplorer Lite CD (1)

Wireless Interface Module with

Bluetooth®

technology, IP30 (NEMA Type 1), Panel Mount with optional bezel kit.

Remote Panel Mount

HIM

DSI Cable

Serial Cable

Null Cable Converter

Splitter Cable

Terminating Resistors

Terminal Block

DriveTools SP Software

22-SCM-232

22-WIM-N1

Wireless Interface Module with

Bluetooth®

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

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

22-WIM-N4S

22-RJ45CBL-C20

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.

For use when connecting the serial converter to

DriveExplorer on a handheld PC.

1203-SFC

1203-SNM

RJ45 one to two port splitter cable

RJ45 120 Ohm resistors (2 pieces)

AK-U0-RJ45-SC1

AK-U0-RJ45-TR1

DriveExplorer Software

(CD-ROM) Version 3.01 or later

DriveExecutive software

(CD-ROM) Version 1.01 or later

RJ45 Two position terminal block (5 pieces)

Windows based software packages that provide 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)

AK-U0-RJ45-TB2P

9303-4DTS01ENE

9306-4EXP01ENE

9303-4DTE01ENE

(1)

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

Accessories and Dimensions

B-7

79.1 (3.11)

64.1 (2.52)

40.6 (1.60)

25.6 (1.01)

Product Dimensions

Table B.K PowerFlex 40P Frames

– Ratings are in kW and (HP)

Frame

B

C

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)

11.0 (15.0)

600V AC –

3-Phase

0.75 (1.0)

1.5 (2.0)

5.5 (7.5)

7.5 (10.0)

2.2 (3.0)

4.0 (5.0)

11.0 (15.0)

Figure B.1 IP 30/NEMA 1/UL Type 1 Option Kit without Communication Option

Dimensions are in millimeters and (inches)

100.0 (3.94)

87.0 (3.43)

148.0 (5.83)

136.0 (5.35)

22.2

(0.87)

RUN

REV

87.4

(3.44)

109.9

(4.33)

74.3

(2.93)

168

(6.61)

213

(8.39)

180

(7.09)

Frame B - 22-JBAB

107.0 (4.21)

66.0 (2.60)

24.0 (0.94)

28.5

(1.12)

22.2

(0.87)

130.0 (5.1)

116.0 (4.57)

REV

FAULT

246

(9.7)

260

(10.2)

320

(12.6)

111.2

(4.38)

152.2

(5.99)

Frame C - 22-JBAC

192.0 (7.56)

180.0 (7.1)

B-8

Accessories and Dimensions

77.5 (3.05)

50.0 (1.97)

22.5 (0.89)

Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit with Communication Option

Dimensions are in millimeters and (inches)

22.2

(0.87)

100.0 (3.94)

87.0 (3.43)

161.0 (6.34)

136.0 (5.35)

REV

FAULT

87.4

(3.44)

134.3

(5.29)

105.3

(4.15)

76.3

(3.00)

244

(9.61)

180

(7.09)

168

(6.61)

Frame B - 22-JBCB

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)

130.0 (5.1)

116.0 (4.57)

RUN

REV

FAULT

320

(12.6)

246

(9.7)

260

(10.2)

109.8

(4.32)

179.8

(7.08)

144.8

(5.70)

205.0 (8.07)

180.0 (7.1)

Frame C - 22-JBCC

Accessories and Dimensions

B-9

Figure B.3 PowerFlex 40P Flange Mount Drives

– Dimensions are in millimeters and

(inches)

244

(9.61)

214

(8.43)

106.3

(4.19)

94.3

(3.71)

63.1

(2.48)

RUN

REV

FAULT

20A-DG01

250

(9.84)

22D-CCB

300

(11.81)

RUN

REV

FAULT

Frame B

119.3

(4.70)

117.8

(4.64)

105.8

(4.17)

138.2

(5.44)

20A-DG01

325

(12.8)

22D-CCC

130.3

(5.13)

Frame C

B-10

Accessories and Dimensions

Figure B.4 PowerFlex 40P 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)

Accessories and Dimensions

B-11

Figure B.5 PowerFlex 40P Plate Drive Dimensions

– Dimensions are in millimeters and (inches)

112

(4.41)

80

(3.15)

125

(4.92)

100

(3.94)

88

(3.46)

9.5

(0.37)

RUN

FAULT

192

(7.56)

20A-DG01

96

(3.78)

204

(8.03)

22D-CCB

180

(7.09)

113

(4.45)

100

(3.94)

142

(5.59)

80

(3.15)

155

(6.10)

5.3

(0.21)

Frame B

110.5

(4.35)

98.5

(3.88)

9.5

(0.37)

RUN

REV

FAULT

272

(10.71)

20A-DG01

136

(5.35)

284

(11.18)

260

(10.24)

22D-CCC

130

(5.12)

5.3

(0.21)

Frame C

123.5

(4.86)

B-12

Accessories and Dimensions

Figure B.6 Dynamic Brake Modules

– Dimensions are in millimeters and (inches).

Weights are in kilograms and (pounds).

17.0

(0.67)

Frame A

3 0.0

(1.1

8 )

60.0

(2.

3 6)

3 1.0

(1.22)

61.0

(2.40)

Frame B

59.0

(2.

3 2)

3 16.0

(12.44)

33 5.0

(1 3 .19)

38 6.0

(15.20)

405.0

(15.94)

SURFACES MAY BE

1 3 .0

(0.51)

Frame

A

B

Catalog Number

AK-R2-091P500, AK-R2-047P500, AK-R2-360P500

AK-R2-030P1K2, AK-R2-120P1K2

Weight

1.1 (2.5)

2.7 (6)

Figure B.7 Recommended External Brake Resistor Circuitry

Three-Phase

AC Input

RUN

REV

FAULT

(Input Contactor) M

R (L1)

S (L2)

T (L3)

Power Off Power On

Power Source

M

M

DB Resistor Thermostat

Accessories and Dimensions

B-13

Figure B.8 Bulletin 1321-3R Series Line Reactors

– Dimensions are in millimeters and

(inches). Weights are in kilograms and (pounds).

A

B

E

D

C

Catalog Number

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

112 (4.40)

112 (4.40)

112 (4.40)

112 (4.40)

112 (4.40)

112 (4.40)

152 (6.00)

152 (6.00)

152 (6.00)

152 (6.00)

152 (6.00)

152 (6.00)

152 (6.00)

183 (7.20)

193 (7.60)

B

104 (4.10)

104 (4.10)

104 (4.10)

104 (4.10)

104 (4.10)

104 (4.10)

127 (5.00)

127 (5.00)

127 (5.00)

127 (5.00)

127 (5.00)

133 (5.25)

133 (5.25)

146 (5.76)

146 (5.76)

C

70 (2.75)

70 (2.75)

76 (3.00)

76 (3.00)

86 (3.38)

92 (3.62)

76 (3.00)

76 (3.00)

85 (3.35)

76 (3.00)

76 (3.00)

79 (3.10)

86 (3.40)

85 (3.35)

91 (3.60)

D

50 (1.98)

50 (1.98)

50 (1.98)

50 (1.98)

60 (2.35)

66 (2.60)

53 (2.10)

53 (2.10)

63 (2.48)

53 (2.10)

53 (2.10)

54 (2.13)

63 (2.48)

60 (2.35)

66 (2.60)

E

37 (1.44)

37 (1.44)

37 (1.44)

37 (1.44)

37 (1.44)

37 (1.44)

51 (2.00)

51 (2.00)

51 (2.00)

51 (2.00)

51 (2.00)

51 (2.00)

51 (2.00)

76 (3.00)

76 (3.00)

3.1 (7)

3.6 (8)

4.9 (11)

4.1 (9)

4.5 (10)

4.1 (9)

5.4 (12)

4.9 (11)

6.3 (14)

Weight

1.8 (4)

1.8 (4)

1.8 (4)

1.8 (4)

2.3 (5)

2.7 (6)

B-14

Accessories and Dimensions

Figure B.9 Frame B EMC Line Filters

– Dimensions are in millimeters and (inches)

Catalog Numbers: 22-RF0P8-BL; 22-RF012-BS, -BL (Series B); 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)

Accessories and Dimensions

B-15

Figure B.10 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-16

Accessories and Dimensions

Figure B.11 Remote (Panel Mount) 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)

Accessories and Dimensions

B-17

Figure B.12 NEMA Type 1 Bezel

– Dimensions are in millimeters and (inches)

Catalog Number: 22-HIM-B1

11.1

(0.44)

93

(3.66)

25.2

(0.99)

180

(7.09)

2m

67

(2.64)

60

(2.36)

19.1

(0.75)

4.8

(0.19)

77

(3.03)

154

(6.06)

23.5

(0.93)

B-18

Accessories and Dimensions

Notes:

Appendix

C

RS485 (DSI) Protocol

PowerFlex 40P 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 40P 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.

Master

TxRxD-

TxRxD+

Figure C.1 Network Wiring Diagram

PowerFlex 40P

Node 1

TxRxD-

5

PowerFlex 40P

Node 2

5

120 ohm resistor

4

TxRxD+

4

TxRxD-

PowerFlex 40P

Node "n"

5

120 ohm resistor

TxRxD+

PIN 8

4

Shield Shield Shield

X X X

PIN 1

FRONT

NOTE: The shield is connected at ONLY ONE end of each cable segment.

01 02 03 04 05 06 07 08 09 01 02 03 04 05 06 07 08 09

R/L1

11 12 13 14 15 16 17 18 19

RS485

(DPI)

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

11 12 13 14 15 16 17 18 19

RS485

(DPI)

AK-00-RJ45-TB2P

TxRxD-

R/L1

TxRxD+

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

TxRxD-

TxRxD+

DC- DC+ BR+ BRDC- 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 40P 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 (DSI Shield) on the PowerFlex 40P must also be connected to PE ground (there are two PE terminals on the drive). See

Table 1.I

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.

RS485 (DSI) Protocol

C-3

Parameter Configuration

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

Parameter

P036 [Start Source]

P038 [Speed Reference]

Details

Set to 5 “Comm Port” if Start is controlled from the network.

Set to 5 “Comm Port” if the Speed Reference is controlled from the network.

A103 [Comm Data Rate]

A104 [Comm Node Addr]

Sets the data rate for the RS485 (DSI) Port. All nodes on the network must be set to the same data rate.

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].

Reference

Page 3-10

Page 3-12

Page 3-34

Page 3-34

Page 3-34

Page 3-34

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.

E207 [Comm Write Mode] Set to 0 “EEPROM” when programming drive.

Set to 1 “RAM only” to only write to volatile memory.

Page 3-35

Page 3-52

Supported Modbus Function Codes

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

Modbus Function Code (Decimal)

03

06

16 (10 Hexadecimal)

Command

Read Holding Registers

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

RS485 (DSI) Protocol

Writing (06) Logic Command Data

The PowerFlex 40P 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 “Comm Port” in order to accept the

commands. Parameter

E249

[Cmd Stat Select] is used to select Velocity or Position Bit definitions.

Velocity Bit Definitions

Address (Decimal)

8192

Position Bit Definitions

Address (Decimal)

RS485 (DSI) Protocol

C-5

8192

11

12

13

14

15

Writing (06) Reference

The Speed Reference to a PowerFlex 40P 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 “Comm Port” in order to accept the Speed Reference.

Address (Decimal)

8193

Reference

Description

A decimal value entered as xxx.xx where the decimal point is fixed. For example, a decimal “100” equals 1.00 Hz and “543” equals 5.43 Hz.

C-6

RS485 (DSI) Protocol

Reading (03) Logic Status Data

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

Parameter

E249

[Cmd Stat Select] is used to select Velocity or Position

Bit definitions.

Velocity Bit Definitions

Address (Decimal)

8448

11

12

13

14

15

7

8

9

10

3

4

5

6

1

2

Bit(s)

0

Logic Status - E249 = 0 “Velocity”

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

Not Used

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

Digital Input 2 Status

Digital Input 3 Status

Digital Input 4 Status

Position Bit Definitions

Address (Decimal)

8448

11

12

13

14

15

7

8

9

10

3

4

5

6

1

2

Bit(s)

0

Logic Status - E249 = 1 “Position”

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 = Forward Travel Position, 0 = Reverse Travel Position

1 = Faulted, 0 = Not Faulted

1 = At Speed, 0 = Not At Speed

1 = At Position, 0 = Not At Position

1 = At Home, 0 = Not At Home

1 = Drive Homed, 0 = Not Drive Homed

1 = Sync Hold, 0 = Not Syc Hold

1 = Sync Ramp, 0 = Not Syc Ramp

1 =Traverse On, 0 = Traverse Off

1 = Traverse Decel, 0 = Not Trav Decel

RS485 (DSI) Protocol

C-7

Reading (03) Feedback

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

Address (Decimal)

(1)

8451

Feedback

(1)

Description

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.

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

Reading (03) Drive Error Codes

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

Codes).

Address (Decimal)

8449

81

94

100

111

122

64

70

71

80

42

43

48

63

38

39

40

41

12

13

29

33

5

6

7

8

2

3

4

Value (Decimal)

0

Logic Status

Description

No Fault

Auxiliary Input

Power Loss

Undervoltage

Overvoltage

Motor Stalled

Motor Overload

Heatsink Overtemperature

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

Phase UW Short

Phase VW Short

Parameters Defaulted

Software Overcurrent

Drive Overload

Power Unit Fail

Network Loss Fault

AutoTune Fail

Communication Loss

Encoder Loss Fault

Parameter Checksum Error

Hardware Enable Fault

I/O Board Fail

C-8

RS485 (DSI) Protocol

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].

Additional Information

Refer to

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

for additional information.

Appendix

D

RJ45 DSI Splitter Cable

The PowerFlex 40P 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

RJ45 DSI Splitter Cable

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

RJ45 DSI Splitter Cable

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-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

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

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

Velocity 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

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

Velocity 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

Velocity 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.

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

E-3

Velocity 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

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

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.

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

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

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

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 Countr”.

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 Countr”

A055

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

A056

[Relay Out Level] set to 5.0 (Counts)

Velocity StepLogic™, Basic Logic and Timer/Counter Functions

E-7

Velocity 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

Velocity 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 In2” is active (logically true)

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

Step if “Logic In2” 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

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

(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

Step after [Stp Logic Time x] and “Logic In2” 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 “Logic In1” is active (logically true)

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

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

Step if “Logic In2” is not active (logically false)

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)

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

(logically false)

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

(logically false)

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

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

AND

NOR

XOR

XOR

TIMED AND

TIMED AND

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

Step after [Stp Logic Time x] and “Logic In2” is not active (logically false) TIMED OR

Use logic programmed in Digit 1 IGNORE

Appendix

F

Encoder Usage and Position

StepLogic Application

Encoder Usage

The PowerFlex 40P includes a pulse-train/encoder input. When

E216

[Motor Fdbk Type] is set to a value other than zero, the drive is set to use an encoder. The drive will use the encoder in several ways depending on the settings of other parameters. The drive will use the encoder as shown below (listed in order of priority):

1.

If enabled by P038

[Speed Reference], the encoder will be used directly as a commanded speed (normally used with a pulse train) or as a position reference (normally used with a quadrature encoder).

2.

If not enabled by P038 [Speed Reference], when the PID Feedback

or PID Reference are set to use an encoder than the PID function will use the encoder or pulse train input.

3.

If not enabled by P038 [Speed Reference] or the PID parameters,

then if E216 [Motor Fdbk Type] is set the encoder is used for direct

feedback and trim of the speed command. The normal slip compensation is not used in this case. Instead the drive will use the encoder to determine actual output frequency and adjust the output

frequency to match the command. Parameters E220 [Ki Speed Loop]

and

E221

[Kp Speed Loop] are used in this control loop. The primary benefit of this mode is increased speed accuracy when compared to open-loop slip compensation. It does not provide speed bandwidth improvement.

F-2

Encoder Usage and Position StepLogic Application

Wiring Notes

The encoder can supply 5V or 12V power (250 mA maximum) for an encoder. Be sure the DIP switch is set properly for the encoder. In general, 12V will provide higher noise immunity.

The pulse-train/encoder inputs can handle 5V, 12V, or 24V inputs. The inputs will automatically adjust to the voltage applied and no additional drive adjustment is necessary. If a pulse-train or single-channel input is used, it must be wired between the A (signal) and A- (signal common) channels.

Important:

A quadrature encoder provides rotor speed and direction.

Therefore, the encoder must be wired such that the forward direction matches the motor forward direction. If the drive is reading encoder speed but the position regulator or other encoder function is not working properly, remove power to the drive and swap the A and B encoder channels or swap any two motor leads. Drives using FRN 2.xx and greater will fault when an encoder is incorrectly wired and E216

[Motor Fdbk Type] is set to option 5 “Quad Check”.

Positioning Overview

The PowerFlex 40P includes a simple position regulator which can be used in a variety of position applications without the need for multiple limit switches or photo-eyes. This can be used as a stand-alone controller for simple applications (up to 8 positions) or in conjunction with a controller for more flexibility.

Please note that this is not intended to replace high end servo controllers or any application that needs high bandwidth or very high torque at low speeds.

Encoder Usage and Position StepLogic Application

F-3

Common Guidelines for All Applications

The position regulator can be configured for operation appropriate for a variety of applications. Certain parameters will need to be adjusted in all cases.

P038 [Speed Reference] must be set to option 9 “Positioning”.

E216

[Motor Fdbk Type] must be set to the match the feedback device.

Positioning mode must use E216 [Motor Fdbk Type] option 4.

E216 [Motor Fdbk Type] Options

0 “None”

indicates no encoder is used. This can not be used for positioning.

1 “Pulse Train”

is a single channel input, no direction, speed feedback only. This should not be used for positioning. The Single Channel selection is similar to a Pulse Train, but uses the standard encoder scaling parameters.

2 “Single Chan”

is a single channel input, no direction, speed feedback only. This should not be used for positioning. Single channel uses the standard encoder scaling parameters.

3 “Single Check”

is a single channel input with encoder signal loss detection. The drive will fault if it detects that the input pulses do not match the expected motor speed. This should not be used for positioning.

4 “Quadrature”

is a dual channel encoder input with direction and speed from the encoder. This may be used for positioning control.

5 “Quad Check”

is a dual channel encoder with encoder signal loss detection. The drive will fault if it detects that the encoder speed does not match the expected motor speed. FRN 2.xx or greater supports Option 5

“Quad Check” in Positioning mode.

Important:

Drives using FRN 1.xx must use option 4 “Quadrature” for

Positioning mode. FRN 1.xx does not support option 5

“Quad Check”.

A095 [Reverse Disable] should be set to option 0 “Rev Enabled” to

allow bidirectional movement necessary for position control.

A125 [Torque Perf Mode] default setting of 1 “Sensrls Vect” is

recommended for most applications to improve the low speed torque for positioning applications. The autotune routine can be completed to further improve the drive-motor performance.

F-4

Encoder Usage and Position StepLogic Application

A117 [Bus Reg Mode] default setting is option 1 “Enabled”. If the

deceleration time is too short, the drive may overshoot the desired position. For best results, a longer deceleration time may be necessary.

A117 [Bus Reg Mode] can be disabled to provide precise stopping

movements, but the deceleration time will need to be manually tuned so that it is long enough to avoid F5 OverVoltage faults.

A082 [DB Resistor Sel] default setting is 0 “Disabled”. If improved

deceleration performance is required a Dynamic Brake resistor can be used. If used, this parameter should be set to the appropriate setting for the resistor selected.

E217

[Motor NP Poles] must be set to match the number of motor poles on the motor driven by the PowerFlex 40P drive.

E218

[Encoder PPR] must be set to match the number of pulses per revolution of the encoder used (i.e., 1024 PPR Encoder).

E226

[Counts Per Unit] sets the number of encoder counts that will be used to define one position unit. This allows the encoder positions to be defined in terms of units important to the application. For example, if

1cm of travel on a conveyor belt requires 0.75 turns of the motor, the motor encoder is 1024 PPR, and the Motor Feedback type is set to

Quadrature, then this parameter would need to be set to (4 x 1024 x 0.75)

= 3072 counts for 1cm of travel. Then all other positions could be setup in units of “cm”.

E225

[Encoder Pos Tol] indicates the desired position tolerance for the system. This will determine how close the drive must be to the commanded position before the drive will indicate “At Home” or “At

Position” in units of raw encoder pulses. This has no effect on the actual positioning control of the motor.

Encoder Usage and Position StepLogic Application

F-5

Positioning Operation

Parameter

E222

[Positioning Mode] must be set to properly match the desired operation of the positioning function.

E222 [Positioning Mode] Options

0 “Time Steps”

uses Step Logic times. This mode ignores the Step

Logic settings and moves through the steps (Step 0 to Step 7 and back to

Step 0) based on the times programmed into

A150 A157

[Stp Logic

Time x]. This can be used when the desired position is based only on time. In addition, this mode only accepts absolute positions in a positive direction from “home”. This option provides an easy way to implement a simple positioning program or to test the basic positioning setup. For additional flexibility one of the other settings should be used.

1 “Preset Input”

directly commands movement to any step based on the status of the digital inputs programmed for “Preset Freq”. This setting ignores the Step Logic Commands settings and instead the drive will

move directly to whatever step is currently commanded by A070 A077

[Preset Freq x] and E230 E244 [Step Units x]. This is useful when an

application needs direct access to any position step based on discrete inputs.

Important:

Advanced Step Logic options such as incremental move are not available in this mode.

2 “Step Logic”

provides a highly flexible mode of operation. This can be used to move through the steps (Step 0 to Step 7 and back to Step 0) or can jump to a different step at any time based on time or the status of digital inputs or communication commands. In this mode the drive always starts at Step 0 of the Step Logic profile.

3 “Preset-StpL”

is identical to option 2 “Step Logic” except the drive will use the current status of the Preset Inputs to determine which Step

Logic step to begin. This only affects the initial step. After start, the drive will move through the steps in the same manner as if setting 2 was selected.

4 “StpLogic-Lst”

is identical to option 2 “Step Logic” except the drive will use the step prior to its last stop command to determine which Step

Logic step to begin. This only affects the initial step. After start, the drive will move through the steps in the same manner as if option 2 was selected. This allows a process to be stopped and then restarted at the position where it stopped.

F-6

Encoder Usage and Position StepLogic Application

In all position modes, the following parameters will control the characteristics at each step:

E230-E244 [Step Units x]

These are the number value to the left of the decimal (whole number) of the 8 positions desired for an application, beginning with Step 0 (

E230 ) and continuing with each step until Step 7 ( E244 ). For example, enter 2

into this parameter if you would like a commanded position of 2.77.

E231-E245 [Step Units F x]

These are the number value to the right of the decimal (the portion less than 1) of the 8 positions desired for an application, beginning with Step

0 (

E231 ) and continuing with each step until Step 7 ( E245 ). For

example, enter 0.77 into this parameter if you would like a commanded position of 2.77.

A070-A077 [Preset Freq x]

In Positioning mode, each preset frequency parameter defines the maximum frequency the drive will run at during the corresponding step.

For example, if [Preset Freq 2] is set to 40Hz, the drive will accelerate to

40Hz maximum when moving to Position 2.

Frequency Source

A070 [Preset Freq 0]

A071 [Preset Freq 1]

A072 [Preset Freq 2]

A073 [Preset Freq 3]

A074 [Preset Freq 4]

A075 [Preset Freq 5]

A076 [Preset Freq 6]

A077 [Preset Freq 7]

Step Source

A140 [Step Logic 0]

A141 [Step Logic 1]

A142 [Step Logic 2]

A143 [Step Logic 3]

A144 [Step Logic 4]

A145 [Step Logic 5]

A146 [Step Logic 6]

A147 [Step Logic 7]

Position Source

E230 [Step Units 0]

E232 [Step Units 1]

E234 [Step Units 2]

E236 [Step Units 3]

E238 [Step Units 4]

E240 [Step Units 5]

E242 [Step Units 6]

E244 [Step Units 7]

Important:

The default value for A070

[Preset Freq 0] is 0.00 Hz. This value needs to be changed or the drive will not be able to move during Step 0.

A150-A157 [Stp Logic Time x]

In Positioning mode, each Step Logic Time parameter defines the time the drive will remain in each corresponding step if that step is time-based. For example, if

A152 [Stp Logic Time 2] is set to 5.0

seconds and that step is time-based, the drive will remain in Step 2 for

5.0 seconds. Note that this is the total time in that step, not the time at that position. Therefore, it will include the time needed to accelerate, run, and decelerate to that position.

Encoder Usage and Position StepLogic Application

F-7

A140 A147

[Stp Logic x] – When a positioning mode is selected that utilizes the Step Logic functions these parameters allow additional flexibility and control various aspects of each step. Note that in

Positioning mode these parameters have a different function than when used for normal velocity Step Logic. Each of the 4 digits controls one aspect of the each position step. The following is a listing of the available settings for each digit:

Logic For Next Step

Logic to Jump to a Different Step

Different Step to Jump

Step Settings

Digit 0

Digit 1

Digit 2

Digit 3 d

E b

C

F

9

A

7

8

5

6

3

4

0

1

2

Settings For Positioning (Digit 3)

Required

Setting

Accel/Decel

Param. Used

Accel/Decel 1

Accel/Decel 1

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

Accel/Decel 2

Accel/Decel 2

StepLogic

Output State

Off

On

On

On

On

On

Off

Off

Off

Off

Off

Off

Off

On

On

On

Settings (Digit 2)

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)

Direction

From Home

REV

FWD

FWD

REV

REV

FWD

FWD

REV

REV

FWD

FWD

REV

REV

FWD

FWD

REV

Type Of

Command

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Absolute

Incremental

Settings (Digit 1 and Digit 0)

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

Note: Incremental move commands will cause the drive to move the amount specified based on the current position. Absolute commands are always with reference to “Home”.

E246

[Pos Reg Filter] provides a low pass filter at the input of the position regulator.

F-8

Encoder Usage and Position StepLogic Application

E247

[Pos Reg Gain] is a single adjustment for increasing or decreasing the responsiveness of the position regulator. For faster response, the filter should be reduced and/or the gain should be increased. For smoother response with less overshoot, the filter should be increased and/or the gain should be reduced. In general, the gain will have a larger effect on most systems than the filter.

Homing Routine

This drive supports incremental encoders only. Therefore, when the drive powers up it will reset the current position to zero. If this is known to be correct the position routine can be started without further adjustment.

However, in most applications the drive will need to be “homed” after each power-up and prior to starting the position routine.

This can be accomplished in one of the following two ways:

1.

Manual Homing–Program the following drive parameters:

A051-A054 [Digital Inx Sel] = 36 “Pos Redefine”

Program one of the digital inputs to option 36 “Pos Redefine”. Then, move the system into the home position via a run command, a jog command, or by manually moving the system into the home position.

Then, toggle the “Pos Redefine” input. This will set the drive to

“Home” at its current position and

d308 [Units Traveled H] and d309

[Units Traveled L] are set to zero. Alternately, the “Pos Redefine” bit in

E248 [Enh Control Word] can be toggled instead of utilizing a

digital input.

Important:

The “Pos Redefine” input or bit must be returned to inactive before starting the position routine. Otherwise the drive will continuously read a position of “0”

(home) and the position routine will not function correctly.

2.

Automatic Homing to Limit Switch–Program the following drive parameters:

A051-A054 [Digital Inx Sel] = 34 “Find Home”

Program one of the digital inputs to option 34 “Find Home”

A051-A054 [Digital Inx Sel] = 33 “Home Limit”

Program one of the digital inputs to option 33 “Home Limit”.

Normally, the “Home Limit” input would be wired to a proximity switch or photo-eye and will indicate the system is in the home position.

Encoder Usage and Position StepLogic Application

F-9

E223 [Find Home Freq]

This parameter sets the frequency the drive will use while it is moving to the home position during the automatic homing routine.

E224 [Find Home Dir]

This parameter sets the direction the drive will use while it is moving to the home position during the automatic homing routine.

To begin the automatic homing routine, activate the “Find Home” input and then initiate a valid start command. The drive will then ramp to the

speed set in E223 [Find Home Freq] and in the direction set in

E224

[Find Home Dir] until the digital input defined as “Home Limit” is activated. If the drive passes this point too quickly it will then reverse direction at 1/10th

E223

[Find Home Freq] to the point where the Home

Limit switch reactivates. Approximately one second after the routine finds home the drive will stop. Alternately, the “Find Home Freq” and/or

“Home Limit” bits in

E248

[Enh Control Word] can be activated instead of utilizing a digital input. The inputs or bits should be returned to inactive after the routine is complete.

Important:

After the position is reached the drive will stop. If the Find

Home is removed before the homing is complete, the drive will begin running the position routine without the proper home. In this case Home will not be reset and the position will be in relation to the power up position.

Encoder and Position Feedback

Parameter

d304

[Speed Feedback] and d305

[Speed Feedback F] indicate the measured speed feedback or the calculated speed feedback when no feedback device is selected. Parameter d304 [Speed Feedback] is the number value to the left of the decimal (whole number) and d305

[Speed Feedback F] is the value to the right of the decimal (the portion less than 1).

d306 [Encoder Speed]

Parameter

d306 [Encoder Speed] and d307

[Encoder Speed F] indicate the measured speed of the feedback device. This is useful if the encoder is not used for motor speed control. However, the encoder must be used for some purpose in order for [Encoder Speed] to indicate a value.

Parameter d306 is the number value to the left of the decimal (whole number) and d307 is the number to the right of the decimal (the portion less than 1).

F-10

Encoder Usage and Position StepLogic Application

d308 [Units Traveled]

Parameter d308

[Units Traveled H] and

d309

[Units Traveled L] indicate the current position of the system in terms of units away from Home.

Parameter d308 is the number value to the left of the decimal (whole number) and d309 is the number to the right of the decimal (the portion less than 1).

d301 [Drive Status 2]

Parameter

d301 [Drive Status 2] indicates the status of the positioning

functions. The indication bits are:

Bit 0 “Dir Positive”

indicates the current direction the drive has moved from Home.

Bit 1 “At Position”

indicates whether the drive is at its commanded

position. If the drive is within E225 [Encoder Pos Tol] of the

commanded position, this bit will be active.

Bit 2 “At Home”

indicates whether the drive is at Home. If the drive is within

E225

[Encoder Pos Tol] of “Home”, this bit will be active.

Bit 3 “Drive Homed”

indicates whether the drive has been homed since power-up. This bit will be active once the drive has been homed either manually or automatically. It will remain active until the next power down.

Use Over Communications

If 8 steps are not adequate for the application or if dynamic program changes are required, many of the positioning functions can be controlled via an active communication network. The following parameters will allow this control.

E207 [Comm Write Mode]

Repeated writes to parameters over a communication network can cause damage to the drive EEPROM. This parameter allows the drive to accept parameter changes without writing to the EEPROM.

Important:

Parameter values set prior to setting option 1 “RAM only” will be saved in drive non-volatile memory (EEPROM).

E249 [Cmd Stat Select]

Selects velocity-specific or position/fibers-specific Command and Status

Word bit definitions for use over a communication network.

Encoder Usage and Position StepLogic Application

F-11

E248 [Enh Control Word]

This parameter allows many of the positioning functions to be completed via parameter control using an explicit message. This allows the operation over communications instead of with hardware inputs. The bits have the same functions as the digital input options of the same name.

Options relating to positioning are:

Bit 0 “Home Limit”

Bit 1 “Find Home”

Bit 2 “Hold Step”

Bit 3 “Pos Redefine”

E230-E244 [Step Units x]

All of the position steps can be written to while the drive is running. The changes will take place at the next move. For example, if step 0 is over-written while the drive is moving to step 0, the drive will move to the previous commanded position at step 0. The next time the drive is commanded to return to step 0 it will proceed to the new position. One possible use of this capability is when an application requires full control of the movement by a controller external to the drive. The Step Logic program might be written to jump from step 0 back to step 0 when Input

1 is active. The controller could write any desired position to step 0 and then toggle the input 1 bit of E248 [Enh Control Word] to cause the drive to move to the new position. This allows almost unlimited flexibility and can be used with absolute or incremental moves.

Setup Notes

The RA computer tools (DriveExplorer and DriveTools SP) can make setup of the positioning functions much easier. Please refer to the latest versions for additional tools or wizards which can aid in the setup.

F-12

Notes:

Encoder Usage and Position StepLogic Application

Appendix

G

PID Set Up

PID Loop

The PowerFlex 40P 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.

G-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, 4 or 5. 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

G-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 6,

7, 8, 9 or 10.

PID Ref

PID Fdbk

+

PID

Error

PID Loop

PID Prop Gain

PID Integ Time

+

+

+

PID Diff Rate

PID

Output

PID Enabled

P038 [Speed Reference]

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

P038 [Speed Reference]

G-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 G.A A132 [PID Ref Sel] Options

Option

0 “PID Disabled”

1 “PID Setpoint“

2 “0-10V Input”

3 “4-20mA Input”

4 “Comm Port”

5 “Encoder”

6 “Setpnt, Trim”

7 “0-10V, Trim”

8 “4-20mA, Trim”

9 “Comm, Trim”

10 “Encoder,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 Exclusive Control. Encoder or Pulse train will be used as an input for the PID 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.

Selects Trim Control. Encoder or Pulse train will be used as a trim input for the PID Feedback

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

Table G.B A133 [PID Feedback Sel] Options

Option

0 “0-10V Input”

1 “4-20mA Input“

2 “Comm Port”

3 “Encoder”

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 40P 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.

Encoder or Pulse train will be used as an input for the PID Feedback.

PID Set Up

G-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 or PID Feedback.

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

A132

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

[PID Ref Sel] = 2 “0-10V Input”

12

10

8

6

4

2

0 10 20 30 40 50 60 70

PID Reference (%)

80 90 100

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

A113

A132

[Anlg In4-20mA Lo] = 100.0%

[Anlg In4-20mA Hi] = 0.0%

[PID Ref Sel] = 3 “4-20mA Input”

24

20

16

12

8

4

0 10 20 30 40 50 60 70

PID Reference (%)

80 90 100

G-6

PID Set Up

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 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.

PID Set Up

G-7

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 0.0 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.

G-8

PID Set Up

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 G.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 G.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 G.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].

PID Set Up

G-9

The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains.

Figure G.1 Unstable

PID Reference

PID Feedback

Figure G.2 Slow Response – Over Damped

Time

PID Reference

PID Feedback

Time

Figure G.3 Oscillation – Under Damped

PID Reference

PID Feedback

Figure G.4 Good Response – Critically Damped

Time

PID Reference

PID Feedback

Time

G-10

PID Set Up

Notes:

Appendix

H

Plate Drive Installation Instructions

Introduction

The PowerFlex 40P is available in a plate drive version without heatsink.

This is designed to allow mounting to a customer supplied heatsink. This may be a large heatsink to be shared by multiple drives, a large thermal mass that is part of a system, or some other heat-sinking system. Care must be taken to insure the heatsink used provides adequate cooling for the drive power components as well as a flat and clean surface for a proper thermal interface.

General Requirements

The drive is designed to operate with the drive enclosed and the heatsink exposed for improved cooling. Therefore, it is expected that the drive control section will experience a higher ambient temperature than the heatsink.

Table H.A Maximum Surrounding Air Temperature

Heatsink

Drive

40° C (104° F)

50° C (122° F)

Note that the standard 480V 11 kW (15 HP) drive includes an internal inductor. This inductor cannot be included in the plate drive. Therefore, this rating requires the use of an external DC inductor or an AC input

reactor as described in Table B.E on page B-3

.

H-2

Plate Drive Installation Instructions

Heatsink Thermal Capacity

The heatsink provided must have the thermal capacity to cool the drive under worst-case loading conditions as well as for short duration

overload conditions in the application. Refer to Table A.C on page A-5

for estimated watts loss data.

Table H.B Required Heatsink Degrees C/W Capabilities

Plate Drive Input Voltage kW (HP)

230V AC 0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

460V AC

7.5 (10)

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)

11 (15)

0.47

0.26

0.25

0.20

0.13

0.13

2.06

1.17

0.73

Heatsink °C/W Needed

1.59

0.88

0.56

0.35

0.23

0.18

Figure H.1 Approximate Heatsink Dimensions for One Drive without Heatsink Fan

Dimensions are in millimeters and (inches)

C

B

Drive Frame Size A

B 214 (8.43)

C 300 (11.81)

A

B

250 (9.84)

325 (12.8)

C

63.1 (2.48)

138.2 (5.44)

Plate Drive Installation Instructions

H-3

Heatsink Surface and Flatness Requirements

The drive comes with a thermal pad designed to provide a good interface between the drive and heatsink. However, in order for this to function properly the mounting surface for the plate drive must be clean and free of dirt, oil, and debris. It must be very flat and smooth and should have no scratches, nicks, or gouges. All mounting holes must be clean and deburred.

Table H.C Surface Requirements

Attribute

Surface Finish

Surface Flatness

Requirement

1.6 µM (Ra Method)

-/+ 1.5 mil

Description

Smoothness – Overall surface texture free from imperfections (scratches, nicks, or gouges)

Trueness – Free from warps, twists, and concavity

(depressions)

Figure H.2 Smoothness Tolerance and Surface Pad Thickness

+0.5 mil

–0.5 mil

5.0 mil

Figure H.3 Trueness Tolerance

+1.5 mil

–1.5 mil

H-4

Plate Drive Installation Instructions

Mounting Dimensions and Requirements

Refer to Figure B.5 on page B-11 for plate drive dimensions and

mounting hole locations.

Use the pattern illustrated in Step 3 below to gradually tighten all mounting bolts to the recommend torque of 2.0 N-m (18 lb.-in.).

1

2

Isopropyl

Alcohol

3

4

2.0 N-m

(18 lb.-in.)

1

4

5

3

2

6

Verification

Once the drive is mounted, a worst-case test should be run to verify the design. The drive should run at its maximum load conditions at the highest expected surrounding air temperature. After four hours in this condition, the temperature of the drive plate should be measured. It should not exceed 75° C (167° F) at its hottest point. Also, parameter

b024 [Drive Temp] should be monitored and should not exceed 80° C

(176° F).

Index

A

AC Supply

Ground,

1-6

Source,

1-4

Ungrounded,

1-4

Advanced Display Group Parameters,

3-62

Advanced Program Group

Parameters,

3-15

Ambient Temperatures,

1-2

Armored Cable,

1-9

Auto Rstrt Tries Fault,

4-4

Auxiliary Input Fault,

4-3

B

Basic Display Group Parameters,

3-3

Basic Program Group Parameters,

3-9

Before Applying Power,

2-1

,

2-2

Bus Capacitors, Discharging,

P-3

C

Cable, Power,

1-9

Capacitors, Discharging,

P-3

CE Conformity,

1-29

Checklist, Start-Up,

2-1

,

2-2

Circuit Breakers

Input,

1-7

Comm Loss Fault,

4-4

Command Sources for Start and

Speed,

1-27

Common Bus,

1-13

Common Symptoms and Corrective

Action,

4-6

Contactors, Input,

1-13

Control Wire,

1-14

Control, 2 and 3 Wire,

1-22

,

1-26

Conventions, Manual,

P-2

Cover, Opening,

1-1

Cross Reference, Parameter

by Name,

3-64

D

Dimensions

Drive,

B-7

Minimum Clearances,

1-2

DIP Switch Locations,

1-15

Discharging Bus Capacitors,

P-3

Display,

2-3

Distribution Systems, Ungrounded,

1-4

Drive Frame Size,

P-2

,

B-7

Drive Grounding,

1-6

Drive Overload Fault,

4-4

Drive Ratings,

A-1

DriveExecutive,

3-1

DriveExplorer,

3-1

E

Earthing, see

Grounding

EMC/RFI

Grounding, Filter,

1-7

Interference,

1-29

Enclosure Rating, Changing,

1-2

Encoder Interface,

1-18

Wire Routing,

1-18

Encoder Wiring,

1-19

Enhanced Program Group

Parameters,

3-49

ESD, Static Discharge,

P-3

F

Fault Reset and Display,

2-3

Faults

Auto Rstrt Tries,

4-4

Auxiliary Input,

4-3

Comm Loss,

4-4

Drive Overload,

4-4

Ground Fault,

4-3

Heatsink OvrTmp,

4-3

HW OverCurrent,

4-3

I/O Board Fail,

4-5

Motor Overload,

4-3

Motor Stalled,

4-3

OverVoltage,

4-3

Index-2

Parameter Checksum,

4-5

Phase Short,

4-4

Phase to Ground Short,

4-4

Power Loss,

4-3

Power Unit,

4-4

SW OverCurrent,

4-4

UnderVoltage,

4-3

Filter, RFI,

1-7

Frame Designations,

P-2

,

A-1

,

B-7

Fuses

Input,

1-7

Ratings,

A-1

G

General Precautions,

P-3

Ground Fault,

4-3

Grounding

Filter,

1-7

General,

1-6

H

Hardware Enable Circuitry

Enable Circuitry,

1-20

Heatsink OvrTmp Fault,

4-3

HW OverCurrent Fault,

4-3

I/O

I

Wiring,

1-13

Wiring Examples,

1-22

,

1-26

I/O Board Fail Fault,

4-5

Input Contactor,

1-13

Input Fusing,

1-7

Input Potentiometer,

1-22

Input Power Conditioning,

1-5

Installation,

1-1

Integral Display,

2-3

Interference, EMC/RFI,

1-29

Internal Precharge,

1-13

L

LEDs,

2-3

M

Minimum Clearances,

1-2

Motor Cable Length,

1-11

Motor Overload,

4-3

Motor Overload Fault,

4-3

Motor Stalled Fault,

4-3

motor starter,

1-7

Mounting Options and Clearances,

1-2

MOVs,

1-4

O

Opening the Cover,

1-1

Operating Temperatures,

1-2

Operator Interface,

2-3

OverVoltage Fault,

4-3

P

Parameter

Descriptions,

3-1

Types,

3-1

Parameter Checksum Fault,

4-5

Parameter Cross Reference by Name,

3-64

Parameters

Advanced Display Group,

3-62

Advanced Program Group,

3-15

Basic Display Group,

3-3

Basic Program Group,

3-9

Enhanced Program Group,

3-49

PE Ground,

1-6

Phase Short Fault,

4-4

Phase to Ground Fault,

4-4

Potentiometer, Wiring,

1-22

Power Cables/Wiring,

1-9

Power Conditioning, Input,

1-5

Power Loss Fault,

4-3

Power Unit Fault,

4-4

Powering Up the Drive,

2-1

,

2-2

Precautions, General,

P-3

Product Selection,

B-1

Programming,

3-1

PTC Analog Input Wiring,

1-22

R

Ratings,

A-1

Reflective Wave Protection,

1-11

Removing Cover,

1-1

Repeated Start/Stop,

1-13

Repeated Start/Stop Precautions,

1-13

RFI, see

EMC/RFI

RWR (Reflective Wave Reducer),

1-11

S

Safe Off Operation,

1-21

Safety Ground,

1-6

Shielded Power Cables,

1-9

Short Circuit Protection,

1-7

Software,

3-1

Start and Speed Reference Selection

and Control,

1-27

,

1-28

Start/Stop, Repeated,

1-13

Start-Up Checklist,

2-1

,

2-2

Static Discharge, ESD,

P-3

Status LEDs,

2-3

Supply Source, AC,

1-4

SW OverCurrent Fault,

4-4

System Grounding,

1-6

T

Terminal Block

I/O,

1-14

Power,

1-12

Three Wire Control,

1-22

,

1-26

Two Wire Control,

1-22

,

1-26

U

UnderVoltage Fault,

4-3

Ungrounded Supply,

1-4

Unshielded Power Cables,

1-9

W

Watts Loss,

A-5

Wire

Control,

1-14

Wiring,

1-1

Block Diagram,

1-15

,

1-17

Encoder,

1-19

I/O,

1-13

I/O Examples,

1-22

,

1-26

Potentiometer,

1-22

Power,

1-9

PTC Example,

1-22

Index-3

Index-4

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, Bel g ium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640

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Publication 22D-UM001B-EN-E – May 2007

Supersedes March 2006 Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

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