Adjustable Frequency AC Drive

FRN 6.xx

User Manual

www.abpowerflex.com

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local 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
The information below summarizes changes made for the September 2010 PowerFlex 4 User Manual, Publication 22A-UM001I-EN-E.
Description of New or Updated Information See Page(s) Parameters A117 [Bus Reg Mode] and A118 [Comm Write Mode] added. 3-13

The information below summarizes changes made for the July 2010 PowerFlex 4 User Manual, Publication 22A-UM001H-EN-E.
Description of New or Updated Information Start and Speed Reference Control See Page(s) 1-18

The information below summarizes changes made for the March 2007 PowerFlex 4 User Manual, Publication 22A-UM001G-EN-E.
Description of New or Updated Information Minimum Mounting Clearances clarified. Footnote (2) on Bulletin 140M catalog edited. Graphic for Analog Input, PTC wiring example corrected. Stop Drive icon and related warning text removed for parameter A110 [Anlg In 0-10V Lo]. New information on reading register address 8192 added. New information on reading register address 8193 added. See Page(s) 1-2 1-7 1-14 3-25 C-3 C-4

The information below summarizes changes made for the September 2005 PowerFlex 4 User Manual, Publication 22A-UM001F-EN-E.
Description of New or Updated Information Attention statement clarified. 240V AC 3-Phase 3.7 kW (5.0 Hp) drive fuse rating revised to 30 amps. Analog Input, PTC wiring example added. Attention statement added to Multiple Digital Input Connections wiring example. Parameter P043 [Motor OL Ret] added. Attention statement added to parameter A082 [DB Resistor Sel]. External Comm Options, Compact I/O added to Table B.G. Modbus function code 16 added. See Page(s) 1-3 1-7, A-2 1-14 1-17 3-12 3-18 B-4 C-2

soc-2

Table of Contents
Preface
Overview
Who Should Use this Manual? . . . . . . . . . Reference Materials . . . . . . . . . . . . . . . . . Manual Conventions . . . . . . . . . . . . . . . . . Drive Frame Sizes . . . . . . . . . . . . . . . . . . . General Precautions . . . . . . . . . . . . . . . . . Catalog Number Explanation . . . . . . . . . . P-1 P-1 P-2 P-2 P-3 P-4

Chapter 1

Installation/Wiring
Opening the Cover . . . . . . . . . . . . . . . . . . 1-1 Mounting Considerations . . . . . . . . . . . . . 1-2 AC Supply Source Considerations . . . . . . 1-3 General Grounding Requirements . . . . . . 1-4 Fuses and Circuit Breakers . . . . . . . . . . . . 1-6 Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-8 I/O Wiring Recommendations . . . . . . . . 1-11 Start and Speed Reference Control . . . . . 1-18 EMC Instructions . . . . . . . . . . . . . . . . . . 1-20

Chapter 2

Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1 Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3 Viewing and Editing Parameters . . . . . . . . 2-4

Chapter 3

Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . 3-1 Parameter Organization. . . . . . . . . . . . . . . 3-2 Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3 Basic Program Group . . . . . . . . . . . . . . . . 3-8 Advanced Program Group. . . . . . . . . . . . 3-13 Parameter Cross Reference by Name. . 3-27

Chapter 4

Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Descriptions . . . . . . . . . . . . . . . . . . . Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . 4-1 4-1 4-3 4-5

Appendix A Appendix B

Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings . . . A-1 Specifications . . . . . . . . . . . . . . . . . . . . . . A-2

Accessories and Dimensions

Product Selection . . . . . . . . . . . . . . . . . . . B-1 Product Dimensions . . . . . . . . . . . . . . . . . B-5

ii

Appendix C

RS485 (DSI) Protocol

Network Wiring . . . . . . . . . . . . . . . . . . . . . Parameter Configuration . . . . . . . . . . . . . . Supported Modbus Function Codes . . . . . Writing (06) Logic Command Data. . . . . . Writing (06) Reference . . . . . . . . . . . . . . . Reading (03) Logic Status Data. . . . . . . . . Reading (03) Feedback . . . . . . . . . . . . . . . Reading (03) Drive Error Codes . . . . . . . . Reading (03) and Writing (06) Drive Parameters . . . . . . . . . . . . . . . . . . . . . . Additional Information . . . . . . . . . . . . . . . C-1 C-2 C-2 C-3 C-4 C-4 C-4 C-5 C-5 C-5

Appendix D

RJ45 DSI Splitter Cable

Connectivity Guidelines . . . . . . . . . . . . . . D-1 DSI Cable Accessories . . . . . . . . . . . . . . . D-2 Connecting an RS-485 Network . . . . . . . . D-3

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 4 Adjustable Frequency AC Drive.
For information on Who Should Use this Manual? Reference Materials Manual Conventions Drive Frame Sizes General Precautions Catalog Number Explanation See page P-1 P-1 P-2 P-2 P-3 P-4

Who Should Use this Manual?

This manual is intended for qualified personnel. You must be able to program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.

Reference Materials
The following manuals are recommended for general drive information:
Title Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives Preventive Maintenance of Industrial Control and Drive System Equipment Safety Guidelines for the Application, Installation and Maintenance of Solid State Control A Global Reference Guide for Reading Schematic Diagrams Guarding Against Electrostatic Damage Publication Available Online at DRIVES-IN001 DRIVES-SB001 SGI-1.1 www.rockwellautomation.com/ literature

0100-2.10 8000-4.5.2

P-P-2

Overview

Manual Conventions
In this manual we refer to the PowerFlex 4 Adjustable Frequency AC Drive as: drive, PowerFlex 4 or PowerFlex 4 Drive. Parameter numbers and names are shown in this format:
P031 [Motor NP Volts] Name Number Group d = Display Group P = Basic Program Group A = Advanced Program Group

The following words are used throughout the manual to describe an action:
Word Can Cannot May 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 4 drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, etc. A cross reference of drive catalog numbers and their respective frame sizes is provided in Appendix B.

Overview

P-3

General Precautions
ATTENTION: The drive contains high voltage capacitors which take time to discharge after removal of mains supply. Before working on drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels.

! !

ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference A-B publication 8000-4.5.2, Guarding Against Electrostatic Damage or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system. 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 unacc eptable, the bus regulator must be disabled (see parameter A117). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases.

! !

P-P-4

Overview

Catalog Number Explanation

12 (1)

1-3
Drive

6-8

10

11

13-14

22A Code 22A PowerFlex 4

1P5

4
Code Version 3 No Brake IGBT 4 Standard

AA
Optional

Dash Voltage Rating Rating

Enclosure HIM Emission Class Type

Code V A B D

Voltage 120V AC 240V AC 240V AC 480V AC

Ph. 1 1 3 3

Code Rating 0 Not Filtered 1 Filtered Code Interface Module 1 Fixed Keypad Code Purpose AA Reserved for thru custom firmware ZZ

Code N F H

Enclosure Panel Mount - IP 20 (NEMA Type Open) Flange Mount - IP 20 (NEMA Type Open) Replacement Plate Drive - IP 20 (NEMA Type Open) - Contact factory for ordering information.

Output Current @ 100-120V Input

Code 1P5 2P3 4P5 6P0

Amps 1.5 2.3 4.5 6.0

kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5)

Output Current @ 200-240V Input, NO BRAKE

Code 1P4 2P1 3P6 6P8 9P6

Amps 1.4 2.1 3.6 6.8 9.6

kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0)

Output Current @ 200-240V Input

Code 1P5 2P3 4P5 8P0 012 017

Amps 1.5 2.3 4.5 8.0 12.0 17.5

(1)

kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0)

Output Current @ 380-480V Input

Code 1P4 2P3 4P0 6P0 8P7

Amps 1.4 2.3 4.0 6.0 8.7

kW (HP) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0)

Position 12 of the Catalog Number now indicates drive type. All PowerFlex 4 drives are equipped with RS485 communication.

Chapter 1

Installation/Wiring
This chapter provides information on mounting and wiring the PowerFlex 4 Drive.
For information on Opening the Cover Mounting Considerations AC Supply Source Considerations See page 1-1 1-2 1-3 For information on Fuses and Circuit Breakers Power Wiring I/O Wiring Recommendations EMC Instructions See page 1-6 1-8 1-11 1-20

General Grounding Requirements 1-4

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. Install on 35 mm DIN Rail. or Install with screws.
Table 1.A Screw Mounting Recommendations Minimum Panel Thickness Screw Size 1.9 mm (0.0747 in.) M4 (#8-32) Mounting Torque 1.56-1.96 N-m (14-17 lb.-in.)

Protect the cooling fan by avoiding dust or metallic particles. Do not expose to a corrosive atmosphere. Protect from moisture and direct sunlight.

Minimum Mounting Clearances

Refer to Appendix B for mounting dimensions.

120 mm (4.7 in.)

120 mm (4.7 in.)

25 mm (1.0 in.)

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

120 mm (4.7 in.)

120 mm (4.7 in.)

Mounting Option A No clearance required between drives.

Mounting Option B

Ambient Operating Temperatures

Ambient Temperature Minimum -10C (14F)
(1)

Table 1.B Enclosure and Clearance Requirements Enclosure Rating IP 20/Open Type Maximum 40C (104F) Minimum Mounting Clearances Use Mounting Option A Use Mounting Option B

IP 30/NEMA 1/UL Type 1(1) Use Mounting Option B

50C (122F) IP 20/Open Type

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

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

Installation/Wiring

1-3

Storage
Store within an ambient temperature range of -40 to +85C. Store within a relative humidity range of 0% to 95%, non-condensing. Do not expose to a corrosive atmosphere.

AC Supply Source Considerations

Ungrounded Distribution Systems
ATTENTION: PowerFlex 4 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 (A Frame Shown)

Important: Tighten screw after jumper removal.

Figure 1.2 Phase to Ground MOV Removal

R/L1 Three-Phase AC Input S/L2 T/L3 Jumper 1 2 3 4

1-4

Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix A). Listed in Table 1.C are certain input power conditions which may cause component damage or reduction in product life. If any of the conditions exist, as described in Table 1.C, install one of the devices listed under the heading Corrective Action on the line side of the drive. Important: Only one device per branch circuit is required. It should be mounted closest to the branch and sized to handle the total current of the branch circuit.
Table 1.C Input Power Conditions Input Power Condition Corrective Action Low Line Impedance (less than 1% line reactance) Install Line Reactor(1) or Isolation Transformer Greater than 120 kVA supply transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6000V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage Ungrounded distribution system
(1)

Remove MOV jumper to ground. or Install Isolation Transformer with grounded secondary if necessary.

Refer to Appendix B for accessory ordering information.

General Grounding Requirements

The drive Safety Ground (PE) must be connected to system ground. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding

R/L1 S/L2 T/L3

U/T1 V/T2 W/T3

SHLD

Installation/Wiring

1-5

Ground Fault Monitoring

If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.

Safety Ground -

(PE)

This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

Motor Ground
The motor ground must be connected to one of the ground terminals on the drive.

Shield Termination - SHLD

Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield. The motor cable shield connected to one of these terminals (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal. The conduit box option may be used with a cable clamp for a grounding point for the cable shield. When shielded cable is used for control and signal wiring, the shield should be grounded at the source end only, not at the drive end.

RFI Filter Grounding

Using single phase drives with integral filter, or an external filter with any drive rating, may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked.

1-6

Installation/Wiring

Fuses and Circuit Breakers

The PowerFlex 4 does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/or electrical codes may determine additional requirements for these installations. ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in this section.

Fusing
The PowerFlex 4 has been UL tested and approved for use with input fuses. The ratings in the table that follows are the minimum recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide.

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

When using Bulletin 140M or UL489 rated circuit breakers, the guidelines listed below must be followed in order to meet the NEC requirements for branch circuit protection. Bulletin 140M can be used in single and group motor applications. Bulletin 140M can be used up stream from the drive without the need for fuses.

Installation/Wiring
Table 1.D Minimum Recommended Branch Circuit Protective Devices Voltage Rating 120V AC 1-Phase Drive Rating kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) Fuse Rating(1) Amps 10 15 30 40 6 10 15 25 30 10 10 15 30 3 6 10 15 25 30 3 6 10 15 15 140M(2) Catalog No. 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-D8E-C25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C16 140M-C2E-C16 140M-D8E-C25 140M-C2E-B63 140M-C2E-B63 140M-C2E-C16 140M-D8E-C20 140M-C2E-B25 140M-C2E-B40 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16

1-7

Recommended MCS Contactors Catalog No. 100-C09 100-C12 100-C23 100-C37 100-C09 100-C09 100-C12 100-C16 100-C23 100-C09 100-C09 100-C12 100-C23 100-C09 100-C09 100-C09 100-C12 100-C16 100-C23 100-C09 100-C09 100-C09 100-C09 100-C16

240V AC 0.2 (0.25) 1-Phase 0.4 (0.5) NO BRAKE 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 240V AC 1-Phase 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0)

240V AC 3-Phase

480V AC 3-Phase

(1) (2)

Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. The AIC ratings of the 140M are based on a maximum 100 kA AIC with the exception of 140M-D and 140M-F which have a maximum of 50 kA AIC. Refer to the selection guide for Bulletin 140M motor protectors for other ratings suitable for your particular application.

1-8

Installation/Wiring

Power Wiring

! !

ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from cross coupled power leads.

Motor Cable Types Acceptable for 200-600 Volt Installations

General A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in.). 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 50C ambient must use 600V, 75C or 90C wire. UL installations in 40C ambient should use 600V, 75C or 90C 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
Location Standard (Option 1) Rating/Type 600V, 75C or 90C (167F or 194F) RHH/RHW-2 Belden 29501-29507 or equivalent Description Four tinned copper conductors with XLPE insulation Foil shield and tinned copper drain wire with 85% braid coverage PVC jacket Three tinned copper conductors with XLPE insulation 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield PVC jacket Three 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 copper grounds on #10 AWG and smaller

Standard (Option 2)

Tray rated 600V, 75C or 90C (167F or 194F) RHH/RHW-2 Shawflex 2ACD/3ACD or equivalent Class I & II; Tray rated 600V, 75C or Division I & II 90C (167F or 194F) RHH/RHW-2

Installation/Wiring

1-9

Reflected Wave Protection

The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition of external devices to limit voltage reflections at the motor (reflected wave phenomena). See Table 1.E for recommendations. The reflected wave data applies to all frequencies 2 to 16 kHz. For 240V ratings, reflected wave effects do not need to be considered.
Table 1.E Maximum Cable Length Recommendations Reflected Wave 380-480V Ratings Motor Insulation Rating 1000 Vp-p 1200 Vp-p 1600 Vp-p
(1)

Motor Cable Only(1) 15 meters (49 feet) 40 meters (131 feet) 170 meters (558 feet)

Longer cable lengths can be achieved by installing devices on the output of the drive. Consult factory for recommendations.

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

1-10

Installation/Wiring

Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. To remove: 1. Press in and hold the locking tab. 2. Slide finger guard down and out. Replace the finger guard when wiring is complete.
Figure 1.4 Power Terminal Block (A Frame Shown)
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3

BR+ BR-

Terminal R/L1, S/L2 R/L1, S/L2, T/L3 U/T1 V/T2 W/T3 BR+, BR-

Description 1-Phase Input 3-Phase Input To Motor U/T1 To Motor V/T2 = To Motor W/T3 Dynamic Brake Resistor Connection Safety Ground - PE

Switch any two motor leads to change forward direction.

Table 1.F Power Terminal Block Specifications Frame A B

(1)

Maximum Wire Size (1) Minimum Wire Size (1) Torque 3.3 mm2 (12 AWG) 5.3 mm2 (10 AWG) 0.8 mm2 (18 AWG) 1.3 mm2 (16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)

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

Installation/Wiring

1-11

I/O Wiring Recommendations

Motor Start/Stop Precautions
ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If used, the input device must not exceed one operation per minute or drive damage can occur. ATTENTION: The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present - the motor will coast to a stop. An auxiliary braking method may be required. Important points to remember about I/O wiring: Always use copper wire. Wire with an insulation rating of 600V or greater is recommended. Control and signal wires should be separated from power wires by at least 0.3 meters (1 foot).

! !

Important: I/O terminals labeled Common are not referenced to the safety ground (PE) terminal and are designed to greatly reduce common mode interference. ATTENTION: Driving the 4-20mA analog input from a voltage source could cause component damage. Verify proper configuration prior to applying input signals.

1-12

Installation/Wiring

Control Wire Types

Table 1.G Recommended Control and Signal Wire(1) Wire Type(s) Belden 8760/9460 (or equiv.) Belden 8770 (or equiv.)
(1)

Description 0.8 mm2 (18AWG), twisted pair, 100% shield with drain. (1) 0.8 mm2 (18AWG), 3 conductor, shielded for remote pot only.

Minimum Insulation Rating 300V 60 degrees C (140 degrees F)

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

I/O Terminal Block

1.3 mm
(1) 2 (16 AWG)

Table 1.H I/O Terminal Block Specifications Maximum Wire Size (1) Minimum Wire Size (1) 0.13 mm2 (26 AWG) Torque 0.5-0.8 N-m (4.4-7 lb.-in.)

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

Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal block Common must be connected to ground terminal/protective earth. If using the RS485 (DSI) port, I/O Terminal 16 should also be connected to ground terminal/protective earth.

Installation/Wiring
Figure 1.5 Control Wiring Block Diagram
Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set to 3-Wire control. In three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode]. All other stop sources are controlled by P037 [Stop Mode]. 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. Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a start. Use a maintained input for I/O Terminal 03 to change direction. Relay N.O.
Relay Common Relay N.C.

1-13

(1)

P036 [Start Source] Keypad 3-Wire 2-Wire RS485 Port

Stop Per P037 Per P037 Per P037 Per P037

I/O Terminal 01 Stop Coast Per P037 Coast Coast

01 02 SNK SRC 03 04 05 06 +24V +10V R1 R2 R3 11 12 13 14 15 16

Stop

(1)

Typical Typical SRC Wiring SNK Wiring

Start/Run FWD (2) Direction/Run REV Digital Common Digital Input 1 Digital Input 2 +24V DC +10V DC 0-10V In Analog Common 4-20mA In RS485 Shield
Potentiometer must be 1-10k ohm 2 Watt Min.

(2)

01 02 03 04 05 06 R1 R2 R3
30V DC 125V AC 240V AC Resistive Inductive 3.0A 0.5A 3.0A 0.5A 3.0A 0.5A

SNK SRC

11

12 13 14 15 16

RS485 (DSI) 8 1

(1)

No.
R1 R2 R3

Signal
Relay N.O. Relay Common Relay N.C.

Default
Fault Fault Source (SRC) Coast Not Active Not Active Preset Freq Preset Freq Not Active Not Active

Description
Normally open contact for output relay. Common for output relay. Normally closed contact for output relay.

Param.
A055 A055

Sink/Source DIP Switch 01 02 03 04 05 06 11 12 13 14 15 16

(3)

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)

Stop (1) Start/Run FWD Direction/Run REV Digital Common Digital Input 1 Digital Input 2 +24V DC +10V DC 0-10V In (3) Analog Common 4-20mA In (3) RS485 (DSI) Shield

P036, P037 Command comes from the integral keypad by default. To disable reverse operation, see A095 [Reverse Disable]. P036, P037, A095 For digital inputs. Electronically isolated with digital inputs from analog I/O. Program with A051 [Digital In1 Sel]. Program with A052 [Digital In2 Sel]. Drive supplied power for digital inputs. Maximum output current is 100mA. Drive supplied power for 0-10V external potentiometer. Maximum output current is 15mA. For external 0-10V input supply (input impedance = 100k ohm) or potentiometer wiper. For 0-10V In or 4-20mA In. Electronically isolated with analog inputs from digital I/O. For external 4-20mA input supply (input impedance = 250 ohm). Terminal should be connected to safety ground - PE when using the RS485 (DSI) communications port. P038 A051 A052

P038 P038

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

1-14

Installation/Wiring

I/O Wiring Examples

Input Potentiometer 1-10k Ohm Pot. Recommended (2 Watt minimum) Connection Example P038 [Speed Reference] = 2 0-10V Input

12 13 14

Analog Input 0 to +10V, 100k ohm impedance 4-20 mA, 100 ohm impedance

Voltage Current P038 [Speed Reference] = 2 0-10V P038 [Speed Reference] = 3 Input 4-20mA Input

+ 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 11 12 13 14 05

Re RPTC

VTrip =

RPTC (hot) RPTC (hot) + Re

100

Installation/Wiring
Input Connection Example 2 Wire SRC Control Internal Supply (SRC) Non-Reversing P036 [Start Source] = 2, 3 11 or 4 Input must be active for Stop-Run 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 Internal Supply (SNK) Non-Reversing
Stop-Run

1-15

External Supply (SRC)

01 02 01 02 04 +24V Common

Stop-Run

Each digital input draws 6 mA.

01 02 04

2 Wire SRC Control Internal Supply (SRC) Run FWD/Run REV P036 [Start Source] = 2, 3 11 or 4 Input must be active for Stop-Run Forward the drive to run. When input is opened, the drive will stop as specified by Stop-Run Reverse 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 Internal Supply (SNK) Run FWD/Run REV

External Supply (SRC)

01 02 03 01 02 03 04

Stop-Run Forward Stop-Run Reverse +24V Common

Each digital input draws 6 mA.

Stop-Run Forward Stop-Run Reverse

01 02 03 04

1-16

Installation/Wiring
Connection Example Internal Supply (SRC)

Input 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].

External Supply (SRC)

Stop

11

01 02

Stop

01 02 04

Start

Start

+24V

Common

Each digital input draws 6 mA. 3 Wire SNK Control Non-Reversing Internal Supply (SNK)
Stop 01 02 03 04

Start

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 01 02 03

External Supply (SRC)

Stop

11

Start Direction

Start Direction +24V Common

01 02 03 04

Each digital input draws 6 mA. 3 Wire SNK Control Reversing Internal Supply (SNK)
Stop 01 02 03 04

Start Direction

Installation/Wiring

1-17

Typical Multiple Drive Connection Examples

Input Connection Example Multiple Digital 02 04 02 04 02 04 02 04 Input Connections Customer Inputs can be wired per External Supply (SRC) or Internal Supply (SNK) Optional Ground Connection Customer Inputs examples on page 1-15. 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

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.

1-18

Installation/Wiring

Start and Speed Reference Control

The drive speed command can be obtained from a number of different sources. The source is normally determined by P038 [Speed Reference]. However, when A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or 6, and the digital input is active, A051 or A052 will override the speed reference commanded by P038 [Speed Reference]. See the chart below for the override priority.
Drive will Start and Run at Jog Speed. Direction comes from Terminal 03 Dir/Run REV No No

Jog Input Enabled and Active: A051 or A052 = 2

Yes

Drive stopped (not Running)

Yes

Local/Remote Input Enabled and Active: A051 or A052 = 5

Yes

Start, Speed and Direction commands come from Integral Keypad.

No

Comm Select Input Enabled and Active: A051 or A052 = 6

Yes

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

No Run as specified by P038 [Speed Reference]. Start and Direction commands come from P036 [Start Source].

P038 [Speed Reference] = 4 or 5

Yes

No Run as specified by A071-A073 [Preset Freq 1-3]. Start and Direction commands come from P036 [Start Source].

A051 / A052 Preset Inputs Active

Yes

No Run as specified by P038 [Speed Reference]. Start and Direction commands come from P036 [Start Source].

Installation/Wiring

1-19

Accel/Decel Selection
The selection of Accel/Decel rates can be made through digital inputs, RS485 (DSI) communications and/or parameters.

Jog Input Enabled and Active: A051 or A052 = 2

Yes

A079 [Jog Accel/Decel] used.

No

RS485 (DSI) Port Controls Speed

Yes

Active when A067 [Accel Time 2]/A068 [Decel Time 2] is selected by RS485 (DSI) port.

No

Input is programmed as Accel 2 & Decel 2 A051 or A052 = 1

Yes

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

No P039 [Accel Time 1]/P040 [Decel Time 1]; A067 [Accel Time 2]/A068 [Decel Time 2] determined by the active Preset Frequency. See A070-A073 [Preset Freq 0-3] on page 3-16.

Speed is controlled by [Preset Freq x] A051 or A052 = 4

Yes

No P039 [Accel Time 1]/P040 [Decel Time 1] are used.

1-20

Installation/Wiring

EMC Instructions
CE Conformity
Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User Manual. CE Declarations of Conformity are available online at: http://www.ab.com/certification/ce/docs.

Low Voltage Directive (73/23/EEC)

EN50178 Electronic equipment for use in power installations EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods. If the plastic top panel is removed or the optional conduit box is not installed, the drive must be installed in an enclosure with side openings less than 12.5 mm (0.5 in.) and top openings less than 1.0 mm (0.04 in.) to maintain compliance with the LV Directive. The motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents. Use of line filters in ungrounded systems is not recommended. Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance.

EMC Directive (89/336/EEC)

General Notes

Installation/Wiring

1-21

Essential Requirements for CE Compliance

Conditions 1-3 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3. 1. Grounding as described in Figure 1.6. Refer to page 1-5 for additional grounding recommendations. 2. Output power, control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation. 3. Allowable cable length in Table 1.I is not exceeded.
Table 1.I Allowable Cable Length Filter Type EN61800-3 First Environment Restricted Distribution or Second Environment (2) 10 meters (33 feet) 10 meters (33 feet) EN61800-3 First Environment Unrestricted Distribution (3) 1 meter (3 feet) 1 meter (3 feet) 5 meters (16 feet)

Integral External - S Type(1) External - L Type(1) 100 meters (328 feet)

(2) (3)

(1) Refer to Appendix B for details on optional external filters.

Equivalent to EN55011 Class A. Equivalent to EN55011 Class B.

Figure 1.6 Connections and Grounding

(1) Shielded Enclosure IP 30/NEMA 1/UL Type 1 Option Kit

(2) EMI Filter

L1 L2 L3 L1' L2' L3' R/L1 S/L2 T/L3

EMI Fittings and Metal Conduit

U/T1 V/T2 W/T3

Enclosure Ground Connection

Shielded Motor Cable

Building Structure Steel

(1)

(2)

First Environment Unrestricted Distribution installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the EMI filter. Integral EMI filters are available on 240V, 1-Phase drives.

1-22

Installation/Wiring

EN61000-3-2
0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5 HP) 240V 1-Phase drives are suitable for installation on a private low voltage power network. Installations on a public low voltage power network may require additional external harmonic mitigation. Other drive ratings meet the current harmonic requirements of EN61000-3-2 without additional external mitigation.

Chapter 2

Start Up
This chapter describes how to start up the PowerFlex 4 Drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group. Important: Read the General Precautions section before proceeding. ATTENTION: Power must be applied to the drive to perform the following start-up procedures. Some of the voltages present are at incoming line potential. To avoid electric shock hazard or damage to equipment, only qualified service personnel should perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, Do Not Proceed. Remove All Power including user supplied control voltages. User supplied voltages may exist even when main AC power is not applied to the drive. Correct the malfunction before continuing.

Prepare For Drive Start-Up

Before Applying Power to the Drive

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

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

3. Verify that any digital control power is 24 volts. 4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See Figure 1.5 on page 1-13 for location. Important: The default control scheme is Source (SRC). The Stop terminal is jumpered (I/O Terminals 01 and 11) to allow starting from the keypad. If the control scheme is changed to Sink (SNK), the jumper must be removed from I/O Terminals 01 and 11 and installed between I/O Terminals 01 and 04.

5. Verify that the Stop input is present or the drive will not start.
Important: If I/O Terminal 01 is used as a stop input, the jumper between I/O Terminals 01 and 11 must be removed.

2-2

Start Up

Applying Power to the Drive

6. Apply AC power and control voltages to the drive. 7. Familiarize yourself with the integral keypad features (see page 2-3)
before setting any Program Group parameters.

Start, Stop, Direction and Speed Control

Factory default parameter values allow the drive to be controlled from the integral keypad. No programming is required to start, stop, change direction and control speed directly from the integral keypad. Important: To disable reverse operation, see A095 [Reverse Disable]. If a fault appears on power up, refer to Fault Descriptions on page 4-3 for an explanation of the fault code.

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

Integral Keypad

PROGRAM

FAULT

RUN FWD REV

Menu

Description
Display Group (View Only) Consists of commonly viewed drive operating conditions. Basic Program Group Consists of most commonly used programmable functions.

VOLTS AMPS HERTZ

Advanced Program Group Consists of remaining programmable functions. Fault Designator Consists of list of codes for specific fault conditions. Displayed only when fault is present.

No. LED Run/Direction Status

LED State Steady Red Flashing Red Steady Red Flashing Red Steady Red Steady Red Flashing Red Steady Green

Alphanumeric Display Displayed Units Program Status Fault Status Pot Status

Description Indicates drive is running and commanded motor direction. Drive has been commanded to change direction. Indicates actual motor direction while decelerating to zero. Indicates parameter number, parameter value, or fault code. Single digit flashing indicates that digit can be edited. All digits flashing indicates a fault condition. Indicates the units of the parameter value being displayed. Indicates parameter value can be changed. Indicates drive is faulted. Indicates potentiometer on Integral Keypad is active. Indicates Start key on Integral Keypad is active. The Reverse key is also active unless disabled by A095 [Reverse Disable]. Description Back one step in programming menu. Cancel a change to a parameter value and exit Program Mode. Advance one step in programming menu. Select a digit when viewing parameter value. Scroll through groups and parameters. Increase/decrease the value of a flashing digit. Advance one step in programming menu. Save a change to a parameter value. Used to control speed of drive. Default is active. Controlled by parameter P038 [Speed Reference]. Used to start the drive. Default is active. Controlled by parameter P036 [Start Source]. Used to reverse direction of the drive. Default is active. Controlled by parameters P036 [Start Source] and A095 [Reverse Disable]. Used to stop the drive or clear a fault. This key is always active. Controlled by parameter P037 [Stop Mode].

Start Key Status Steady Green

No. Key

Name Escape Select Up Arrow Down Arrow Enter

Potentiometer Start Reverse Stop

2-4

Start Up

Viewing and Editing Parameters

The last user-selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied. The following is an example of basic integral keypad and display functions. This example provides basic navigation instructions and illustrates how to program the first Program Group parameter. Step Key(s) 1. When power is applied, the last user-selected Display Group parameter number is briefly displayed with flashing characters. The display then defaults to that parameters current value. (Example shows the value of d001 [Output Freq] with the drive stopped.) 2. Press Esc once to display the Display Group parameter number shown on power-up. The parameter number will flash. 3. Press Esc again to enter the group menu. The group menu letter will flash. 4. Press the Up Arrow or Down Arrow to scroll through the group menu (d, P and A). 5. Press Enter or Sel to enter a group. The right digit of the last viewed parameter in that group will flash. 6. Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group. 7. Press Enter or Sel to view the value of a parameter. If you do not want to edit the value, press Esc to return to the parameter number. 8. Press Enter or Sel to enter program mode to edit the parameter value. The right digit will flash and the Program LED will illuminate if the parameter can be edited. 9. Press the Up Arrow or Down Arrow to change the parameter value. If desired, press Sel to move from digit to digit or bit to bit. The digit or bit that you can change will flash. 10. Press Esc to cancel a change. The digit will stop flashing, the previous value is restored and the Program LED will turn off. Or Press Enter to save a change. The digit will stop flashing and the Program LED will turn off.
PROGRAM FAULT VOLTS AMPS HERTZ

Example Displays
VOLTS AMPS HERTZ PROGRAM FAULT

VOLTS AMPS HERTZ PROGRAM FAULT

VOLTS AMPS HERTZ

or or

PROGRAM

FAULT

VOLTS AMPS HERTZ PROGRAM FAULT

or or
PROGRAM FAULT VOLTS AMPS HERTZ

or
PROGRAM FAULT

VOLTS AMPS HERTZ

or

11. Press Esc to return to the parameter list. Continue to press Esc to back out of the programming menu. If pressing Esc does not change the display, then d001 [Output Frequency] is displayed. Press Enter or Sel to enter the group menu.

VOLTS AMPS HERTZ PROGRAM FAULT

The Basic Program Group (page 3-8) contains the most commonly changed parameters.

Chapter 3

Programming and Parameters

Chapter 3 provides a complete listing and description of the PowerFlex 4 parameters. Parameters are programmed (viewed/edited) using the integral keypad. As an alternative, programming can also be performed using DriveExplorer or DriveExecutive software, a personal computer and a serial converter module. Refer to Appendix B for catalog numbers.
For information on About Parameters Parameter Organization Basic Program Group Advanced Program Group Parameter Cross Reference by Name See page 3-1 3-2 3-8 3-13 3-27

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
B Progr asic am G roup Ad Progrvanced am G roup

Displa

y Gro

up

See page 3-3 Output Freq Commanded Freq Output Current Output Voltage DC Bus Voltage Drive Status Fault 1 Code Fault 2 Code Fault 3 Code Process Display Control Source Contrl In Status Dig In Status Comm Status Control SW Ver Drive Type Elapsed Run Time Testpoint Data Analog In 0-10V Analog In 4-20mA Drive Temp

d001 d002 d003 d004 d005 d006 d007 d008 d009 d010 d012 d013 d014 d015 d016 d017 d018 d019 d020 d021 d024

See page 3-8 Motor NP Volts Motor NP Hertz Motor OL Current Minimum Freq Maximum Freq Start Source Stop Mode Speed Reference Accel Time 1 Decel Time 1 Reset To Defalts Motor OL Ret

P031 P032 P033 P034 P035 P036 P037 P038 P039 P040 P041 P043

See page 3-13 Digital In1 Sel Digital In2 Sel Relay Out Sel Relay Out Level Accel Time 2 Decel Time 2 Internal Freq Preset Freq 0 Preset Freq 1 Preset Freq 2 Preset Freq 3 Jog Frequency Jog Accel/Decel DC Brake Time DC Brake Level DB Resistor Sel S Curve % Boost Select Maximum Voltage Current Limit Motor OL Select PWM Frequency Auto Rstrt Tries Auto Rstrt Delay Start At PowerUp Reverse Disable Flying Start En Compensation SW Current Trip Process Factor Fault Clear Program Lock Testpoint Sel Comm Data Rate Comm Node Addr Comm Loss Action Comm Loss Time Comm Format Anlg In 0-10V Lo Anlg In 0-10V Hi Anlg In 4-20mA Lo Anlg In 4-20mA Hi Slip Hertz @ FLA Process Time Lo Process Time Hi Bus Reg Mode Comm Write Mode

A051 A052 A055 A056 A067 A068 A069 A070 A071 A072 A073 A078 A079 A080 A081 A082 A083 A084 A088 A089 A090 A091 A092 A093 A094 A095 A096 A097 A098 A099 A100 A101 A102 A103 A104 A105 A106 A107 A110 A111 A112 A113 A114 A115 A116 A117 A118

Programming and Parameters

3-3

Display Group
d001 [Output Freq]
Values Default Min/Max: Display: Related Parameter(s): d002, d010, P034, P035, P038 Read Only 0.0/P035 [Maximum Freq] 0.1 Hz Output frequency present at T1, T2 & T3 (U, V & W).

d002 [Commanded Freq]

Related Parameter(s): d001, d013, P034, P035, P038

Value of the active frequency command. Displays the commanded frequency even if the drive is not running. Important: The frequency command can come from a number of sources. Refer to Start and Speed Reference Control on page 1-18 for details. Values Default Min/Max: Display: Read Only 0.0/P035 [Maximum Freq] 0.1 Hz

d003 [Output Current]

The output current present at T1, T2 & T3 (U, V & W). Values Default Min/Max: Display: Read Only 0.00/(Drive Rated Amps 2) 0.01 Amps

d004 [Output Voltage]

Output voltage present at terminals T1, T2 & T3 (U, V & W). Values Default Min/Max: Display: Read Only 0/Drive Rated Volts 1 VAC

Related Parameter(s): P031, A084, A088

d005 [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

Display Group (continued)

d006 [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

d007 [Fault 1 Code] d008 [Fault 2 Code] d009 [Fault 3 Code]

A code that represents a drive fault. The codes will appear in these parameters in the order they occur (d007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once. Refer to Chapter 4 for fault code descriptions. Values Default Min/Max: Display: Read Only F2/F122 F1

d010 [Process Display]

32

Related Parameter(s): d001, A099, A115, A116

32 bit parameter.

The output frequency scaled by A099 [Process Factor] or by A115 [Process Time Lo] and A116 [Process Time Hi].
Output Process Process Freq x Factor = Display

Values

Default Min/Max: Display:

Read Only 0.00/9999 0.01 1

Programming and Parameters

3-5

Display Group (continued)

d012 [Control Source]
Related Parameter(s): P036, P038, A051, A052 Displays the active source of the Start Command and Speed Command which are normally defined by the settings of P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital inputs. Refer to the flowcharts on pages 1-18 and 1-19 for details.

Start Command Digit 0 0 = Keypad 1 = 3-Wire 2 = 2-Wire 3 = 2-Wire Level Sensitive 4 = 2-Wire High Speed 5 = RS485 (DSI) Port 9 = Jog Speed Command Digit 1 0 = Drive Potentiometer 1 = A069 [Internal Freq] 2 = 0-10V Input/Remote Potentiometer 3 = 4-20mA Input 4 = A070 - A073 [Preset Freq x] (A051 - A052 [Digital Inx Sel] must be set to 4) 5 = RS485 (DSI) Port 9 = Jog Freq Reserved Digit 2 Reserved Digit 3

Values

Default Min/Max: Display:

Read Only 0/9 1

d013 [Contrl In Status]

Related Parameter(s): d002, P034, P035

Status of the control terminal block control inputs. Important: Actual control commands may come from a source other than the control terminal block.

1 = Input Present, 0 = Input Not Present Start / Run FWD Input (I/O Terminal 02) Bit 0 Direction / Run REV Input (I/O Terminal 03) Bit 1 Bit 2 Stop Input(1) (I/O Terminal 01) Reserved Bit 3
(1)

The stop input must be present in order to start the drive. When this bit is a 1 the drive can be started. When this bit is a 0 the drive will stop.

Values

Default Min/Max: Display:

Read Only 0/1 1

3-6

Programming and Parameters

Display Group (continued)

d014 [Dig In Status]
Status of the control terminal block digital inputs. Related Parameter(s): A051, A052

1 = Input Present, 0 = Input Not Present Digital In1 Sel (I/O Terminal 05) Bit 0 Digital In2 Sel (I/O Terminal 06) Bit 1 Reserved Bit 2 Reserved Bit 3

Values

Default Min/Max: Display:

Read Only 0/1 1

d015 [Comm Status]

Status of the communications ports.

Related Parameter(s): A103 - A107

1 = Condition True, 0 = Condition False Receiving Data Bit 0 Transmitting Data Bit 1 RS485 (DSI) Based Option Connected Bit 2 (Allen-Bradley devices only.) Communication Error Occurred Bit 3

Values

Default Min/Max: Display:

Read Only 0/1 1

d016 [Control SW Ver]

Main Control Board software version. Values Default Min/Max: Display: Read Only 1.00/99.99 0.01

d017 [Drive Type]

Used by Rockwell Automation field service personnel. Values Default Min/Max: Display: Read Only 1001/9999 1

Programming and Parameters

3-7

Display Group (continued)

d018 [Elapsed Run Time]
Accumulated time drive is outputting power. Time is displayed in 10 hour increments. Values Default Min/Max: Display: Read Only 0/9999 Hrs 1 = 10 Hrs

d019 [Testpoint Data]

The present value of the function selected in A102 [Testpoint Sel]. Values Default Min/Max: Display: Read Only 0/FFFF 1 Hex

Related Parameter(s): A102

d020 [Analog In 0-10V]

Values Default Min/Max: Display: Read Only 0.0/100.0% 0.1%

Related Parameter(s): A110, A111

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

d021 [Analog In 4-20mA]

Values Default Min/Max: Display: Read Only 0.0/100.0% 0.1%

Related Parameter(s): A112, A113

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

d024 [Drive Temp]

Present operating temperature of the drive power section. Values Default Min/Max: Display: Read Only 0/120 degC 1 degC

3-8

Programming and Parameters

Basic Program Group

P031 [Motor NP Volts]
Stop drive before changing this parameter. Set to the motor nameplate rated volts. Values Default Min/Max: Display: Based on Drive Rating 20/Drive Rated Volts 1 VAC Related Parameter(s): d004, A084

P032 [Motor NP Hertz]

Stop drive before changing this parameter. Set to the motor nameplate rated frequency. Values Default Min/Max: Display: 60 Hz 10/240 Hz 1 Hz

Related Parameter(s): A084, A090

P033 [Motor OL Current]

Related Parameter(s): P043, A055, A089, A090, A098, A114

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: Display: Based on Drive Rating 0.0/(Drive Rated Amps 2) 0.1 Amps

P034 [Minimum Freq]

Values Default Min/Max: Display:

Related Parameter(s): d001, d002, d013, P035, A110, A112, A115 0.0 Hz 0.0/240.0 Hz 0.1 Hz Related Parameter(s): d001, d002, d013, P034, A078, A111, A113, A115

Sets the lowest frequency the drive will output continuously.

P035 [Maximum Freq]

Stop drive before changing this parameter. Sets the highest frequency the drive will output. Values Default Min/Max: Display: 60 Hz 0/240 Hz 1 Hz

Programming and Parameters

3-9

Basic Program Group (continued)

P036 [Start Source]
Stop drive before changing this parameter. Sets the control scheme used to start the drive. Refer to Start and Speed Reference Control on page 1-18 for details about how other drive settings can override the setting of this parameter. Important: For all settings except option 3, the drive must receive a leading edge from the start input for the drive to start after a stop input, loss of power or fault condition. Options 0 Keypad (Default) Integral keypad controls drive operation. I/O Terminal 1 Stop = coast to stop. When active, the Reverse key is also active unless disabled by A095 [Reverse Disable]. I/O Terminal 1 Stop = stop according to the value set in P037 [Stop Mode]. I/O Terminal 1 Stop = coast to stop. Drive will restart after a Stop command when: Stop is removed and Start is held active ATTENTION: Hazard of injury exists due to unintended operation. When P036 [Start Source] is set to option 3, and the Run input is maintained, the Run inputs do not need to be toggled after a Stop input for the drive to run again. A Stop function is provided only when the Stop input is active (open). Important: There is greater potential voltage on the output terminals when using this option. Outputs are kept in a ready-to-run state. The drive will respond to a Start command within 10 ms. I/O Terminal 1 Stop = coast to stop. 5 Comm Port Remote communications. Refer to Appendix C for details. I/O Terminal 1 Stop = coast to stop. Related Parameter(s): d012, P037

1 3-Wire 2 2-Wire 3 2-W Lvl Sens

4 2-W Hi Speed

Important: When commanding Jog via the RS485 communications port on drives with firmware version 1.02 or earlier, the Jog command will follow the commanded direction from I/O Terminal 03. On firmware versions 1.03 and later, the commanded direction will be provided via the RS485 communications port. Important: When sending a continuous start command via the RS485 communications port on drives with firmware version 1.02 or earlier, a maintained stop input is required to stop the drive. Once the stop input is inactive, the drive will restart. On firmware versions 1.03 and later, once a stop input is received, the start command must transition from high to low to high for the drive to start.

3-10

Programming and Parameters

Basic Program Group (continued)

P037 [Stop Mode]
Related Parameter(s): P036, A080, A081, A082, A105 Active stop mode for all stop sources [e.g. keypad, run forward (I/O Terminal 02), run reverse (I/O Terminal 03), RS485 port] except as noted below. Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set for 3-Wire control. When in three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode]. Hardware Enable Circuitry By default, I/O Terminal 01 is a coast to stop input. The status of the input is interpreted by drive software. If the application requires the drive to be disabled without software interpretation, a dedicated hardware enable configuration can be utilized. This is accomplished by removing the ENBL enable jumper on the control board. In this case, the drive will always coast to a stop regardless of the settings of P036 [Start Source] and P037 [Stop Mode]. Options 0 Ramp, CF(1) (Default) Ramp to Stop. Stop command clears active fault. 1 Coast, CF(1) 2 DC Brake, CF
(1)

Coast to Stop. Stop command clears active fault. DC Injection Braking Stop. Stop command clears active fault. DC Injection Braking Stop with Auto Shutoff. Standard DC Injection Braking for value set in A080 [DC Brake Time]. OR Drive shuts off if the drive detects that the motor is stopped. Stop command clears active fault.

3 DCBrkAuto,CF(1)

4 Ramp 5 Coast 6 DC Brake 7 DC BrakeAuto

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 A080 [DC Brake Time]. OR Drive shuts off if current limit is exceeded.

(1)

Stop input also clears active fault.

Programming and Parameters

3-11

Basic Program Group (continued)

P038 [Speed Reference] Related Parameter(s): d001, d002, d012, P039, P040, A051, A052,
A069, A070-A073, A110, A111, A112, A113 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 - A052 [Digital Inx Sel] is set to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, the speed reference commanded by P038 [Speed Reference] will be overridden. Refer to the flowchart on page 1-18 for more information on speed reference control priority. Options 0 Drive Pot (Default) 1 InternalFreq 2 0-10V Input 3 4-20mA Input 4 Preset Freq Internal frequency command from the potentiometer on the integral keypad. Internal frequency command from A069 [Internal Freq]. External frequency command from the 0-10V analog input or remote potentiometer. External frequency command from the 4-20mA analog input. External frequency command as defined by A070 - A073 [Preset Freq x] when A051 and A052 [Digital Inx Sel] are programmed as Preset Frequencies and the digital inputs are active. External frequency command from the communications port.

5 Comm Port

P039 [Accel Time 1]

Maximum Freq = Accel Rate Accel Time

Related Parameter(s): P038, P040, A051, A052, A067, A070-A073

Sets the rate of acceleration for all speed increases.

Values

Default Min/Max: Display:

10.0 Secs 0.0/600.0 Secs 0.1 Secs

P035 [Maximum Freq]

De

ratio

cele

ele

Speed

ratio

Acc

0 0

P039 or A067 [Accel Time x]

Time

P040 or A068 [Decel Time x]

3-12

Programming and Parameters

Basic Program Group (continued)

P040 [Decel Time 1]
Maximum Freq = Decel Rate Decel Time

Related Parameter(s): P038, P039, A051, A052, A068, A070-A073

Sets the rate of deceleration for all speed decreases.

Values

Default Min/Max: Display:

10.0 Secs 0.1/600.0 Secs 0.1 Secs

P035 [Maximum Freq]

n ratio cele De

0 0

P039 or A067 [Accel Time x]

Acc ele

Speed

ratio

Time

P040 or A068 [Decel Time x]

P041 [Reset To Defalts]

Stop drive before changing this parameter. Resets all parameter values to factory defaults. Options 0 Idle State (Default) 1 Reset Defaults After the reset function is complete, this parameter will set itself back to 0. Causes an F48 Params Defaulted fault. Related Parameter(s): P033

P043 [Motor OL Ret]

Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor overload counter is saved at power-down and restored at power-up. A change to this parameter setting resets the counter. Options 0 Disabled (Default) 1 Enabled

Programming and Parameters

3-13

Advanced Program Group

A051 [Digital In1 Sel] A052 [Digital In2 Sel]
(I/O Terminal 6) Selects the function for the digital inputs. Refer to the flowchart on page 1-18 for more information on speed reference control priority. Options 0 Not Used 1 Acc 2 & Dec 2 Terminal has no function but can be read over network communications via d014 [Dig In Status] When active, A067 [Accel Time 2] and A068 [Decel Time 2] are used for all ramp rates except Jog. Can only be tied to one input. Refer to the flowchart on page 1-19 for more information on Accel/Decel selection. When input is present, drive accelerates according to the value set in A079 [Jog Accel/Decel] and ramps to the value set in A078 [Jog Frequency]. When input is removed, drive ramps to a stop according to the value set in A079 [Jog Accel/Decel]. A valid Start command will override this input. When enabled, an F2 Auxiliary Input fault will occur when the input is removed. (I/O Terminal 5) Related Parameter(s): d012, d014, P038, P039, P040, A067, A068, A070-A073, A078, A079 Stop drive before changing this parameter.

2 Jog

3 Aux Fault

4 Preset Freq (Default) Refer to A070 - A073 [Preset Freq x]. Important: Digital Inputs have priority for frequency control when programmed as a Preset Speed and are active. Refer to the flowchart on 1-18 for more information on speed reference control priority. 5 Local 6 Comm Port When active, sets integral keypad as start source and potentiometer on the integral keypad as speed source. When active, sets communications device as default start/ speed command source. Can only be tied to one input. When active, clears an active fault. Causes drive to immediately ramp to a stop regardless of how P037 [Stop Mode] is set. Causes drive to immediately coast to a stop regardless of how P037 [Stop Mode] is set. Causes drive to immediately begin a DC Injection stop regardless of how P037 [Stop Mode] is set. Drive accelerates to A078 [Jog Frequency] according to A079 [Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start will override this command. Drive accelerates to A078 [Jog Frequency] according to A079 [Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start will override this command.

7 Clear Fault 8 RampStop,CF 9 CoastStop,CF 10 DCInjStop,CF 11 Jog Forward

12 Jog Reverse

3-14

Programming and Parameters

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. Reserved 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]. Related Parameter(s): P033, A056, A092 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. Drive reaches commanded frequency. Motor is receiving power from the drive. 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]. Drive exceeds the current (% Amps) value set in A056 [Relay Out Level]. Important: Value for A056 [Relay Out Level] must be entered in percent of drive rated output current. 8 Above DCVolt 9 Retries Exst 10 Above Anlg V Drive exceeds the DC bus voltage value set in A056 [Relay Out Level]. Value set in A092 [Auto Rstrt Tries] is exceeded. Analog input voltage (I/O Terminal 13) exceeds the value set in A056 [Relay Out Level]. 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. Reserved Enables the output to be controlled over network communications by writing to A056 [Relay Out Level]. (0 = Off, 1 = On.) Value set in A092 [Auto Rstrt Tries] is exceeded.

A051 & 13 10V In Ctrl A052 Options 14 20mA In Ctrl (Cont.) 15 - 25 26 Anlg Invert

A055 [Relay Out Sel]

Options 0 Ready/Fault (Default) 1 At Frequency 2 MotorRunning 3 Reverse 4 Motor Overld 5 Ramp Reg 6 Above Freq 7 Above Cur

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

11-19 20 ParamControl 21 NonRec Fault

Programming and Parameters

3-15

Advanced Program Group (continued)

A056 [Relay Out Level]
32

Related Parameter(s): A055

32 bit parameter.

Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7, 8, 10 or 20.
A055 Setting 6 7 8 10 20 A056 Min/Max 0/240 Hz 0/180% 0/815 Volts 0/100% 0/1

Values

Default Min/Max: Display:

0.0 0.0/9999 0.1 Related Parameter(s): P039

A067 [Accel Time 2]

Maximum Freq = Accel Rate Accel Time

When active, sets the rate of acceleration for all speed increases except jog. Refer to the flowchart on page 1-19 for details.

Values

Default Min/Max: Display:

20.0 Secs 0.0/600.0 Secs 0.1 Secs

P035 [Maximum Freq]

De

ratio

cele

ele

Speed

ratio

Acc

0 0

P039 or A067 [Accel Time x]

Time

P040 or A068 [Decel Time x]

A068 [Decel Time 2]

Maximum Freq = Decel Rate Decel Time

Related Parameter(s): P040

When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart on page 1-19 for details.

Values

Default Min/Max: Display:

20.0 Secs 0.1/600.0 Secs 0.1 Secs

P035 [Maximum Freq]

De

ratio

cele

ele

Speed

ratio

Acc

0 0

P039 or A067 [Accel Time x]

Time

P040 or A068 [Decel Time x]

3-16

Programming and Parameters

Advanced Program Group (continued)

A069 [Internal Freq]
Related Parameter(s): P038 Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 Internal Freq. When enabled, this parameter will change the frequency command in real time using the integral keypad Up Arrow or Down Arrow when in program mode. Important: Once the desired command frequency is reached, the Enter key must be pressed to store this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return to the original value following the normal accel/decel curve. Values Default Min/Max: Display: 60.0 Hz 0.0/240.0 Hz 0.1 Hz Related Parameter(s): P038, P039, P040, A051, A052, A067, A068

A070 [Preset Freq 0](1) A071 [Preset Freq 1] A072 [Preset Freq 2] A073 [Preset Freq 3]
Values A070 Default A071 Default A072 Default A073 Default Min/Max: Display:

0.0 Hz 5.0 Hz 10.0 Hz 20.0 Hz 0.0/240.0 Hz 0.1 Hz

Provides a fixed frequency command value when A051 - A052 [Digital Inx Sel] is set to 4 Preset Frequencies. An active preset input will override speed command as shown in the flowchart on page 1-19.
(1)

To activate A070 [Preset Freq 0] set P038 [Speed Reference] to option 4 Preset Freq 0-3.
Input State of Digital In 2 (I/O Terminal 06) 0 0 1 1

Input State of Digital In 1 (I/O Terminal 05) 0 1 0 1

(2)

Frequency Source A070 [Preset Freq 0] A071 [Preset Freq 1] A072 [Preset Freq 2] A073 [Preset Freq 3]

Accel / Decel Parameter Used(2) [Accel Time 1] / [Decel Time 1] [Accel Time 1] / [Decel Time 1] [Accel Time 2] / [Decel Time 2] [Accel Time 2] / [Decel Time 2]

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]

Values Default Min/Max: Display: 10.0 Hz

Related Parameter(s): P035, A051, A052, A079

Sets the output frequency when a jog command is issued. 0.0/P035 [Maximum Freq] 0.1 Hz

Programming and Parameters

3-17

Advanced Program Group (continued)

A079 [Jog Accel/Decel]
Values Default Min/Max: Display: 10.0 Secs 0.1/600.0 Secs 0.1 Secs Related Parameter(s): A051, A052, A078 Sets the acceleration and deceleration time when a jog command is issued.

A080 [DC Brake Time]

Values Default Min/Max: Display: 0.0 Secs 0.0/90.0 Secs 0.1 Secs

Related Parameter(s): P037, A081

Sets the length of time that DC brake current is injected into the motor. Refer to parameter A081 [DC Brake Level].

A081 [DC Brake Level]

Values Default Min/Max: Display:
Ramp-to-Stop Mode

Related Parameter(s): P037, A080

Defines the maximum DC brake current, in amps, applied to the motor when P037 [Stop Mode] is set to either Ramp or DC Brake. Drive Rated Amps 0.05 0.0/(Drive Rated Amps 1.8) 0.1 Amps
DC Injection Braking Mode Voltage Volts/Speed
Vo

lta

Volts/Speed

Spe

ge

ed

[DC Brake Time] [DC Brake Level]

Speed

[DC Brake Time] [DC Brake Level] Time

Stop Command

Time

Stop Command

! !

ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used. ATTENTION: This feature should not be used with synchronous or permanent magnet motors. Motors may be demagnetized during braking.

3-18

Programming and Parameters

Advanced Program Group (continued)

A082 [DB Resistor Sel]
Stop drive before changing this parameter. Enables/disables external dynamic braking.
Setting 0 1 2 3-99 Min/Max Disabled Normal RA Res (5% Duty Cycle) - Refer to Table B.C on page B-2 No Protection (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 RA resistor is used (see selection Table B.C), the drive provides calculated resistor overload protection. However, the drive cannot protect against a brake IGBT failure. ATTENTION: A risk of fire exists if external braking resistors are not protected. The external resistor package must be self-protected from over temperature or the protective circuit shown in Figure B.7 on page B-9, 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: Display: Example: Accel Time = 10 Seconds S Curve Setting = 50% S Curve Time = 10 0.5 = 5 Seconds Total Time = 10 + 5 = 15 Seconds 0% (Disabled) 0/100% 1%
50% S Curve Target

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

Programming and Parameters

3-19

Advanced Program Group (continued)

A084 [Boost Select]
(1)

Related Parameter(s): d004, P031, P032

Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.(1) Drive may add additional voltage unless option 5 is selected. 2 35.0, VT 3 40.0, VT 4 45.0, VT 5 0.0 no IR 6 0.0 7 2.5, CT [Default for 3.7kW (5HP) Drives] 8 5.0, CT (Default) 9 7.5, CT 10 10.0, CT 11 12.5, CT 12 15.0, CT 13 17.5, CT 14 20.0, CT
100

Options 1 30.0, VT Variable Torque

Constant Torque

% P031 [Motor NP Volts]

50

1/2 [Motor NP Volts] 4 3 2 1

Settings 5-14 0

50 % P032 [Motor NP Hertz]

1/2 [Motor NP Hertz]

100

A088 [Maximum Voltage]

Sets the highest voltage the drive will output. Values Default Min/Max: Display: Drive Rated Volts 20/Drive Rated Volts 1 VAC

3-20

Programming and Parameters

Advanced Program Group (continued)

A089 [Current Limit]
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]

Options 0 No Derate (Default) 1 Min Derate 2 Max Derate
100 80 60 40 20 0 0 25 50 75 100 125 150 175 200 100 80 60 40 20 0 0 25 50 75 100 125 150 175 200 % of P033 [Motor OL Curent]
No Derate Min Derate

Related Parameter(s): P032

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I2t overload function.

100 80 60 40 20 0 0

Max Derate

25 50 75 100 125 150 175 200

A091 [PWM Frequency]

Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting. Important: Ignoring derating guidelines can cause reduced drive performance. Values Default Min/Max: Display:
100 96 92 88 84 80 76 72 68 64 60 56 52

4.0 kHz 2.0/16.0 kHz 0.1 kHz

10 11 12 13 14 15 16

Programming and Parameters

3-21

Advanced Program Group (continued)

A092 [Auto Rstrt Tries]
Sets the maximum number of times the drive attempts to reset a fault and restart. Clear a Type 1 fault and restart the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than 0. 2. Set A093 [Auto Rstrt Delay] to a value other than 0. Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than 0. 2. Set A093 [Auto Rstrt Delay] to 0. 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

!
Values

A093 [Auto Rstrt Delay]

Values Default Min/Max: Display: 1.0 Secs 0.0/300.0 Secs 0.1 Secs

Related Parameter(s): A092

Sets the time between restart attempts when A092 [Auto Rstrt Tries] is set to a value other than zero.

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 Disabled (Default) 1 Enabled

3-22

Programming and Parameters

Advanced Program Group (continued)

A095 [Reverse Disable]
Stop drive before changing this parameter. Enables/disables the function that allows the direction of motor rotation to be changed. The reverse command may come from a digital command, the keypad or a serial command. All reverse inputs including two-wire Run Reverse will be ignored with reverse disabled. Options 0 Rev Enabled (Default) 1 Rev Disabled Related Parameter(s): d006

A096 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM. Options 0 Disabled (Default) 1 Enabled

A097 [Compensation]
Enables/disables correction options that may improve problems with motor instability. Options 0 Disabled 1 Electrical (Default) 2 Mechanical Some drive/motor combinations have inherent instabilities which are exhibited as non-sinusodial motor currents. This setting attempts to correct this condition. Some motor/load combinations have mechanical resonances which can be excited by the drive current regulator. This setting slows down the current regulator response and attempts to correct this condition.

3 Both

A098 [SW Current Trip]

Enables/disables a software instantaneous (within 100 ms) current trip. Values Default Min/Max: Display: 0.0 (Disabled) 0.0/(Drive Rated Amps 2) 0.1 Amps

Related Parameter(s): P033

A099 [Process Factor]

Scales the value displayed by d010 [Process Display].
Output Process Process Freq x Factor = Display

Related Parameter(s): d010

Values

Default Min/Max: Display:

30.0 0.1/999.9 0.1

Programming and Parameters

3-23

Advanced Program Group (continued)

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 Reset Fault 2 Clear Buffer (Parameters d007-d009 [Fault x Code])

A101 [Program Lock]

Protects parameters against change by unauthorized personnel. Options 0 Unlocked (Default) 1 Locked

A102 [Testpoint Sel]

Used by Rockwell Automation field service personnel. Values Default Min/Max: Display: 400 0/FFFF 1 Hex

A103 [Comm Data Rate]

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

Related Parameter(s): d015

Important: Power to drive must be cycled before any changes will affect drive operation. Options 0 1200 1 2400 2 4800 3 9600 (Default) 4 19.2K 5 38.4K

A104 [Comm Node Addr]

Related Parameter(s): d015

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 Min/Max: Display: 100 1/247 1

3-24

Programming and Parameters

Advanced Program Group (continued)

A105 [Comm Loss Action]
Options 0 Fault (Default) 1 Coast to Stop 2 Stop 3 Continu Last Related Parameter(s): d015, P037, A106 Selects the drives response to a loss of the communication connection or excessive communication errors. Drive will fault on an F81 Comm Loss and coast to stop. Stops drive via coast to stop. Stops drive via P037 [Stop Mode] setting. Drive continues operating at communication commanded speed saved in RAM.

A106 [Comm Loss Time]

Values Default Min/Max: Display: 5.0 Secs 0.1/60.0 Secs 0.1 Secs

Related Parameter(s): d015, A105

Sets the time that the drive will remain in communication loss before implementing the option selected in A105 [Comm Loss Action].

A107 [Comm Format]

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) 1 RTU 8-E-1 2 RTU 8-O-1 3 RTU 8-N-2 4 RTU 8-E-2 5 RTU 8-O-2

Programming and Parameters

3-25

A110 [Anlg In 0-10V Lo]

Related Parameter(s): d020, P034, P038, A051, A052

Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038 [Speed Reference]. Analog inversion can be accomplished by setting this value larger than A111 [Anlg In 0-10V Hi] or by setting A051 - A052 [Digital Inx Sel] to option 26 Anlg Invert Values Default Min/Max: Display:
P035 [Maximum Freq]
en ce

0.0% 0.0/100.0% 0.1%

Sp

ee

e dR

fer

P034 [Minimum Freq] 0 0 A110 [Anlg In 0-10V Lo] A111 [Anlg In 0-10V Hi]

A111 [Anlg In 0-10V Hi]

Related Parameter(s): d020, P035, P038, A051, A052

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 0-10V In Lo] or by setting A051 - A052 [Digital Inx Sel] to option 26 Anlg Invert. Values Default Min/Max: Display: 100.0% 0.0/100.0% 0.1% Related Parameter(s): d021, P034, P038, A051, A052

A112 [Anlg In4-20mA Lo]

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] or by setting A051 - A052 [Digital Inx Sel] to option 26 Anlg Invert. Values Default Min/Max: Display: 0.0% 0.0/100.0% 0.1% Related Parameter(s): d021, P035, P038, A051, A052

A113 [Anlg In4-20mA Hi]

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] or by setting A051 - A052 [Digital Inx Sel] to option 26 Anlg Invert. Values Default Min/Max: Display: 100.0% 0.0/100.0% 0.1%

3-26

Programming and Parameters

A114 [Slip Hertz @ FLA]

Values Default Min/Max: Display: 2.0 Hz 0.0/10.0 Hz 0.1 Hz

Related Parameter(s): P033

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

A115 [Process Time Lo]

Values Default Min/Max: Display: 0.00 0.00/99.99 0.01

Related Parameter(s): d010, P034

Scales the time value when the drive is running at P034 [Minimum Freq]. When set to a value other than zero, d010 [Process Display] indicates the duration of the process.

A116 [Process Time Hi]

Values Default Min/Max: Display: 0.00 0.00/99.99 0.01

Related Parameter(s): d010, P035

Scales the time value when the drive is running at P035 [Maximum Freq]. When set to a value other than zero, d010 [Process Display] indicates the duration of the process.

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 [Comm Write Mode]

Determines whether parameter changes made over communication port are saved and stored in Non-Volatile Storage (NVS) or RAM only. If they are stored in RAM, the values will be lost at power-down. Options 0 1 Save (Default) RAM nly O

ATTENTION: Risk of equipment damage exists. If a controller is programmed to write parameter data to Non-Volatile Storage (NVS) frequently, the NVS will quickly exceed its life cycle and cause the drive to malfunction. Do not create a program that frequently uses configurable outputs to write parameter data to NVS unless A164 [Comm Write Mode] is set to option 1.

Programming and Parameters

3-27

Parameter Cross Reference by Name

Parameter Name
Accel Time 1 Accel Time 2 Analog In 0-10V Analog In 4-20mA Anlg In 0-10V Hi Anlg In 0-10V Lo Anlg In4-20mA Hi Anlg In4-20mA Lo Auto Rstrt Delay Auto Rstrt Tries Boost Select Bus Reg Mode Comm Data Rate Comm Format Comm Loss Action Comm Loss Time Comm Node Addr Comm Status Comm Write Mode Commanded Freq Compensation Contrl In Status Control Source Control SW Ver Current Limit DB Resistor Sel DC Brake Level DC Brake Time DC Bus Voltage Decel Time 1 Decel Time 2 Dig In Status Digital Inx Sel Drive Status Drive Temp Drive Type Elapsed Run Time

No.
P039 A067 d020 d021 A111 A110 A113 A112 A093 A092 A084 A117 A103 A107 A105 A106 A104 d015 A118 d002 A097 d013 d012 d016 A089 A082 A081 A080 d005 P040 A068 d014 A051, A052 d006 d024 d017 d018

Group
Basic Program Advanced Program Display Display Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Display Advanced Program Display Advanced Program Display Display Display Advanced Program Advanced Program Advanced Program Advanced Program Display Basic Program Advanced Program Display Advanced Program Display Display Display Display

Parameter Name
Fault x Code Fault Clear Flying Start En Internal Freq Jog Accel/Decel Jog Frequency Maximum Freq Maximum Voltage Minimum Freq Motor NP Hertz Motor NP Volts Motor OL Current Motor OL Ret Motor OL Select Output Current Output Freq Output Voltage Preset Freq x Process Display Process Factor Process Time Hi Process Time Lo Program Lock PWM Frequency Relay Out Level Relay Out Sel Reset To Defalts Reverse Disable S Curve % Slip Compensation Speed Reference Start At PowerUp Start Source Stop Mode SW Current Trip Testpoint Data Testpoint Sel

No.
d007-d009 A100 A096 A069 A079 A078 P035 A088 P034 P032 P031 P033 P043 A090 d003 d001 d004 A070-A073 d010 A099 A116 A115 A101 A091 A056 A055 P041 A095 A083 A114 P038 A094 P036 P037 A098 d019 A102

Group
Display Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Basic Program Advanced Program Basic Program Basic Program Basic Program Basic Program Basic Program Advanced Program Display Display Display Advanced Program Display Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Advanced Program Basic Program Advanced Program Advanced Program Advanced Program Basic Program Advanced Program Basic Program Basic Program Advanced Program Display Advanced Program

3-28

Programming and Parameters

Notes:

Chapter 4

Troubleshooting
Chapter 4 provides information to guide you in troubleshooting the PowerFlex 4 drive. Included is a listing and description of drive faults (with possible solutions, when applicable).
For information on Drive Status Faults See page For information on 4-1 Fault Descriptions 4-1 Common Symptoms and Corrective Actions See page 4-3 4-5

Drive Status
The condition or state of your drive is constantly monitored. Any changes will be indicated through the integral keypad.

LED Indications
See page 2-3 for information on drive status indicators and controls.

Faults
A fault is a condition that stops the drive. There are two fault types.
Type Fault Description Auto-Reset/Run When this type of fault occurs, and A092 [Auto Rstrt Tries] is set to a value greater than 0, a user-configurable timer, A093 [Auto Rstrt Delay], begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. Non-Resetable This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared.

4-2

Troubleshooting

Fault Indication
Condition Display Drive is indicating a fault. The integral keypad provides visual notification of a fault condition by displaying the following. Flashing fault number Flashing fault indicator Press the Escape key to regain control of the integral keypad.
RUN FWD REV PRGOGRAM FAULT VOLTS AMPS HERTZ

Manually Clearing Faults

Step Key(s) 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the integral keypad. Access d007 [Fault 1 Code] to view the most recent fault information. 2. Address the condition that caused the fault. The cause must be corrected before the fault can be cleared. See Table 4.A. 3. After corrective action has been taken, clear the fault by one of these methods. Press Stop if P037 [Stop Mode] is set to a value between 0 and 3. Cycle drive power. Set A100 [Fault Clear] to 1 or 2. Cycle digital input if A051 - A052 [Digital Inx Select] is set to option 7 Clear Fault.

Automatically Clearing Faults

Option / Step Clear a Type 1 fault and restart the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than 0. 2. Set A093 [Auto Rstrt Delay] to a value other than 0. Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than 0. 2. Set A093 [Auto Rstrt Delay] to 0.

Auto Restart (Reset/Run)

The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or unattended operation. Only certain faults are allowed to be reset. Certain faults (Type 2) that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming.

Troubleshooting

4-3

Fault Descriptions
Table 4.A Fault Types, Descriptions and Actions Type(1)

No. F2

Fault Auxiliary Input

Description Auxiliary input interlock is open.

F3

Power Loss

F4 F5

UnderVoltage OverVoltage

F6

Motor Stalled

F7

Motor Overload

F8

Heatsink OvrTmp

F12

HW OverCurrent

F13

Ground Fault

Action 1. Check remote wiring. 2. Verify communications programming for intentional fault. DC bus voltage remained below 1. Monitor the incoming AC line for 85% of nominal. low voltage or line power interruption. 2. Check input fuses. DC bus voltage fell below the Monitor the incoming AC line for low minimum value. voltage or line power interruption. DC bus voltage exceeded Monitor the AC line for high line maximum value. voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. Drive is unable to accelerate Increase P039 - A067 [Accel Time x] motor. or reduce load so drive output current does not exceed the current set by parameter A089 [Current Limit]. Internal electronic overload trip. 1. An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current]. 2. Verify A084 [Boost Select] setting Heatsink temperature exceeds a 1. Check for blocked or dirty heat predefined value. sink fins. Verify that ambient temperature has not exceeded 40C (104F) for IP 30/NEMA 1/UL Type 1 installations or 50C (122F) for IP20/Open type installations. 2. Check fan. The drive output current has Check programming. Check for exceeded the hardware current excess load, improper A084 [Boost Select] setting, DC brake volts set limit. too high or other causes of excess current. A current path to earth ground Check the motor and external wiring has been detected at one or to the drive output terminals for a more of the drive output grounded condition. terminals.

(1)

See page 4-1 for a description of fault types.

4-4

Troubleshooting
Type(1)

No. F33

Fault Auto Rstrt Tries

F38 F39 F40

Phase U to Gnd Phase V to Gnd Phase W to Gnd

F41 F42 F43 F48

Phase UV Short Phase UW Short Phase VW Short Params Defaulted

F63 F64 F70

SW OverCurrent Drive Overload Power Unit

F71

Net Loss

F81

Comm Loss

F100 Parameter Checksum F122 I/O Board Fail

1. Check the wiring between the drive and motor. 2. Check motor for grounded phase. 3. Replace drive if fault cannot be cleared. Excessive current has been 1. Check the motor and drive output detected between these two terminal wiring for a shorted output terminals. condition. 2. Replace drive if fault cannot be cleared. The drive was commanded to 1. Clear the fault or cycle power to write default values to EEPROM. the drive. 2. Program the drive parameters as needed. Programmed A098 [SW Current Check load requirements and A098 Trip] has been exceeded. [SW Current Trip] setting. Drive rating of 150% for 1 minute Reduce load or extend Accel Time. or 200% for 3 seconds has been exceeded. Failure has been detected in the 1. Cycle power. drive power section. 2. Replace drive if fault cannot be cleared. The communication network has 1. Cycle power. faulted. 2. Check communications cabling. 3. Check network adapter setting. 4. Check external network status. RS485 (DSI) port stopped 1. If adapter was not intentionally communicating. disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required. 2. Check connection. 3. An adapter was intentionally disconnected. 4. Turn off using A105 [Comm Loss Action]. The checksum read from the Set P041 [Reset To Defalts] to board does not match the option 1 Reset Defaults. checksum calculated. Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared.

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)

See page 4-1 for a description of fault types.

Troubleshooting

4-5

Common Symptoms and Corrective Actions

Motor does not Start.
Cause(s) No output voltage to the motor. Indication None Corrective Action Check the power circuit. Check the supply voltage. Check all fuses and disconnects. Check the motor. Verify that the motor is connected properly. Check the control input signals. Verify that a Start signal is present. If 2-Wire control is used, verify that either the Run Forward or Run Reverse signal is active, but not both. Verify that I/O Terminal 01 is active. Verify that P036 [Start Source] matches your configuration. Verify that A095 [Reverse Disable] is not prohibiting movement. Set A084 [Boost Select] to option 2 35.0, VT.

Improper boost setting at initial start-up.

None

Drive does not Start from Integral Keypad.

Cause(s) Indication Corrective Action Integral keypad is not enabled. Green LED above Start key is Set parameter P036 [Start Source] to option 0 Keypad. not illuminated. Set parameter A051 - A052 [Digital Inx Select] to option 5 Local and activate the input. I/O Terminal 01 Stop input is None Wire inputs correctly and/or install not present. jumper.

4-6

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

Cause(s) Drive is Faulted

Indication Flashing red status light

None Incorrect programming. P036 [Start Source] is set to option 0 Keypad or option 5 RS485 (DSI) Port. A051 - A052 [Digital Inx Select] is set to option 5 Local and the input is active. None Incorrect input wiring. See 1-14 for wiring examples. 2 wire control requires Run Forward, Run Reverse or Jog input. 3 wire control requires Start and Stop inputs Stop input is always required. Incorrect Sink/Source DIP switch None setting.

Corrective Action Clear fault. Press Stop Cycle power Set A100 [Fault Clear] to option 1 Clear Faults. Cycle digital input if A051 - A052 [Digital Inx Select] is set to option 7 Clear Fault. Check parameter settings.

Wire inputs correctly and/or install jumper.

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. Indication The drive Run indicator is lit and output is 0 Hz. Corrective Action Check d012 d012 [Control Source] for correct source. If the source is an analog input, check wiring and use a meter to check for presence of signal. Check d002 [Commanded Freq] to verify correct command. Check d012 [Control Source] for correct source. Check d014 [Dig In Status] to see if inputs are selecting an alternate source. Verify settings for A051 - A052 [Digital Inx Select]. Check P038 [Speed Reference] for the source of the speed reference. Reprogram as necessary. Review the Speed Reference Control chart on page 1-18.

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

None

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

Cause(s) Indication Acceleration time is excessive. None Excess load or short None acceleration times force the drive into current limit, slowing or stopping acceleration.

4-7

Speed command source or value is not as expected.

None

Programming is preventing the None drive output from exceeding limiting values.

Corrective Action Reprogram P039 [Accel Time 1] or A067 [Accel Time 2]. Compare d003 [Output Current] with A089 [Current Limit]. Remove excess load or reprogram P039 [Accel Time 1] or A067 [Accel Time 2]. Check for improper A084 [Boost Select] setting. Verify d002 [Commanded Freq]. Check d012 [Control Source] for the proper Speed Command. Check P035 [Maximum Freq] to insure that speed is not limited by programming.

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) Indication Digital input is not selected for None reversing control. Digital input is incorrectly wired. Motor wiring is improperly phased for reverse. Reverse is disabled. None None None Corrective Action Check [Digital Inx Sel] (See page 3-13). Choose correct input and program for reversing mode. Check input wiring. (See page 1-13) Switch two motor leads. Check A095 [Reverse Disable].

4-8

Troubleshooting

Notes:

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
Drive Ratings Input Ratings Branch Circuit Protection Voltage 140M Motor kW (HP) Amps Range kVA Amps Fuses Protectors(2) 100 - 120V AC (10%) 1-Phase Input, 0 - 230V 3-Phase Output Catalog Number
22A-V1P5N104 22A-V2P3N104 22A-V4P5N104 22A-V6P0N104 22A-A1P4N103 22A-A2P1N103 22A-A3P6N103 22A-A6P8N103 22A-A9P6N103 22A-A1P5N104 22A-A2P3N104 22A-A4P5N104 22A-A8P0N104 22A-B1P5N104 22A-B2P3N104 22A-B4P5N104 22A-B8P0N104 22A-B012N104 22A-B017N104 22A-D1P4N104 22A-D2P3N104 22A-D4P0N104 22A-D6P0N104 22A-D8P7N104 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 1.5 2.3 4.5 6.0 90-126 90-126 90-126 90-126 0.75 1.15 2.25 3.0 6.0 9.0 18.0 24.0 10 15 30 40 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-D8E-C25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C16 140M-C2E-C16 140M-D8E-C25 140M-C2E-B63 140M-C2E-B63 140M-C2E-C16 140M-D8E-C20 140M-C2E-B25 140M-C2E-B40 140M-C2E-C10 140M-C2E-C16 140M-C2E-C16 140M-F8E-C25 140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C10 140M-C2E-C16

Output Ratings

Contactors
100-C09 100-C12 100-C23 100-C37 100-C09 100-C09 100-C12 100-C16 100-C23 100-C09 100-C09 100-C12 100-C23 100-C09 100-C09 100-C09 100-C12 100-C16 100-C23 100-C09 100-C09 100-C09 100-C09 100-C16

200 - 240V AC (10%) 1-Phase(1) Input, 0 - 230V 3-Phase Output, NO BRAKE

0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 1.4 2.1 3.6 6.8 9.6 180-265 180-265 180-265 180-265 180-265 0.7 1.05 1.8 3.4 4.8 3.2 5.3 9.2 14.2 19.6 6 10 15 25 30

200 - 240V AC (10%) 1-Phase(1) Input, 0 - 230V 3-Phase Output

0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 1.5 2.3 4.5 8.0 1.5 2.3 4.5 8.0 12.0 17.5 1.4 2.3 4.0 6.0 8.7 180-265 180-265 180-265 180-265 180-265 180-265 180-265 180-265 180-265 180-265 340-528 340-528 340-528 340-528 340-528 0.75 1.15 2.25 4.0 0.75 1.15 2.25 4.0 5.5 8.6 1.4 2.3 4.0 5.9 8.6 5.0 6.0 10.0 18.0 1.8 2.5 5.2 9.5 15.5 21.0 1.8 3.2 5.7 7.5 9.0 10 10 15 30 3 6 10 15 25 30 3 6 10 15 15

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

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

Input/Output Ratings
Output Frequency: 0-240 Hz (Programmable) Efficiency: 97.5% (Typical)

Approvals
C

UL

UL508C CSA 22.2 US No. 14

EMC Directive 89/336/EEC, LV Dir. 73/23/EEC L V: EN 50178 EMC: EN 61800-3

Digital Control Inputs (Input Current = 6mA)

SRC (Source) Mode: 18-24V = ON 0-6V = OFF SNK (Sink) Mode: 0-6V = ON 18-24V = OFF

Analog Control Inputs

4-20mA Analog: 250 ohm input impedance 0-10V DC Analog: 100k ohm input impedance External Pot: 1-10k ohms, 2 Watt minimum Inductive Rating: 0.5A at 30V DC, 125V AC, and 240V AC

Control Output (Programmable Output, form C relay)

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

Recommended Fuses and Circuit Breakers

Fuse: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. Circuit Breakers: HMCP or Bulletin 140U or equivalent. Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection) Overcurrent: 200% hardware limit, 300% instantaneous fault Over Voltage: 100-120V AC Input Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line) 200-240V AC Input Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line) 380-460V AC Input Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line) Under Voltage: 100-120V AC Input Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line) 200-240V AC Input Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line) 380-480V AC Input Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line) Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs Faultless Power Ride Through: 100 milliseconds

Protective Features

Dynamic Braking
Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 4 User Manual on CD for ordering information.
(1) (2)

200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N103 to N113 and N104 to N114. Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001 to determine the frame and breaking capacity required for your application.

Supplemental Drive Information

A-3

Category Environment

Specification Altitude: Maximum Surrounding Air Temperature without derating: IP20: NEMA 1: Flange Mount: Cooling Method Convection: Fan: Storage Temperature: Atmosphere:

1000 m (3300 ft) max. without derating

10 to 50 C (14 to 122 F) 10 to 40 C (14 to 104 F) Heatsink: 10 to 40 C (14 to 104 F) Drive: 10 to 50 C (14 to 122 F) 0.2 kW (0.25 HP) drives Flange Mount drives, all ratings All other drive ratings. 40 to 85 degrees C (40 to 185 degrees F) Important: Drive must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors or dust. If the drive is not going to be installed for a period of time, it must be stored in an area where it will not be exposed to a corrosive atmosphere. 0 to 95% non-condensing 15G peak for 11ms duration (1.0ms) 1G peak, 5 to 2000 Hz 2-16 kHz. Drive rating based on 4 kHz. Within 0.05% of set output frequency. Within 0.5% of maximum output frequency. 2% of base speed across a 40:1 speed range. Multiple programmable stop modes including Ramp, Coast, DC-Brake, Ramp-to-Hold and S Curve. Two independently programmable accel and decel times. Each time may be programmed from 0 - 600 seconds in 0.1 second increments. 150% Overload capability for up to 1 minute 200% Overload capability for up to 3 seconds Class 10 protection with speed sensitive response and power-down overload retention function.

Control

Relative Humidity: Shock (operating): Vibration (operating): Carrier Frequency Frequency Accuracy Digital Input: Analog Input: Speed Regulation - Open Loop with Slip Compensation: Stop Modes: Accel/Decel: Intermittent Overload: Electronic Motor Overload Protection

A-4

Supplemental Drive Information

PowerFlex 4 Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage 100120V kW (HP) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 0.2 (0.25) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) External Watts 16 22 35 58 16 22 35 63 100 150 17 30 48 75 125 Internal Watts 16 18 20 22 16 18 20 22 25 30 18 20 22 25 25 Total Watts Loss 32 40 55 80 32 40 55 85 125 180 35 50 70 100 150

200240V

380480V

Appendix B

Accessories and Dimensions

For information on Product Selection Product Dimensions See page B-1 B-5

Product Selection
Table B.A Catalog Number Description

22A Drive
Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase No Filter

A
Voltage Rating

1P5
Rating

N
Enclosure

1
HIM

1
Emission Class

4
Type

Table B.B PowerFlex 4 Drives

Catalog Number HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 3.0 5.0 0.5 1.0 2.0 3.0 5.0 Output Current 1.5A 2.3A 4.5A 6.0A 1.4A 2.1A 3.6A 6.8A 9.6A 1.4A 2.1A 3.6A 6.8A 9.6A 1.5A 2.3A 4.5A 8.0A 1.5A 2.3A 4.5A 8.0A 1.5A 2.3A 4.5A 8.0A 12.0A 17.5 1.4A 2.3A 4.0A 6.0A 8.7A Panel Mount Flange Mount (1) 22A-V1P5N104 22A-V1P5F104 22A-V2P3N104 22A-V2P3F104 22A-V4P5N104 22A-V4P5F104 22A-V6P0N104 22A-V6P0F104 22A-A1P4N113 22A-A2P1N113 22A-A3P6N113 22A-A6P8N113 22A-A9P6N113 22A-A1P4N103 22A-A1P4F103 22A-A2P1N103 22A-A2P1F103 22A-A3P6N103 22A-A3P6F103 22A-A6P8N103 22A-A6P8F103 22A-A9P6N103 22A-A9P6F103 22A-A1P5N114 22A-A2P3N114 22A-A4P5N114 22A-A8P0N114 22A-A1P5N104 22A-A1P5F104 22A-A2P3N104 22A-A2P3F 104 22A-A4P5N104 22A-A4P5F104 22A-A8P0N104 22A-A8P0F104 22A-B1P5N104 22A-B1P5F104 22A-B2P3N104 22A-B2P3F104 22A-B4P5N104 22A-B4P5F104 22A-B8P0N104 22A-B8P0F104 22A-B012N104 22A-B012F104 22A-B017N104 22A-B017F104 22A-D1P4N104 22A-D1P4F104 22A-D2P3N104 22A-D2P3F104 22A-D4P0N104 22A-D4P0F104 22A-D6P0N104 22A-D6P0F104 22A-D8P7N104 22A-D8P7F104 Frame Size A A B B A A A B B A A A B B A A A B A A A B A A A A B B A A A B B kW 0.2 0.4 0.75 1.1 240V 50/60 Hz 0.2 1-Phase 0.4 NO BRAKE 0.75 With Integral S Type 1.5 EMC Filter 2.2 240V 50/60 Hz 0.2 1-Phase 0.4 NO BRAKE 0.75 No Filter 1.5 2.2 240V 50/60 Hz 0.2 1-Phase 0.4 With Integral S Type 0.75 EMC Filter 1.5 240V 50/60 Hz 0.2 1-Phase 0.4 No Filter 0.75 1.5 240V 50/60 Hz 0.2 3-Phase 0.4 No Filter 0.75 1.5 2.2 3.7 480V 50/60 Hz 0.4 3-Phase 0.75 No Filter 1.5 2.2 3.7

(1)

Replacement Plate drives are also available. Contact factory for ordering information.

B-2

Accessories and Dimensions

Table B.C Dynamic Brake Modules
Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase kW 0.2 0.4 0.75 1.1 240V 50/60 Hz 1-Phase 0.2 0.4 0.75 1.5 240V 50/60 Hz 3-Phase 0.2 0.4 0.75 1.5 2.2 3.7 480V 50/60 Hz 3-Phase 0.4 0.75 1.5 2.2 3.7
(1) (2)

HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 3.0 5.0 0.5 1.0 2.0 3.0 5.0

Minimum Resistance 60 60 60 60 60 60 60 60 60 60 60 60 48 32 121 121 121 97 97

Catalog Number (1) (2) AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-047P500 AK-R2-091P500 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2

The resistors listed in this table 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 varity of applications. Alternative resistors may be used, however care must be taken when making a selection. Refer to the PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001.

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

Input Voltage kW HP 0.5 2.0 3.0 5.0 Maximum Fundamental Continuous Watts Amps Amps Inductance Loss 3 6 12 12 18 27 3 6 6 12 27 12.0 mh 12.0 mh 3.0 mh 1.5 mh 1.25 mh 0.8 mh 20.0 mh 9.0 mh 6.5 mh 5.0 mh 3.0 mh 7.5 W 21 W 29 W 19.5 W 26 W 36 W 11.3 W 20 W 20 W 25.3 W 29 W 4 8 8 12 18 2 4 4 8 18 Catalog Number (1) 1321-3R2-A 1321-3R4-D 1321-3R8-B 1321-3R8-A 1321-3R12-A 1321-3R18-A 1321-3R2-B 1321-3R4-C 1321-3R4-B 1321-3R8-C 1321-3R-12-B

240V 50/60 Hz 0.2 3-Phase 0.4 1.5 2.2 3.7

0.25 2

0.75 1.0

480V 50/60 Hz 0.4 0.5 3-Phase 0.75 1.0 1.5 2.2 3.7
(1)

2.0 3.0 5.0

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.

Accessories and Dimensions

Table B.E EMC Line Filters
Drive Ratings Input Voltage 120V 50/60 Hz 1-Phase kW 0.2 0.4 0.75 1.1 0.2 0.4 0.75 1.5 0.2 0.4 0.75 1.5 2.2 0.2 0.4 0.75 1.5 2.2 3.7 0.4 0.75 1.5 2.2 3.7 HP 0.25 0.5 1.0 1.5 0.25 0.5 1.0 2.0 0.25 0.5 1.0 2.0 3.0 0.25 0.5 1.0 2.0 3.0 5.0 0.5 1.0 2.0 3.0 5.0 S Type Filter Catalog Number (1)
(2) (2) (2) (2) (2) (2) (2) (2) (2)

B-3

240V 50/60 Hz 1-Phase

240V 50/60 Hz 1-Phase NO BRAKE

240V 50/60 Hz 3-Phase

480V 50/60 Hz 3-Phase

22-RF9P5-AS 22-RF9P5-AS 22-RF9P5-AS 22-RF9P5-AS 22-RF021-BS 22-RF021-BS 22-RF5P7-AS 22-RF5P7-AS 22-RF5P7-AS 22-RF012-BS 22-RF012-BS

L Type Filter Catalog Number (3) 22-RF010-AL 22-RF010-AL 22-RF018-BL 22-RF025-CL (4) 22-RF010-AL 22-RF010-AL 22-RF010-AL 22-RF018-BL 22-RF010-AL 22-RF010-AL 22-RF010-AL 22-RF018-BL 22-RF025-CL (4) 22-RF9P5-AL 22-RF9P5-AL 22-RF9P5-AL 22-RF9P5-AL 22-RF021-BL 22-RF021-BL 22-RF5P7-AL 22-RF5P7-AL 22-RF5P7-AL 22-RF012-BL 22-RF012-BL

(1) (2) (3) (4)

This filter is suitable for use with a cable length up to 10 meters (33 feet) for Class A and 1 meter for Class B environments. These ratings can be ordered with internal S Type filters. Refer to the Catalog Number explanation on page P-4 and Table B.B for details. This filter is suitable for use with a cable length up to 100 meters for Class A and 5 meters for Class B environments. The piggyback mounting option cannot be used with Frame B PowerFlex 4 drives and Frame C EMC Line Filters.

Table B.F Human Interface Module (HIM) Option Kits and Accessories
Item LCD Display, Remote Panel Mount Description Digital speed control CopyCat capable IP66 (NEMA Type 4X/12) indoor use only 22-HIM-C2 includes 2.9 meter cable. 22-HIM-C2S includes 2 meter cable. Catalog Number 22-HIM-C2 22-HIM-C2S (1)

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 DSI HIM Cable (DSI HIM to RJ45 cable)
(1)

22-HIM-A3

Panel mount for LCD Display, Remote Handheld unit, IP30 (NEMA Type 1) 1.0 Meter (3.3 Feet) 2.9 Meter (9.51 Feet)

22-HIM-B1 22-HIM-H10 22-HIM-H30

The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement.

B-4

Accessories and Dimensions

Table B.G Communication Option Kits
Item External DSI Communications Kit External Comms Power Supply Compact I/O Module Description External mounting kit for 22-COMM-C, -D, -E, -P. Catalog Number (2) 22-XCOMM-DC-BASE

Optional 100-240V AC Power Supply for External 20-XCOMM-AC-PS1 DSI Communications Kit. Three channel. 1769-SM2 22-SCM-232

Serial Converter Module Provides serial communication via DF1 protocol (RS485 to RS232) for use with DriveExplorer and DriveExecutive software. Includes: DSI to RS232 serial converter (1) 1203-SFC serial cable (1) 22-RJ45CBL-C20 cable (1) DriveExplorer Lite CD (1) DSI Cable Serial Cable 2.0 meter RJ45 to RJ45 cable, male to male connectors.

22-RJ45CBL-C20

2.0 meter serial cable with a locking low profile 1203-SFC 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. RJ45 one to two port splitter cable RJ45 120 Ohm resistors (2 pieces) RJ45 Two position terminal block (5 pieces) 1203-SNM AK-U0-RJ45-SC1 AK-U0-RJ45-TR1 AK-U0-RJ45-TB2P

Null Cable Converter Splitter Cable Terminating Resistors Terminal Block

DriveExplorer Software Windows based software package that provides 9306-4EXP01ENE (CD-ROM) Version 3.01 an intuitive means for monitoring or configuring or later Allen-Bradley drives and communication adapters online. Compatibility: Windows 95, 98, ME, NT 4.0 (Service Pack 3 or later), 2000, XP and CE(1) DriveExecutive software Windows based software package that provides 9303-4DTE01ENE (CD-ROM) Version 1.01 an intuitive means for monitoring or configuring or later Allen-Bradley drives and communication adapters online and offline. Compatibility: Windows 98, ME, NT 4.0 (Service Pack 3 or later), 2000 and XP
(1) (2)

See www.ab.com/drives/driveexplorer.htm for supported devices. For pricing information, refer to the PowerFlex 4-Class Price List, Publication 22-PL001.

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

Item Description Drive Frame Catalog Number (1) A B 22-JBAA 22-JBAB

IP30/NEMA 1/UL Type 1 Field installed kit. Converts drive to IP30/ Kit NEMA 1/UL Type 1 enclosure. Includes conduit box with mounting screws and plastic top panel.
(1)

For pricing information, refer to the PowerFlex 4-Class Price List, Publication 22-PL001.

Accessories and Dimensions

B-5

Product Dimensions
Table B.I PowerFlex 4 Panel Mount Drives Ratings are in kW and (HP)
Frame 120V AC 1-Phase
0.2 (0.25) 0.37(0.5) 0.75(1.0) 1.1 (1.5)

240V AC 1-Phase 240V AC 1-Phase 240V AC 3-Phase 480V AC 3-Phase No Brake

0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) 0.2 (0.25) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 0.37 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0)

Figure B.1 PowerFlex 4 Panel Mount Drives Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).
a d c

g e b

5.5 (0.22)

Frame
A
(1) (2)

a
80 (3.15)

b(1)
185 (7.28)

c
136 (5.35)

d
67 (2.64)

e(2)
152 (5.98)

f
59.3 (2.33) 87.4 (3.44)

g
140 (5.51) 168 (6.61)

Shipping Weight
1.4 (3.1) 2.2 (4.9)

100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) Overall height of drive with IP 30/NEMA 1/UL Type 1 option kit installed. Overall height of standard IP 20/Open Type drive.

Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit Dimensions are in millimeters and (inches)
59.2 (2.33) 40.0 (1.57) 79.1 (3.11) 64.1 (2.52) 40.6 (1.60)

20.7 (0.81)

22.2 (0.87)

25.6 (1.01)

22.2 (0.87)

109.3 (4.30) 75.3 (2.96)

109.9 (4.33) 74.3 (2.93)

Frame A - 22-JBAA

Frame B - 22-JBAB

B-6

Accessories and Dimensions

Figure B.3 PowerFlex 4 Flange Mount Drives Dimensions are in millimeters and (inches)
Frame A
175 (6.89) 145 (5.71) 92.8 (3.65) 54.7 (2.15)

210 (8.27)

Frame B
244 (9.61) 94.3 (3.71) 63.1 (2.48)

214 (8.43)

250 (9.84)

Accessories and Dimensions

Figure B.4 PowerFlex 4 Cutout Dimensions Dimensions are in millimeters and (inches)
Frame A
8 (0.31) 114 (4.49) 5.3 (0.21)

B-7

195 (7.68) 179 (7.05)

97.5 (3.84)

16 (0.63)

49 (1.93)

98 (3.86) 130 (5.12)

8 (0.31)

Frame B
6.5 (0.26) 145 (5.71) 23.5 (0.93)

197 (7.76) 225 (8.86) 98.5 (3.88) 5.3 (0.21) 210 (8.27)

14 (0.55)

31 (1.22)

49 (1.93)

98 (3.86)

7.5 (0.30) 160 (6.30)

B-8

Accessories and Dimensions

Figure B.5 PowerFlex 4 Replacement Plate Drive Dimensions Dimensions are in millimeters and (inches)
Frame A
104.8 (4.13)

92 (3.62)

50 (1.97)

88 (3.46)

6 (0.24)

163 (6.42) 175 (6.89) 81.5 (3.21) 152 (5.98)

80 (3.15)

5.3 (0.21)

Frame B
112 (4.41) 125 (4.92) 80 (3.15) 88 (3.46) 9.5 (0.37)

192 (7.56) 180 (7.09)

204 (8.03) 96 (3.78)

100 (3.94)

5.3 (0.21)

Accessories and Dimensions

Figure B.6 Dynamic Brake Modules Dimensions are in millimeters and (inches)

B-9

Frame A
17.0 (0.67) 30.0 (1.18) 60.0 (2.36) 31.0 (1.22) 61.0 (2.40)

Frame B
59.0 (2.32)

US

316.0 (12.44)
ROCKWELL AUTOMATION

335.0 (13.19)

US

386.0 (15.20)

405.0 (15.94)

13.0 (0.51)

Frame A B

Catalog Number AK-R2-091P500, AK-R2-047P500, AK-R2-360P500 AK-R2-030P1K2, AK-R2-120P1K2

Figure B.7 Recommended External Brake Resistor Circuitry

Three-Phase AC Input

(Input Contactor) M R (L1) S (L2) T (L3)

Power Off

Power On

M M Power Source DB Resistor Thermostat

ROCKWELL AUTOMATION

SURFACES MAY BE

B-10

Accessories and Dimensions

Figure B.8 Bulletin 1321-3R Series Line Reactors Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).
a b

c
b 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) 133 (5.25) c 70 (2.75) 70 (2.75) 76 (3.00) 86 (3.38) 92 (3.62) 76 (3.00) 76 (3.00) 85 (3.35) 76 (3.00) 79 (3.10) d 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) 54 (2.13) e 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) Weight 1.8 (4) 1.8 (4) 1.8 (4) 2.3 (5) 2.7 (6) 3.1 (7) 3.6 (8) 4.9 (11) 4.1 (9) 4.1 (9)

Catalog Number 1321-3R2-A 1321-3R2-B 1321-3R4-B 1321-3R4-C 1321-3R4-D 1321-3R8-A 1321-3R8-B 1321-3R8-C 1321-3R12-A 1321-3R18-A

a 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)

Accessories and Dimensions

B-11

Figure B.9 Frame A EMC Line Filters Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL
29.8 (1.17) 50 (1.97) 80 60 (3.15) (2.36)

208 (8.19)

220 (8.66) 208 (8.19)

17.8 (0.70)

24 (0.94)

5.5 (0.22)

Figure B.10 Frame B EMC Line Filters Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF012-BS, -BL (Series B); 22-RF018-BS; 22-RF021-BS, -BL
29.8 (1.17) 50 (1.97) 100 78 (3.94) (3.07)

217 (8.54)

229 (9.02) 216 (8.50)

17.8 (0.70)

24.0 (0.94)

5.5 (0.22)

B-12

Accessories and Dimensions

Figure B.11 Frame C EMC Line Filters Dimensions are in millimeters and (inches) Catalog Number: 22-RF025-CL
32 (1.26) 60 (2.36) 130 90 (5.12) (3.54)

297 (11.69)

309 (12.17) 297 (11.69)

17 (0.67)

30 (1.18)

5.5 (0.22)

Important: The piggyback mounting option cannot be used with Frame B PowerFlex 4 drives and Frame C EMC Line Filters.

Accessories and Dimensions

B-13

Figure B.12 Remote (Panel Mount) HIM Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2
17.6 (0.69) 104 (4.09)

220 (8.66)

2.9m

78 (3.07) 66 (2.60)

194 (7.64)

125 (4.92) 60.5 (2.38) 19.1 (0.75) 4.8 (0.19) 38 (1.50)

B-14

Accessories and Dimensions

Figure B.13 Remote (Panel Mount) Small HIM Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2S
25 (0.98) 93 (3.66)

180 (7.09)

2m

67 (2.64)

60 (2.36)

154 (6.06)

19.1 (0.75) 4.8 (0.19)

77 (3.03)

23.5 (0.93)

Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement.

Accessories and Dimensions

Figure B.14 NEMA Type 1 Bezel Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-B1
93 (3.66) 11.1 (0.44)

B-15

25.2 (0.99)

180 (7.09)

2m

67 (2.64)

60 (2.36)

154 (6.06)

19.1 (0.75) 4.8 (0.19)

77 (3.03)

23.5 (0.93)

B-16

Accessories and Dimensions

Notes:

Appendix C

RS485 (DSI) Protocol

PowerFlex 4 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 4 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 usr manual.

Network Wiring
Network wiring consists of a shielded 2-conductor cable that is daisy-chained from node to node.
Figure C.1 Network Wiring Diagram
Master TxRxD+ TxRxDPowerFlex 4 Node 1
120 ohm resistor

4 5

TxRxD+ TxRxDShield

PowerFlex 4 Node 2 4 5

TxRxD+ TxRxDShield

PowerFlex 4 Node "n" 4 5

120 ohm resistor

FRONT

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

Shield

PIN 1 PIN 8

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

C-2

RS485 (DSI) Protocol 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. Control Terminal 16 on the PowerFlex 4 must also be connected to PE ground (there are two PE terminals on the drive). See Figure 1.5 for more information.

Parameter Configuration
The following PowerFlex 4 parameters are used to configure the drive to operate on a network.
Parameter P036 [Start Source] P038 [Speed Reference] A103 [Comm Data Rate] A104 [Comm Node Addr] Details Set to 5 RS485 (DSI) Port if Start is controlled from the network. Set to 5 RS485 (DSI) Port if the Speed Reference is controlled from the network. 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. Reference Page 3-9 Page 3-11 Page 3-23 Page 3-23 Page 3-24

A105 [Comm Loss Action] Selects the drives response to communication problems. A106 [Comm Loss Time] A107 [Comm Format]

Sets the time that the drive will remain in Page 3-24 communication loss before the drive implements A105 [Comm Loss Action]. Sets the transmission mode, data bits, parity and stop Page 3-24 bits for the RS485 (DSI) Port. All nodes on the network must be set to the same setting.

Supported Modbus Function Codes

The peripheral interface (DSI) used on PowerFlex 4 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).

RS485 (DSI) Protocol

C-3

Writing (06) Logic Command Data

The PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8192 (Logic Command). P036 [Start Source] must be set to 5 RS485 (DSI) Port in order to accept the commands. In addition to being written, register address 8192 can be read using Function Code 03.
Logic Command Address (Decimal) Bit(s) 0 1 2 3 Description 1 = Stop, 0 = Not Stop 1 = Start, 0 = Not Start 1 = Jog, 0 = No Jog 1 = Clear Faults, 0 = Not Clear Faults 00 = No Command 5,4 01 = Forward Command 10 = Reverse Command 11 = No Command 6 7 Not Used Not Used 00 = No Command 9,8 8192 01 = Accel Rate 1 Enable 10 = Accel Rate 2 Enable 11 = Hold Accel Rate Selected 00 = No Command 11,10 01 = Decel Rate 1 Enable 10 = Decel Rate 2 Enable 11 = Hold Decel Rate Selected 000 = No Command 001 = Freq. Source = P036 [Start Source] 010 = Freq. Source = A069 [Internal Freq] 14,13,12 011 = Freq. Source = Comms (Addr 8193) 100 = A070 [Preset Freq 0] 101 = A071 [Preset Freq 1] 110 = A072 [Preset Freq 2] 111 = A073 [Preset Freq 3] 15 Not Used

C-4

RS485 (DSI) Protocol

Writing (06) Reference

The Speed Reference to a PowerFlex 4 drive can be controlled via the network by sending Function Code 06 writes to register address 8193 (Reference). P038 [Speed Reference] must be set to 5 RS485 (DSI) Port in order to accept the Speed Reference. In addition to being written, register address 8193 can be read using Function Code 03.
Reference Address (Decimal) 8193 Description A decimal value entered as xxx.x where the decimal point is fixed. For example, a decimal 100 equals 10.0 Hz and 543 equals 54.3 Hz.

Reading (03) Logic Status Data

The PowerFlex 4 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 (Logic Status).
Logic Status Address (Decimal) Bit(s) 0 1 2 3 4 5 6 8448 7 8 9 10 11 12 13 14 15 Description 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse 1 = Accelerating, 0 = Not Accelerating 1 = Decelerating, 0 = Not Decelerating 1 = Alarm, 0 = No Alarm 1 = Faulted, 0 = Not Faulted 1 = At Reference, 0 = Not At Reference 1 = Reference Controlled by Comm 1 = Operation Cmd Controlled by Comm 1 = Parameters have been locked Digital Input 1 Status Digital Input 2 Status Not Used Not Used

Reading (03) Feedback

The Feedback (Output Frequency) from the PowerFlex 4 drive can be read via the network by sending Function Code 03 reads to register address 8451 (Feedback).
Feedback(1) Address (Decimal) 8451
(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].

RS485 (DSI) Protocol

C-5

Reading (03) Drive Error Codes

The PowerFlex 4 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error Codes).
Logic Status Address (Decimal) Value (Decimal) 0 2 3 4 5 6 7 8 12 13 29 33 8449 38 39 40 41 42 43 63 64 70 80 81 100 122 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 Software Overcurrent Drive Overload Power Unit Fail AutoTune Fail Communication Loss Parameter Checksum Error I/O Board Fail

Reading (03) and Writing (06) Drive Parameters

To access drive parameters, the Modbus register address equals the parameter number. For example, a decimal 1 is used to address Parameter d001 [Output Freq] and decimal 39 is used to address Parameter P039 [Accel Time 1].

Additional Information
Refer to http://www.ab.com/drives/ for additional information.

C-6

RS485 (DSI) Protocol

Notes:

Index
A
AC Supply Ground, 1-4 Source, 1-3 Ungrounded, 1-3 Advanced Program Group Parameters, 3-13 Ambient Temperatures, 1-2 Armored Cable, 1-8 Auto Rstrt Tries Fault, 4-4 Auxiliary Input Fault, 4-3 Distribution Systems, Ungrounded, 1-3 Drive Frame Size, P-2, B-5 Drive Grounding, 1-4 Drive Overload Fault, 4-4 Drive Ratings, P-4, A-1 DriveExecutive, 3-1 DriveExplorer, 3-1

E
Earthing, see Grounding EMC/RFI Grounding, Filter, 1-5 Interference, 1-20 Enclosure Rating, Changing, 1-2 ESD, Static Discharge, P-3

B
Before Applying Power, 2-1, 2-2 Bus Capacitors, Discharging, P-3

C
Cable Length, 1-12 Cable, Power, 1-8 Capacitors, Discharging, P-3 Catalog Number Explanation, P-4 CE Conformity, 1-20 Checklist, Start-Up, 2-1, 2-2 Circuit Breakers Input, 1-6 Comm Loss Fault, 4-4 Command Sources for Start and Speed, 1-18 Contactors, Input, 1-11 Control, 2 and 3 Wire, 1-14, 1-17 Conventions, Manual, P-2 Cover, Opening, 1-1 Cross Reference, Parameter by Name, 3-27

F
Faults Auto Rstrt Tries, 4-4 Auxiliary Input, 4-3 Comm Loss, 4-4 Drive Overload, 4-4 Ground Fault, 4-3 Heatsink OvrTmp, 4-3 HW OverCurrent, 4-3 I/O Board Fail, 4-4 Motor Overload, 4-3 Motor Stalled, 4-3 OverVoltage, 4-3 Parameter Checksum, 4-4 Phase Short, 4-4 Phase to Ground Short, 4-4 Power Loss, 4-3 Power Unit, 4-4 SW OverCurrent, 4-4 UnderVoltage, 4-3 Filter, RFI, 1-5 Frame Designations, P-2, A-1, B-5 Fuses Input, 1-6 Ratings, A-1

D
Dimensions Drive, B-5 Minimum Clearances, 1-2 Discharging Bus Capacitors, P-3 Display, 2-3 Display Group Parameters, 3-3

Index-2

G
General Precautions, P-3 Ground Fault, 4-3 Grounding Filter, 1-5 General, 1-4

P
Parameter Descriptions, 3-1 Types, 3-1 Viewing and Editing, 2-4 Parameter Checksum Fault, 4-4 Parameter Cross Reference by Name, 3-27 Parameters Advanced Program Group, 3-13 Display Group, 3-3 Program Group, 3-8 PE Ground, 1-5 Phase Short Fault, 4-4 Phase to Ground Fault, 4-4 Potentiometer, Wiring, 1-14 Power Cables/Wiring, 1-8 Power Conditioning, Input, 1-4 Power Loss Fault, 4-3 Power Unit Fault, 4-4 Powering Up the Drive, 2-1, 2-2 Precautions, General, P-3 Product Selection, B-1 Program Group Parameters, 3-8 Programming, 3-1 PTC Analog Input Wiring, 1-14

H
Heatsink OvrTmp Fault, 4-3 HW OverCurrent Fault, 4-3

I
I/O Wiring, 1-11 Wiring Examples, 1-14, 1-17 I/O Board Fail Fault, 4-4 Input Contactor, 1-11 Input Fusing, 1-6 Input Potentiometer, 1-14 Input Power Conditioning, 1-4 Installation, 1-1 Integral Keypad, 2-3 Interference, EMC/RFI, 1-20

K
Keypad, 2-3

L
LEDs, 2-3

R
Ratings, A-1 Reflective Wave Protection, 1-9 Removing Cover, 1-1 Repeated Start/Stop, 1-11 Repeated Start/Stop Precautions, 1-11 RFI, see EMC/RFI RWR (Reflective Wave Reducer), 1-9

M
Minimum Clearances, 1-2 Motor Cable Length, 1-9 Motor Overload Fault, 4-3 Motor Stalled Fault, 4-3 motor starter, 1-6 Mounting Options and Clearances, 1-2 MOVs, 1-3

S
Safety Ground, 1-5 Shielded Power Cables, 1-8 Short Circuit Protection, 1-6 Software, 3-1 Start and Speed Reference Selection and Control, 1-18, 1-19

O
Opening the Cover, 1-1 Operating Temperatures, 1-2 Operator Interface, 2-3 OverVoltage Fault, 4-3

Index-3 Start/Stop, Repeated, 1-11 Start-Up Checklist, 2-1, 2-2 Static Discharge, ESD, P-3 Status LEDs, 2-3 Supply Source, AC, 1-3 SW OverCurrent Fault, 4-4 System Grounding, 1-4

T
Terminal Block I/O, 1-12 Power, 1-10 Three Wire Control, 1-14, 1-17 Two Wire Control, 1-14, 1-17

U
UnderVoltage Fault, 4-3 Ungrounded Supply, 1-3 Unshielded Power Cables, 1-8

W
Watts Loss, A-4 Wiring, 1-1 Block Diagram, 1-13 I/O, 1-11 I/O Examples, 1-14, 1-17 Potentiometer, 1-14 Power, 1-8 PTC Example, 1-14

Index-4

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Publication 22A-UM001I-EN-E September 2010

Supersedes Publication 22A-UM001H-EN-E July 2010 Copyright 2010 Rockwell Automation, Inc. All rights reserved.