Allen-Bradley PowerFlex 4 User manual

Adjustable

Frequency AC

Drive

FRN 7.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.

Important: Identifies information that is critical for successful application and

understanding of the product.

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.

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.

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.

Summary of Changes

The information below summarizes changes made for the July 2017

PowerFlex 4 User Manual, Publication 22A-UM001K-EN-E.

The information below summarizes changes made for the June 2013

PowerFlex 4 User Manual, Publication 22A-UM001J-EN-E.

The information below summarizes changes made for the September

2010 PowerFlex 4 User Manual, Publication 22A-UM001I-EN-E.

The information below summarizes changes made for the July 2010

PowerFlex 4 User Manual, Publication 22A-UM001H-EN-E.

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 See Page(s)

Line fuse footnote added to Fuse Rating column. 1-7

Low Voltage Directive updated. 1-20

Attention statement on Option 3 “2-W Lvl Sens” and Important statement

about Option 4 “2-W Hi Speed” added to parameter P036 [Start Source].

3-9

Specifications table Approvals column updated. A-2

Sound Pressure Level specification added. A-3

Product Environmental Information added. A-4

Dynamic Brake Fuse Rating column and new footnote added. B-2

Network Wiring topic updated. C-1

Description of New or Updated Information See Page(s)

Minimum Enclosure Volume column and new footnotes added. 1-7, A-2

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

Electronic Motor Overload Protection description updated. A-3

Description of New or Updated Information See Page(s)

Parameters A117 [Bus Reg Mode] and A118 [Comm Write Mode] added. 3-13

Description of New or Updated Information See Page(s)

Start and Speed Reference Control 1-18

Description of New or Updated Information See Page(s)

Minimum Mounting Clearances clarified. 1-2

Footnote (2) on Bulletin 140M catalog edited. 1-7

Graphic for Analog Input, PTC wiring example corrected. 1-14

soc-2

The information below summarizes changes made for the September

2005 PowerFlex 4 User Manual, Publication 22A-UM001F-EN-E.

Stop Drive icon and related warning text removed for parameter

A110 [Anlg In 0-10V Lo].

3-25

New information on reading register address 8192 added. C-4

New information on reading register address 8193 added. C-5

Description of New or Updated Information See Page(s)

Attention statement clarified. 1-3

240V AC – 3-Phase 3.7 kW (5.0 Hp) drive fuse rating revised to 30 amps. 1-7, A-2

Analog Input, PTC wiring example added. 1-14

Attention statement added to Multiple Digital Input Connections wiring

example.

1-17

Parameter P043 [Motor OL Ret] added. 3-12

Attention statement added to parameter A082 [DB Resistor Sel]. 3-18

External Comm Options, Compact I/O added to Table B. G .B-4

Modbus function code 16 added. C-3

Description of New or Updated Information See Page(s)

Table of Contents

Preface Overview

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

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

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

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

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

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

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

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

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

Common Symptoms and Corrective Actions . .

4-5

Appendix A Supplemental Drive Information

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

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

Product Environmental Information . . . . . A-4

Appendix B Accessories and Dimensions

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

Product Dimensions . . . . . . . . . . . . . . . . . B-5

Appendix C RS485 (DSI) Protocol

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

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

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

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

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

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

Reading (03) Feedback . . . . . . . . . . . . . . . C-5

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

Reading (03) and Writing (06) Drive

Parameters . . . . . . . . . . . . . . . . . . . . . . C-6

Additional Information . . . . . . . . . . . . . . . C-6

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.

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.

The following manuals are recommended for general drive information:

For information on… See page…

Who Should Use this Manual? P-1

Reference Materials P-1

Manual Conventions P-2

Drive Frame Sizes P-2

General Precautions P-3

Catalog Number Explanation P-4

Who Should Use this Manual?

Reference Materials

Title Publication Available Online at …

Wiring and Grounding

Guidelines for Pulse Width

Modulated (PWM) AC Drives

DRIVES-IN001…

www.rockwellautomation.com/

literature

Preventive Maintenance of

Industrial Control and Drive

System Equipment

DRIVES-SB001…

Safety Guidelines for the

Application, Installation and

Maintenance of Solid State

Control

SGI-1.1

A Global Reference Guide for

Reading Schematic Diagrams

0100-2.10

Guarding Against Electrostatic

Damage

8000-4.5.2

P-P-2 Overview

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:

The following words are used throughout the manual to describe an

action:

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.

Manual Conventions

P031 [Motor NP Volts]

Name

Number

Group

d = Display Group

P = Basic Program Group

A = Advanced Program Group

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not Recommended

Drive Frame Sizes

Overview P-3

General Precautions

ATTENTION: The drive contains high voltage capacitors which take

time to discharge after removal of mains supply. Before working on

drive, ensure isolation of mains supply from line inputs [R, S, T (L1,

L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage

levels. Failure to do so may result in personal injury or death.

Darkened display LEDs is not an indication that capacitors have

discharged to safe voltage levels.

ATTENTION: Only qualified personnel familiar with adjustable

frequency AC drives and associated machinery should plan or

implement the installation, start-up and subsequent maintenance of the

system. Failure to comply may result in personal injury and/or

equipment damage.

ATTENTION: This drive contains ESD (Electrostatic Discharge)

sensitive parts and assemblies. Static control precautions are required

when installing, testing, servicing or repairing this assembly.

Component damage may result if ESD control procedures are not

followed. If you are not familiar with static control procedures,

reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic

Damage” or any other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed drive can result in

component damage or a reduction in product life. Wiring or application

errors, such as, undersizing the motor, incorrect or inadequate AC

supply, or excessive ambient temperatures may result in malfunction of

the system.

ATTENTION: The bus regulator function is extremely useful for

preventing nuisance overvoltage faults resulting from aggressive

decelerations, overhauling loads, and eccentric loads. However, it can

also cause either of the following two conditions to occur.

1. Fast positive changes in input voltage or imbalanced input voltages

can cause uncommanded positive speed changes;

2. Actual deceleration times can be longer than commanded

deceleration times

However, a “Stall Fault” is generated if the drive remains in this state

for 1 minute. If this condition is unacceptable, the bus regulator must be

disabled (see parameter A117). In addition, installing a properly sized

dynamic brake resistor will provide equal or better performance in most

cases.

P-P-4 Overview

Catalog Number Explanation

Code Voltage Ph.

V 120V AC 1

A 240V AC 1

B 240V AC 3

D 480V AC 3

Code Version

3 No Brake IGBT

4 Standard

Code Interface Module

1 Fixed Keypad

Code Enclosure

N Panel Mount - IP 20 (NEMA Type Open)

F Flange Mount - IP 20 (NEMA Type Open)

H Replacement Plate Drive - IP 20 (NEMA Type Open)

- Contact factory for ordering information.

1-3 4 5 6-8 9 10 11 12 (1) 13-14

22A - A 1P5 N 1 1 4 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional

Output Current @ 100-120V Input

Code Amps kW (HP)

1P5 1.5 0.2 (0.25)

2P3 2.3 0.4 (0.5)

4P5 4.5 0.75 (1.0)

6P0 6.0 1.1 (1.5)

Code Rating

0 Not Filtered

1Filtered

Code

22A PowerFlex 4

Code Purpose

AA Reserved for

thru custom firmware

Output Current @ 200-240V Input, NO BRAKE

Code Amps kW (HP)

1P4 1.4 0.2 (0.25)

2P1 2.1 0.4 (0.5)

3P6 3.6 0.75 (1.0)

6P8 6.8 1.5 (2.0)

9P6 9.6 2.2 (3.0)

Output Current @ 380-480V Input

Code Amps kW (HP)

1P4 1.4 0.4 (0.5)

2P3 2.3 0.75 (1.0)

4P0 4.0 1.5 (2.0)

6P0 6.0 2.2 (3.0)

8P7 8.7 3.7 (5.0)

Output Current @ 200-240V Input

Code Amps kW (HP)

1P5 1.5 0.2 (0.25)

2P3 2.3 0.4 (0.5)

4P5 4.5 0.75 (1.0)

8P0 8.0 1.5 (2.0)

012 12.0 2.2 (3.0)

017 17.5 3.7 (5.0)

(1) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 4 drives

are equipped with RS485 communication.

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