Allen-Bradley PowerFlex 40P User manual

Adjustable

Frequency AC

Drive

FRN 1.xx - 3.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

Manual Updates

The information below summarizes the changes to the PowerFlex 40P

User Manual since the June 2013 release.

The information below summarizes the changes to the PowerFlex 40P

User Manual since the May 2007 release.

Parameter Updates

The following parameters have been added or updated with Firmware

Revision Number (FRN) 3.xx.

Description of New or Updated Information See Page(s)

Replaced ISO 13849 with EN ISO 13849-1:2008+AC:2009 1-21, 3-11, and

A-3

Certification for Australian C-Tick, CE Directives, and TUV updated. 1-29, 1-30, and

A-3

Description of New or Updated Information See Page(s)

Link to Rockwell Automation Literature Library under Reference

Materials has been fixed

Preface-1

Minimum Enclosure Volume column and new footnotes added. 1-8, A-2

Information on swapping encoder channels updated 1-18 and F-2

Certification standard for DriveGuard Safe-Off Option updated to ISO

13849-1; Performance Level d (Safety Category 3)

1-21, 3-11 and

A-3

USB Converter Module added to Drive Programming Tools 2-3

Parameters A164 and d310–d316 added to Parameter Organzation 3-2

Max value for Parameter A069 [Internal Freq] updated to 500.0 Hz 3-24

Cross-reference to parameters d310–d316 added to description for

Parameter A100 [Fault Clear]

3-33

Attention added to Parameters A140–A147 [Stp Logic x] 3-45

Max vaule for A150–A157 [Stp Logic Time x] increased to 6553.5 sec 3-47

Parameters A164 and d310–d316 added to Parameter

Cross-Reference – by Name

3-66

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

Electronic Motor Overload Protection description updated. A-3, A-4

Description of Option 1 for Parameter E222 [Positioning Mode] updated F-5

Parameter Number Description Page

Stp Logic Time A150–A157 Max value increased to 6553.5 sec 3-47

PID Invert Error A164 New Parameter 3-48

Fault 4 Code d310 New Parameter 3-64

soc-2

Fault 5 Code d311 New Parameter 3-64

Fault 6 Code d312 New Parameter 3-64

Fault 7 Code d313 New Parameter 3-64

Fault 8 Code d314 New Parameter 3-65

Fault 9 Code d315 New Parameter 3-65

Fault 10 Code d316 New Parameter 3-65

Parameter Number Description Page

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

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

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

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

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

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

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

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

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

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

Chapter 2 Start Up

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

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

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

Chapter 3 Programming and Parameters

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

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

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

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

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

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

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

Parameter Cross Reference – by Name. . 3-66

Chapter 4 Troubleshooting

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

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

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

Common Symptoms and Corrective Actions . .

4-6

Appendix A Supplemental Drive Information

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

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

Appendix B Accessories and Dimensions

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

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

2Table of Contents

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-6

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

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

Reading (03) and Writing (06) Drive

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

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

Appendix D RJ45 DSI Splitter Cable

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

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

Connecting One Temporary Peripheral . . . D-3

Connecting One Temporary Peripheral and

One Permanent Peripheral . . . . . . . . . . . D-3

Connecting Two Permanent Peripherals . . D-4

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

Appendix E Velocity StepLogic™, Basic Logic and Timer/Counter Functions

Velocity StepLogic Using Timed Steps. . . E-2

Velocity StepLogic Using Basic Logic

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

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

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

Appendix F Encoder Usage and Position StepLogic Application

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

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

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

Common Guidelines for All Applications. F-3

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

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

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

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

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

Appendix G PID Set Up

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

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

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

Appendix H Plate Drive Installation Instructions

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

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

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

Heatsink Surface and Flatness Requirements .

H-3

Mounting Dimensions and Requirements . H-4

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

Index

Preface

Overview

The purpose of this manual is to provide you with the basic information

needed to install, start-up and troubleshoot the PowerFlex 40P

Adjustable Frequency AC Drive.

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-TD001…

Safety Guidelines for the

Application, Installation and

Maintenance of Solid State

Control

SGI-1.1

A Global Reference Guide for

Reading Schematic Diagrams

100-2.10

Guarding Against Electrostatic

Damage

8000-4.5.2

DriveGuard® Safe-Off Option

(Series B) for PowerFlex AC

Drives

PFLEX-UM003…

P-2 Overview

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

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

•Parameter numbers and names are shown in this format:

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

action:

Similar PowerFlex 40P drive sizes are grouped into frame sizes to

simplify spare parts ordering, dimensioning, etc. A cross reference of

drive catalog numbers and their respective frame sizes is provided in

Appendix B.

Manual Conventions

P031 [Motor NP Volts]

Name

Number

Group

b = Basic Display Group

P = Basic Program Group

A = Advanced Program Group

E = Enhanced Program Group

d = Advanced Display Group

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.

ATTENTION: Risk of injury or equipment damage exists. Drive does

not contain user-serviceable components. Do not disassemble drive

chassis.

P-4 Overview

Catalog Number Explanation

Code Voltage Ph.

B 240V AC 3

D 480V AC 3

E 600V AC 3

Code Version

4 Standard

Code HIM Version

1 Display/Fault Reset Only

2 Display/Fault Reset Only (Plate Drive)

Code Enclosure

N Panel Mount - IP 20 (NEMA Type Open)

F Flange Mount - IP 20 (NEMA Type Open)

H Plate Drive - IP 20 (NEMA Type Open)

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

22D - B 2P3 N 1 0 4 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Version Optional

Code EMC Filter

0 Not Filter

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)

010 10.5 4.0 (5.0)

012 12 5.5 (7.5)

017 17 7.5 (10)

024 24 11 (15)

Code

22D PowerFlex 40P

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

Output Current @ 460-600V Input

Code Amps kW (HP)

1P7 1.7 0.75 (1.0)

3P0 3.0 1.5 (2.0)

4P2 4.2 2.2 (3.0)

6P6 6.6 4.0 (5.0)

9P9 9.9 5.5 (7.5)

012 12 7.5 (10)

019 19 11 (15)

Code Purpose

AA Reserved for

thru custom firmware

Output Current @ 200-240V Input

Code Amps kW (HP)

2P3 2.3 0.4 (0.5)

5P0 5.0 0.75 (1.0)

8P0 8.0 1.5 (2.0)

012 12 2.2 (3.0)

017 17.5 3.7 (5.0)

024 24 5.5 (7.5)

033 33 7.5 (10)

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