Allen-Bradley PowerFlex 4M User manual

Adjustable

Frequency AC

Drive

FRN 1.xx - 2.xx

User Manual

www.abpowerflex.com

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. Safety Guidelines for the Application, Installation

and Maintenance of Solid State Controls (Publication SGI-1.1 available from your

local Rockwell Automation sales office or online at

http://www.rockwellautomation.com/literature)describes some important

differences between solid state equipment and hard-wired electromechanical

devices. Because of this difference, and also because of the wide variety of uses for

solid state equipment, all persons responsible for applying this equipment must

satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or

consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative

purposes. Because of the many variables and requirements associated with any

particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of

information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written

permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety

considerations.

Important: Identifies information that is critical for successful application and

understanding of the product.

Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks 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.

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

Summary of Changes

The information below summarizes the changes to the PowerFlex 4M

User Manual since the July 2008 release.

Manual Updates

The information below summarizes the changes to the PowerFlex 4M

User Manual since the August 2007 release.

Manual Updates

Description of New or Updated Information Page(s)

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

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

Electronic Motor Overload Protection description updated. A-4

Description of New or Updated Information Page(s)

Footnote (2) deleted from “EN61800-3 Second Environment” in Table 1.I.1-22

Note to stop drive before changing parameter t211 [Anlg In 0-10V Lo]

removed.

3-14

New option 13, I/O Control, for parameter t221 [Relay Out Sel] added. 3-15

Fault description for F3 corrected. 4-3

Corrected Ta ble B.F by adding the 0.75 kW (1.0 HP) and 1.5 kW (2.0 HP)

ratings for the 22F-RF025-BL EMC line filter.

B-4

Description for bits 14, 13, and 12 of register address 8192 corrected. C-4

Information on reading register address 8192 clarified. C-4

Description for bits 6, 7, and 15 of register address 8192 updated. C-4

Information on reading register address 8193 clarified. C-5

Figure C.1, Network Wiring Diagram, updated. C-1

Guidelines on standard RS485 wiring practices added. C-1

soc-2

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

The information below summarizes the changes to the PowerFlex 4M

User Manual since the February 2007 release.

Manual Updates

Description of New or Updated Information Page(s)

Input description and attention text for Multiple Digital Input Connection

example corrected.

1-18

Description for option 21 of parameter t221 [Relay Out Sel] corrected. 3-15

Invalid catalog number for L Type Filter deleted. B-4, B-10

Graphic for the “Connecting an RS-485 Network” section corrected D-3

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

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 . . . . . . 1-5

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

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

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

Start and Speed Reference Control . . . . . 1-19

EMC Instructions . . . . . . . . . . . . . . . . . . 1-21

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

Terminal Block Group. . . . . . . . . . . . . . . 3-13

Communications Group . . . . . . . . . . . . . 3-17

Advanced Program Group. . . . . . . . . . . . 3-19

Parameter Cross Reference – by Name. . 3-31

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

Appendix B Accessories and Dimensions

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

Product Dimensions . . . . . . . . . . . . . . . . . B-6

ii Table of Contents

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

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-6

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

Reading (03) and Writing (06) Drive

Parameters . . . . . . . . . . . . . . . . . . . . . . C-7

Additional Information . . . . . . . . . . . . . . . C-7

Appendix D RJ45 DSI Splitter Cable

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

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

Connecting an RS-485 Network . . . . . . . . D-3

Index

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

Preface

Overview

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

needed to install, start-up and troubleshoot the PowerFlex 4M

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-2 Overview

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

•In this manual we refer to the PowerFlex 4M Adjustable Frequency

AC Drive as: drive, PowerFlex 4M or PowerFlex 4M Drive.

•Parameter numbers and names are shown in this format:

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

action:

Similar PowerFlex 4M 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

P101 [Motor NP Volts]

Name

Number

Group

d = Display Group

P = Basic Program Group

t = Terminal Block Group

C = Communications 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

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

General Precautions

ATTENTION: To avoid an electric shock hazard, verify that the

voltage on the bus capacitors has discharged before performing any

work on the drive. Measure the DC bus voltage at the –DC and +DC

terminals on the Power Terminal Block (refer to Chapter 1 Power

Terminal descriptions). The voltage must be zero.

Darkened LEDs or a darkened LCD display 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 A441). In addition, installing a properly sized

dynamic brake resistor will provide equal or better performance in most

cases.

P-4 Overview

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Publication 22F-UM001D-EN-E

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)

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

22F - D 8P7 N 1 1 3 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional

Code

22F PowerFlex 4M

Code Purpose

AA Reserved for

thru custom firmware

Output Current @ 380-480V Input

Code Amps kW (HP)

1P5 1.5 0.4 (0.5)

2P5 2.5 0.75 (1.0)

4P2 4.2 1.5 (2.0)

6P0 6.0 2.2 (3.0)

8P7 8.7 3.7 (5.0)

013 13.0 5.5 (7.5)

018 18.0 7.5 (10.0)

024 24.0 10.0 (15.0)

Output Current @ 100-120V Input

Code Amps kW (HP)

1P6 1.6 0.2 (0.25)

2P5 2.5 0.4 (0.5)

4P5 4.5 0.75 (1.0)

6P0 6.0 1.1 (1.5)

Output Current @ 200-240V Input

Code Amps kW (HP)

1P6 1.6 0.2 (0.25)

2P5 2.5 0.4 (0.5)

4P2 4.2 0.75 (1.0)

8P0 8.0 1.5 (2.0)

011 11.0 2.2 (3.0)

012 12.0 2.2 (3.0)

017 17.5 3.7 (5.0)

025 25.0 5.5 (7.5)

033 33.0 7.5 (10.0)

Code Rating

0 Not Filtered

1Filtered

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

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