Allen-Bradley PowerFlex40 User manual

Adjustable

Frequency AC

Drive

FRN 1.xx - 7.xx

User Manual

www.abpowerflex.com

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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.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 and DriveExecutive are trademarks 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.

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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-EN-E

Summary of Changes

Manual Updates

The information below summarizes the changes to the PowerFlex 40

User Manual since the June 2013 release.

The information below summarizes the changes to the PowerFlex 40

User Manual since the August 2008 release.

The information below summarizes the changes to the PowerFlex 40

User Manual since the April 2008 release.

The information below summarizes the changes to the PowerFlex 40

User Manual since the January 2007 release.

Description of New or Updated Information Page(s)

Certifications for Australian RCM and CE Directives updated. 1-25,

A-3

Certifications for EAC, KCC, and NSF/ANSI added. A-3

Description of New or Updated Information Page(s)

Minimum Enclosure Volume column and new footnotes added. 1-9, 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)

Description of A056 revised. 3-17

Description of A059/A062 revised. 3-19

Fault description for F3 revised. 4-3

A table row for electrical specifications added. A-4

Graphic for the “Network Wiring” section revised. C-1

Second last paragraph in the “Network Wiring” section revised. C-2

Text in the “Writing (06) Logic Command Data” section revised. C-4

Frequency source for logic command 001 of bits 14, 13, and 12 corrected. C-4

Text in the “Writing (06) Reference” section revised. C-5

Description of New or Updated Information Page(s)

Input description and attention text for Multiple Digital Input Connection

example corrected.

1-22

New method of changing speed reference for IP66, NEMA/UL Type 4X rated

drives described.

2-2

Description for Up Arrow and Down Arrow keys revised. 2-4

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soc-2

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-EN-E

Parameter Updates

The following parameters have been updated with firmware version 6.xx.

The following parameters have been updated with firmware version 5.xx.

New Parameter

The following parameter has been added with firmware version 5.xx.

Fault description for F3 revised. 4-3

Graphic for the “Network Wiring” section revised. C-1

Descriptions for bits 6, 7, and 15 of register address 8192 (Logic Command)

updated.

C-4

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

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

Graphic for the “Connecting an RS-485 Network” section corrected. D-4

New method for inverting sign of PID error added. F-6

Parameter Number Description Page

[Relay Out Sel] A055 Function of option 20, ParamControl,

changed.

Option 24, MsgControl, added.

3-16

[Relay Out Sel] A058, A061 Function of option 20, ParamControl,

changed.

Option 24, MsgControl, added.

3-18

Parameter Number Description Page

[Control Source] d012 Options 7 and 8 added. 3-5

[Start Source] P036 Description revised for option 6. 3-10

[Relay Out Sel] A055 Description revised for option 20. 3-16

[Relay Out Level] A056 Description revised. 3-17

[Opto Outx Sel] A058, A061 Description revised for option 20. 3-18

[Opto Outx Level] A059, A062 Description revised. 3-19

[Internal Freq] A069 Default value for IP66, NEMA/

UL Type 4X drives is 0.0 Hz.

Default value for IP20 rated drives is

60.0 Hz.

3-22

[PID Trim Hi] A130 Description revised. 3-38

[PID Trim Lo] A131 Description revised. 3-38

Parameter Number Description Page

[PID Invert Error] A167 New 3-44

Description of New or Updated Information Page(s)

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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-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 . . . . . . . . . . . . . 1-3

AC Supply Source Considerations . . . . . . 1-5

General Grounding Requirements . . . . . . 1-7

Fuses and Circuit Breakers . . . . . . . . . . . . 1-8

Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-10

IP66, NEMA/UL Type 4X Installations . 1-14

I/O Wiring Recommendations . . . . . . . . 1-14

Start and Speed Reference Control . . . . . 1-23

EMC Instructions . . . . . . . . . . . . . . . . . . 1-25

Chapter 2 Start Up

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

Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-4

Viewing and Editing Parameters. . . . . . . . 2-5

Remote HIM Menu Structure . . . . . . . . . . 2-6

Chapter 3 Programming and Parameters

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

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

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

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

Advanced Program Group. . . . . . . . . . . . 3-14

Parameter Cross Reference – by Name. . 3-45

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-7

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2Table of Contents

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-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 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 StepLogic, Basic Logic and

Timer/Counter Functions

StepLogic Using Timed Steps . . . . . . . . . . E-2

StepLogic Using Basic Logic Functions . . E-3

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

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

Appendix F PID Set Up

PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

PID Reference and Feedback . . . . . . . . . . F-4

Analog PID Reference Signals . . . . . . . . . F-5

Index

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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-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 40 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

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P-2 Overview

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-EN-E

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

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

•Parameter numbers and names are shown in this format:

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

action:

Similar PowerFlex 40 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

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Overview P-3

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-EN-E

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.

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P-4 Overview

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual

Publication 22B-UM001I-EN-E

Catalog Number Explanation

Code Voltage Ph.

V 120V AC 1

A 240V AC 1

B 240V AC 3

D 480V AC 3

E 600V AC 3

Code Version

3 No Brake IGBT

4 Standard

Code Interface Module

1 Fixed Keypad

Code Enclosure

N Panel Mount - IP20, NEMA/UL Type Open

C Panel Mount - IP66, NEMA/UL Type 4X

F Flange Mount - IP20, NEMA/UL Type Open

H Replacement Plate Drive - IP20, NEMA/UL Type Open

- Contact factory for ordering information.

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

22B - A 1P5 N 1 1 4 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional

Output Current

@ 100-120V 50/60 Hz Input

Code Amps kW (HP)

2P3 2.3 0.4 (0.5)

5P0 5.0 0.75 (1.0)

6P0 6.0 1.1 (1.5)

Code Rating

0 Not Filtered

1Filtered

Output Current

@ 380-480V 50/60 Hz 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

22B PowerFlex 40

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

Output Current

@ 500-600V 50/60 Hz 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 12.2 7.5 (10)

019 19 11 (15)

Code Purpose

AA Reserved for

thru custom firmware

Output Current

@ 200-240V 50/60 Hz 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)

(1) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 40

drives are equipped with RS485 communication.

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