PowerFlex 40 Adjustable Frequency AC Drive

Transcription

1 PowerFlex 4 Adjustable Frequency AC Drive Quick Start This Quick Start guide summarizes the basic steps needed to install, start-up and program the PowerFlex 4 Adjustable Frequency AC Drive. The information provided Does Not replace the User Manual and is intended for qualified drive service personnel only. For detailed PowerFlex 4 information including EMC instructions, application considerations and related precautions refer to the PowerFlex 4 User Manual, Publication 22B-UM1 on the CD supplied with the drive or at 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: Equipment damage and/or personal injury may result if parameter A92 [Auto Rstrt Tries] or A94 [Start At PowerUp] is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines. 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 , 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.

2 English-2 Mounting Considerations Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque DIN Rail B M4 (#8-32) N-m (14-17 lb.-in.) 35 mm C M5 (#1-24) N-m (22-26 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 See page 16 for mounting dimensions. 25 mm (1. in.) 12 mm (4.7 in.) Mounting Option A No clearance required between drives. 12 mm (4.7 in.) Mounting Option B 12 mm (4.7 in.) 12 mm (4.7 in.) Ambient Operating Temperatures Ambient Temperature Enclosure Rating Minimum Mounting Minimum Maximum Clearances IP 2/Open Type Use Mounting Option A 4 C (14 F) -1 C (14 F) IP 3/NEMA 1/UL Type 1 (1) Use Mounting Option B 5 C (122 F) IP 2/Open Type Use Mounting Option B (1) Rating requires installation of the PowerFlex 4 IP 3/NEMA 1/UL Type 1 option kit. General Grounding Requirements Important: Remove the MOV to ground jumper if the drive is installed on an ungrounded distribution system. Tighten screw after jumper removal. Jumper Location R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 SHLD CE Conformity Refer to the PowerFlex 4 User Manual on the CD supplied with the drive for details on how to comply with the Low Voltage (LV) and Electromagnetic Compatibility (EMC) Directives.

3 LISTED 966X English-3 Specifications, Fuses and Circuit Breakers Drive Ratings Output Ratings Input Ratings Branch Circuit Protection Power Catalog Dissipation Number kw (HP) Amps Voltage Range kva Amps Fuses 14M Motor Protectors (2) IP2 Open Contactors Watts 1-12V AC 1-Phase Input, - 23V 3-Phase Output 22B-V2P3N14.4 (.5) M-xxE-C16 1-C B-V5PN14.75 (1.) M-xxE-C2 1-C B-V6PN (1.5) M-xxE-C32 1-C V AC 1-Phase (1) Input, - 23V 3-Phase Output 22B-A2P3N14.4 (.5) M-xxE-B63 1-C9 3 22B-A5PN14.75 (1.) M-xxE-C16 1-C B-A8PN (2.) M-xxE-C2 1-C B-A12N (3.) M-xxE-C32 1-C V AC 3-Phase Input, - 23V 3-Phase Output 22B-B2P3N14.4 (.5) M-xxE-B4 1-C7 3 22B-B5PN14.75 (1.) M-xxE-C1 1-C B-B8PN (2.) M-xxE-C16 1-C B-B12N (3.) M-xxE-C16 1-C B-B17N (5.) M-xxE-C25 1-C B-B24N (7.5) M-xxE-C32 1-C B-B33N (1.) M-xxE-C45 1-C V AC 3-Phase Input, - 46V 3-Phase Output 22B-D1P4N14.4 (.5) M-xxE-B25 1-C7 3 22B-D2P3N14.75 (1.) M-xxE-B4 1-C7 4 22B-D4PN (2.) M-xxE-B63 1-C9 6 22B-D6PN (3.) M-xxE-C1 1-C9 9 22B-D1N14 4. (5.) M-xxE-C16 1-C B-D12N (7.5) M-xxE-C2 1-C B-D17N (1.) M-xxE-C2 1-C23 2 Input/Output Ratings Output Frequency: -4 Hz (Programmable) Efficiency: 97.5% (Typical) Digital Control Inputs (Input Current = 6mA) SRC (Source) Mode: SNK (Sink) Mode: 18-24V = ON -6V = ON -6V = OFF 18-24V = OFF Approvals Control Output Programmable Output (form C relay) Resistive Rating: 3.A at 3V DC, 3.A at 125V AC, 3.A at 24V AC Inductive Rating:.5A at 3V DC,.5A at 125V AC,.5A at 24V AC Analog Control Inputs 4-2mA Analog: 25 ohm input impedance -1V DC Analog: 1k ohm input impedance External Pot: 1-1k ohms, 2 Watt minimum Opto Outputs 3V DC, 5mA Non-inductive Fuses and Circuit Breakers Recommended Fuse Type: UL Class J, CC, T or Type BS88; 6V (55V) or equivalent. Recommended Circuit Breakers: HMCP circuit breakers or equivalent. Protective Features Analog Outputs (1 bit) -1V, 1k ohm Min. 4-2mA, 525 ohm Max. Motor Protection: I 2 t overload protection - 15% for 6 Secs, 2% for 3 Secs (Provides Class 1 protection) Overcurrent: 2% hardware limit, 3% instantaneous fault Over Voltage: 1-12V AC Input Trip occurs at 45V DC bus voltage (equivalent to 15V AC incoming line) 2-24V AC Input Trip occurs at 45V DC bus voltage (equivalent to 29V AC incoming line) 38-46V AC Input Trip occurs at 81V DC bus voltage (equivalent to 575V AC incoming line) Under Voltage: 1-12V AC Input Trip occurs at 21V DC bus voltage (equivalent to 75V AC incoming line) 2-24V AC Input Trip occurs at 21V DC bus voltage (equivalent to 15V AC incoming line) 38-48V AC Input Trip occurs at 39V DC bus voltage (equivalent to 275V AC incoming line) Control Ride Through: Minimum ride through is.5 Secs - typical value 2 Secs Faultless Power Ride Through: 1 milliseconds Dynamic Braking Internal brake IGBT included with all ratings.75 kw (1 HP) and larger. Refer to Appendix B of the PowerFlex 4 User Manual on CD for DB resistor ordering information. (1) 2-24V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N14 to N114. (2) Refer to the Bulletin 14M Motor Protectors Selection Guide, publication 14M-SG1 to determine the frame and breaking capacity required for your application. LISTED 966X UL IND CONT EQ UL58C UL C CSA 22.2 IND CONT EQ EMC Directive 89/336 LV: EN 5178, EN 624 EMC: EN 618-3, EN 581-1, EN 582-2

4 English-4 Power Wiring Power Wire Rating Unshielded 6V, 75 C (167 F) THHN/THWN Shielded 6V, 75 C or 9 C (167 F or 194 F) RHH/ RHW-2 Shielded Tray rated 6V, 75 C or 9 C (167 F or 194 F) RHH/RHW-2 Recommended Copper Wire 15 Mils insulated, dry location Anixter OLF-7xxxxx, Belden or equivalent Anixter 7V-7xxxx-3G Shawflex 2ACD/3ACD or equivalent Power Terminal Block B Frame R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 C Frame R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1 DC- DC+ BR+ DC- DC+ BR+ BR- BR- Terminal (1) R/L1, S/L2 R/L1, S/L2, T/L3 U/T1 V/T2 W/T3 P2, P1 DC+, DC- Description 1-Phase Input 3-Phase Input To Motor U/T1 To Motor V/T2 To Motor W/T3 Power Terminal Block Specifications = Switch any two motor leads to change forward direction. DC Bus Inductor Connection The drive is shipped with a jumper between Terminals P2 and P1. Remove this jumper only when a DC Bus Inductor will be connected. Drive will not power up without a jumper or inductor connected. DC Bus Connection BR+, BR- Dynamic Brake Resistor Connection [.75 kw (1 HP) ratings and higher] Safety Ground - PE (1) Important: Terminal screws may become loose during shipment. Ensure that all terminal screws are tightened to the recommended torque before applying power to the drive. Frame Maximum Wire Size (2) Minimum Wire Size (2) Torque B 5.3 mm 2 (1 AWG) 1.3 mm 2 (16 AWG) N-m (16-19 lb.-in.) C 8.4 mm 2 (8 AWG) 1.3 mm 2 (16 AWG) N-m (26-33 lb.-in.) (2) Maximum/minimum sizes that the terminal block will accept - these are not recommendations.

5 English-5 Input Power Conditions Input Power Condition Corrective Action Low Line Impedance (less than 1% line reactance) Install Line Reactor (1) Greater than 12 kva supply transformer Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6V (lightning) Phase to ground voltage exceeds 125% of normal line to line voltage Ungrounded distribution system or Isolation Transformer Remove MOV jumper to ground. or Install Isolation Transformer with grounded secondary if necessary. (1) Refer to Appendix B of the PowerFlex 4 User Manual on CD for accessory ordering information. I/O Wiring Recommendations (2) Wire Type(s) Description Minimum Insulation Rating Belden 876/946 (or equiv.) Belden 877 (or equiv.) I/O Terminal Block Specifications.8 mm 2 (18AWG), twisted pair, 1% shield with drain..8 mm 2 (18AWG), 3 conductor, shielded for remote pot only. 3V 6 degrees C (14 degrees F) (2) 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. Frame Maximum Wire Size (3) Minimum Wire Size (3) Torque B & C 1.3 mm 2 (16 AWG).13 mm 2 (26 AWG).5-.8 N-m (4.4-7 lb.-in.) (3) Maximum / minimum that the terminal block will accept - these are not recommendations. Refer to the PowerFlex 4 User Manual on CD for maximum power and control cable length recommendations.

6 English-6 Relay N.O. Relay Common Relay N.C. Control Terminal Block Control Wiring Block Diagram Enable (4) Jumper R1 R2 R3 SNK SRC 3V DC 5mA Non-inductive +24V +1V -1V /4-2mA Stop (1) Typical SRC Wiring Start/Run FWD (2) Direction/Run REV Digital Common Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Opto Common +24V DC +1V DC -1V (or ±1V) Input Analog Common 4-2mA Input Analog Output Opto Output 1 Opto Output 2 RS485 Shield Pot must be 1-1k ohm 2 Watt Min. Typical SNK Wiring Common (3) 24V -1V -2mA R1 R2 R3 3V DC 125V AC 24V AC Resistive 3.A 3.A 3.A Inductive.5A.5A.5A SNK SRC Analog Output Select ENBL (1) Enable (4) Jumper RS485 (DSI) 1 (1) Important: I/O Terminal 1 is always a coast to stop input except when P36 [Start Source] is set to 3-Wire control. In three wire control, I/O Terminal 1 is controlled by P37 [Stop Mode]. All other stop sources are controlled by P37 [Stop Mode]. (2) P36 [Start Source] Stop I/O Terminal 1 Stop Keypad Per P37 Coast 3-Wire Per P37 Per P37 2-Wire Per P37 Coast RS485 Port Per P37 Coast Important: The drive is shipped with a jumper installed between I/O Terminals 1 and 11. Remove this jumper when using I/O Terminal 1 as a stop or enable input. Two wire control shown. For three wire control use a momentary input on I/O Terminal 2 to command a start. Use a maintained input for I/O Terminal 3 to change direction. (3) When using an opto output with an inductive load such as a relay, install a recovery diode parallel to the relay as shown, to prevent damage to the output. (4) When the ENBL jumper is removed, I/O Terminal 1 will always act as a hardware enable, causing a coast to stop. Refer to the PowerFlex 4 User Manual on CD for more information.

7 English-7 Control I/O Terminal Designations No. Signal Default Description Param. R1 Relay N.O. Fault Normally open contact for output relay. A55 R2 Relay Common Common for output relay. R3 Relay N.C. Fault Normally closed contact for output relay. A55 Analog Output Select DIP Switch Sink/Source DIP Switch -1V Sets analog output to either voltage or current. Setting must match A65 [Analog Out Sel]. Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting. 1 Stop (1) Coast The factory installed jumper or a normally closed input must be present for the drive to start. P36 (1) 2 Start/Run FWD Not Active Command comes from the integral keypad by default. P36, P37 3 Direction/Run REV Not Active To disable reverse operation, see A95 [Reverse P36, P37, Disable]. A95 4 Digital Common For digital inputs. Electronically isolated with digital inputs from analog I/O and opto outputs. 5 Digital Input 1 Preset Freq Program with A51 [Digital In1 Sel]. A51 6 Digital Input 2 Preset Freq Program with A52 [Digital In2 Sel]. A52 7 Digital Input 3 Local Program with A53 [Digital In3 Sel]. A53 8 Digital Input 4 Jog Forward Program with A54 [Digital In4 Sel]. A54 9 Opto Common For opto-coupled outputs. Electronically isolated with opto outputs from analog I/O and digital inputs V DC Referenced to Digital Common. Drive supplied power for digital inputs. Maximum output current is 1mA V DC Referenced to Analog Common. Drive supplied power for -1V external potentiometer. Maximum output current is 15mA. P38 13 ±1V In (2) Not Active For external -1V (unipolar) or ±1V (bipolar) input supply (input impedance = 1k ohm) or potentiometer wiper. 14 Analog Common For -1V In or 4-2mA In. Electronically isolated with analog inputs and outputs from digital I/O and opto outputs mA In (2) Not Active For external 4-2mA input supply (input impedance = 25 ohm). 16 Analog Output OutFreq -1 The default analog output is -1V. To covert to a current value, change the Analog Output Select DIP Switch to -2mA. Program with A65 [Analog Out Sel]. Max analog value can be scaled with A66 [Analog Out High]. Maximum Load: 4-2mA = 525 ohm (1.5V) -1V = 1k ohm (1mA) P38, A51-A54, A123, A132 P38, A51-A54, A132 A65, A66 17 Opto Output 1 MotorRunning Program with A58 [Opto Out1 Sel] A589, A59, A64 18 Opto Output 2 At Frequency Program with A61 [Opto Out2 Sel] A61, A62, A64 19 RS485 (DSI) Shield Terminal should be connected to safety ground - PE when using the RS485 (DSI) communications port. (1) See Footnote (1) on page 6. (2) -1V In and 4-2mA In are distinct input channels and may be connected simultaneously. Inputs may be used independently for speed control or jointly when operating in PID mode.

8 English-8 Prepare For Drive Start-Up! 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. 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 page 7 for location. Important: The default control scheme is Source (SRC). The Stop terminal is jumpered (I/O Terminals 1 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 1 and 11 and installed between I/O Terminals 1 and Verify that the Stop input is present or the drive will not start. Important: If I/O Terminal 1 is used as a stop input, the jumper between I/O Terminals 1 and 11 must be removed. Applying Power to the Drive 6. Apply AC power and control voltages to the drive. 7. Familiarize yourself with the integral keypad features (see next page) 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 A95 [Reverse Disable]. If a fault appears on power up, refer to page 15 for an explanation of the fault code. For complete troubleshooting information, refer to the PowerFlex 4 User Manual on the CD supplied with the drive.

9 See the PowerFlex 4 User Manual on CD for more information on parameters. English-9 Integral Keypad ➏ ➋ ➊ RUN FWD REV ➍ PROGRAM ➐ ➎ FAULT ➌ ➑ Menu Description Display Group (View Only) Consists of commonly viewed drive operating conditions. Basic Program Group Consists of most commonly used programmable functions. Advanced Program Group Consists of remaining programmable functions. ➒ Fault Designator Consists of list of codes for specific fault conditions. Displayed only when fault is present. No. LED LED State Description ➊ Run/Direction Steady Red Indicates drive is running and commanded motor direction. Status Flashing Red Drive has been commanded to change direction. Indicates actual motor direction while decelerating to zero. ➋ Alphanumeric Steady Red Indicates parameter number, parameter value, or fault code. Display Flashing Red Single digit flashing indicates that digit can be edited. All digits flashing indicates a fault condition. Displayed Units Steady Red Indicates the units of the parameter value being displayed. ➌ ➍ ➎ ➏ ➐ Program Status Steady Red Indicates parameter value can be changed. Fault Status Flashing Red Indicates drive is faulted. Pot Status Steady Green Indicates potentiometer on Integral Keypad is active. Start Key Status Steady Green Indicates Start key on Integral Keypad is active. The Reverse key is also active unless disabled by A95 [Reverse Disable]. No. Key Name Description ➑ Escape Back one step in programming menu. Cancel a change to a parameter value and exit Program Mode. Select Advance one step in programming menu. Select a digit when viewing parameter value. Up Arrow Down Arrow Enter 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. ➒ Potentiometer Used to control speed of drive. Default is active. Controlled by parameter P38. Start Reverse Stop Used to start the drive. Default is active. Controlled by parameter P36. Used to reverse direction of the drive. Default is active. Controlled by parameters P36 and A95. Used to stop the drive or clear a fault. This key is always active. Controlled by parameter P37.

10 English-1 See the PowerFlex 4 User Manual on CD for more information on parameters. 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) Example Displays 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 parameter s current value. PROGRAM FAULT (Example shows the value of d1 [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. PROGRAM FAULT 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). or PROGRAM FAULT 5. Press Enter or Sel to enter a group. The right digit of the last viewed parameter in that group will flash. or PROGRAM FAULT 6. Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group. or 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. or PROGRAM FAULT 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. or PROGRAM FAULT 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. or 1. 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 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 d1 [Output Frequency] is displayed. Press Enter or Sel to enter the group menu. PROGRAM FAULT

11 See the PowerFlex 4 User Manual on CD for more information on parameters. English-11 Display Group Parameters No. Parameter Min/Max Display/Options d1 [Output Freq]./[Maximum Freq].1 Hz d2 [Commanded Freq]./[Maximum Freq].1 Hz d3 [Output Current]./Drive Amps 2.1 Amps d4 [Output Voltage] /Drive Rated Volts 1 VAC d5 [DC Bus Voltage] Based on Drive Rating 1 VDC d6 [Drive Status] /1 (1 = Condition True) Bit 3 Bit 2 Bit 1 Bit Decelerating Accelerating Forward Running d7- [Fault x Code] F2/F122 F1 d9 d1 [Process Display]./ d12 [Control Source] /9 Bit 1 = Speed Command Bit = Start Command (See P38; 9 = Jog Freq ) (See P36; 9 = Jog ) d13 [Contrl In Status] /1 (1 = Input Present) Bit 3 Bit 2 Bit 1 Bit Dynamic Brake Stop Input Dir/Run REV Start/Run FWD d14 [Dig In Status] /1 (1 = Input Present) Bit 3 Bit 2 Bit 1 Bit Digital In4 Sel Digital In3 Sel Digital In2 Sel Digital In1 Sel d15 [Comm Status] /1 (1 = Condition True) Bit 3 Bit 2 Bit 1 Bit Fault Occurred RS485 Option Transmitting Receiving d16 [Control SW Ver] 1./ d17 [Drive Type] 11/ d18 [Elapsed Run Time] /9999 Hrs 1 = 1 Hrs d19 [Testpoint Data] /FFFF 1 Hex d2 [Analog In -1V]./1.%.1% d21 [Analog In 4-2mA]./1.%.1% d22 [Output Power]./Drive Power 2.1 kw d23 [Output Powr Fctr]./18. deg.1 deg d24 [Drive Temp] /12 degc 1 degc d25 [Counter Status] / d26 [Timer Status]./ Secs d28 [Stp Logic Status] /7 1 Smart Start-Up with Basic Program Group Parameters The PowerFlex 4 is designed so that start up is simple and efficient. The Program Group contains the most commonly used parameters. = Stop drive before changing this parameter. No. Parameter Min/Max Display/Options Default P31 [Motor NP Volts] 2/Drive Rated Volts 1 VAC Based on Drive Rating Set to the motor nameplate rated volts. P32 [Motor NP Hertz] 15/4 Hz 1 Hz 6 Hz Set to the motor nameplate rated frequency. P33 [Motor OL Current]./(Drive Rated Amps 2).1 Amps Based on Drive Rating Set to the maximum allowable motor current. P34 [Minimum Freq]./4. Hz.1 Hz. Hz Sets the lowest frequency the drive will output continuously. P35 [Maximum Freq] /4 Hz 1 Hz 6 Hz Sets the highest frequency the drive will output. P36 [Start Source] /5 = Keypad (1) Sets the control scheme used to start the drive. 1 = 3-Wire 2 = 2-Wire (1) When active, the Reverse key is also active 3 = 2-W Lvl Sens unless disabled by A95 [Reverse Disable]. 4 = 2-W Hi Speed 5 = Comm Port P37 [Stop Mode] /7 = Ramp, CF (1) Active stop mode for all stop sources [e.g. keypad, 1 = Coast, CF (1) run forward (I/O Terminal 2), run reverse (I/O 2 = DC Brake, CF (1) Terminal 3), RS485 port] except as noted below. 3 = DCBrkAuto,CF (1) Important: I/O Terminal 1 is always a coast to 4 = Ramp stop input except when P36 [Start Source] is set 5 = Coast for 3-Wire control. When in three wire control, I/O 6 = DC Brake Terminal 1 is controlled by P37 [Stop Mode]. 7 = DC BrakeAuto (1) Stop input also clears active fault.

12 English-12 = Stop drive before changing this parameter. No. Parameter Min/Max Display/Options Default P38 [Speed Reference] /6 = Drive Pot Sets the source of the speed reference to the 1 = InternalFreq drive. 2 = -1V Input Important: When A51 or A52 [Digital Inx Sel] is 3 = 4-2mA Input set to option 2, 4, 5, 6, 13 or 14 and the digital 4 = Preset Freq input is active, A51, A52, A53 or A54 will 5 = Comm Port override the speed reference commanded by this 6 = Stp Logic parameter. Refer to Chapter 1 of the PowerFlex 4 User Manual on CD for details. P39 [Accel Time 1]./6. Secs.1 Secs 1. Secs Sets the rate of accel for all speed increases. P4 [Decel Time 1].1/6. Secs.1 Secs 1. Secs Sets the rate of decel for all speed decreases. P41 [Reset To Defalts] /1 = Ready/Idle Resets all parameter values to factory defaults. 1 = Factory Rset Advanced Group Parameters No. Parameter Min/Max Display/Options Default A51 A52 A53 A54 [Digital In1 Sel] I/O Terminal 5 [Digital In2 Sel] I/O Terminal 6 [Digital In3 Sel] I/O Terminal 7 [Digital In4 Sel] I/O Terminal 8 /25 = Not Used 1 = Acc & Dec 2 2 = Jog 3 = Aux Fault 4 = Preset Freq 5 = Local 6 = Comm Port 7 = Clear Fault 8 = RampStop,CF 9 = CoastStop,CF 1 = DCInjStop,CF 11 = Jog Forward 12 = Jog Reverse 13 = 1V In Ctrl 14 = 2mA In Ctrl 15 = PID Disable 16 = MOP Up 17 = MOP Down 18 = Timer Start 19 = Counter In 2 = Reset Timer 21 = Reset Countr 22 = Rset Tim&Cnt 23 = Logic In1 24 = Logic In2 25 = Current Lmt A55 [Relay Out Sel] /2 = Ready/Fault 1 = At Frequency 2 = MotorRunning 3 = Reverse 4 = Motor Overld 5 = Ramp Reg 6 = Above Freq 7 = Above Cur 8 = Above DCVolt 9 = Retries Exst 1 = Above Anlg V 11 = Logic In 1 12 = Logic In 2 13 = Logic 1 & 2 14 = Logic 1 or 2 15 = StpLogic Out 16 = Timer Out 17 = Counter Out 18 = Above PF Ang 19 = Anlg In Loss 2 = ParamControl A56 [Relay Out Level]./ A58 A61 [Opto Out1 Sel] [Opto Out2 Sel] /2 = Ready/Fault 1 = At Frequency 2 = MotorRunning 3 = Reverse 4 = Motor Overld 5 = Ramp Reg 6 = Above Freq 7 = Above Cur 8 = Above DCVolt 9 = Retries Exst 1 = Above Anlg V 11 = Logic In 1 12 = Logic In 2 13 = Logic 1 & 2 14 = Logic 1 or 2 15 = StpLogic Out 16 = Timer Out 17 = Counter Out 18 = Above PF Ang 19 = Anlg In Loss 2 = ParamControl 2 1 A59 A62 [Opto Out1 Level] [Opto Out2 Level]./ A55, A58 & A61 Setting A56, A59 & A62 Min/Max 6 /4 Hz 7 /18% 8 /815 Volts 1 /1% 16.1/9999 Secs 17 1/9999 Counts 18 1/18 degs 2 /1

13 English-13 No. Parameter Min/Max Display/Options Default A64 [Opto Out Logic] /3 1 A64 Option Opto Out1 Logic Opto Out2 Logic NO (Normally Open) NO (Normally Open) 1 NC (Normally Closed) NO (Normally Open) 2 NO (Normally Open) NC (Normally Closed) 3 NC (Normally Closed) NC (Normally Closed) A65 [Analog Out Sel] /14 1 A66 [Analog Out High] /8% 1% 1% A67 [Accel Time 2]./6. Secs.1 Secs 2. Secs A68 [Decel Time 2].1/6. Secs.1 Secs 2. Secs A69 [Internal Freq]./4. Hz.1 Hz 6. Hz A7 A71 A72 A73 A74 A75 A76 A77 Option Output Range Minimum Output Value Maximum Output Value [Analog Out High] DIP Switch Position OutFreq -1-1V V = Hz P35 [Maximum Freq] -1V 1 OutCurr -1-1V V = Amps 2% Drive Rated FLA -1V 2 OutVolt -1-1V V = Volts 12% Drive Rated Output Volts -1V 3 OutPowr -1-1V V = kw 2% Drive Rated Power -1V 4 TstData -1-1V V = (Hex FFFF) -1V 5 OutFreq -2-2mA ma = Hz P35 [Maximum Freq] -2mA 6 OutCurr -2-2mA ma = Amps 2% Drive Rated FLA -2mA 7 OutVolt -2-2mA ma = Volts 12% Drive Rated Output Volts -2mA 8 OutPowr -2-2mA ma = kw 2% Drive Rated Power -2mA 9 TstData -2-2mA ma = (Hex FFFF) -2mA 1 OutFreq mA 4 ma = Hz P35 [Maximum Freq] -2mA 11 OutCurr mA 4 ma = Amps 2% Drive Rated FLA -2mA 12 OutVolt mA 4 ma = Volts 12% Drive Rated Output Volts -2mA 13 OutPowr mA 4 ma = kw 2% Drive Rated Power -2mA 14 TstData mA 4 ma = (Hex FFFF) -2mA [Preset Freq ] (1) [Preset Freq 1] [Preset Freq 2] [Preset Freq 3] [Preset Freq 4] [Preset Freq 5] [Preset Freq 6] [Preset Freq 7]./4. Hz.1 Hz. Hz 5. Hz 1. Hz 2. Hz 3. Hz 4. Hz 5. Hz 6. Hz (1) To activate [Preset Freq ] set P38 [Speed Reference] to option 4. Input State of Digital In 1 (I/O Terminal 5) Input State of Digital In 2 (I/O Terminal 6) Input State of Digital In 3 (I/O Terminal 7) A78 [Jog Frequency]./[Maximum Freq].1 Hz 1. Hz A79 [Jog Accel/Decel].1/6. Secs.1 Secs 1. Secs A8 [DC Brake Time]./99.9 Secs.1 Secs. Secs A setting of 99.9 Secs = Continuous A81 [DC Brake Level]./(Drive Amps 1.8).1 Amps Amps.5 A82 [DB Resistor Sel] /99 = Disabled 1 = Normal RA Res Frequency Source Accel / Decel Parameter Used (2) [Preset Freq ] [Accel Time 1] / [Decel Time 1] 1 [Preset Freq 1] [Accel Time 1] / [Decel Time 1] 1 [Preset Freq 2] [Accel Time 2] / [Decel Time 2] 1 1 [Preset Freq 3] [Accel Time 2] / [Decel Time 2] 1 [Preset Freq 4] [Accel Time 1] / [Decel Time 1] 1 1 [Preset Freq 5] [Accel Time 1] / [Decel Time 1] 1 1 [Preset Freq 6] [Accel Time 2] / [Decel Time 2] [Preset Freq 7] [Accel Time 2] / [Decel Time 2] (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. 2 = NoProtection 3-99 = % of Duty Cycle A83 [S Curve %] /1% 1% % (Disabled) A84 [Boost Select] /14 Settings in % of base voltage. 8 Only active when A125 [Torque Perf Mode] is = Custom V/Hz 7 (5, 7.5 & 1 set to V/Hz. Variable Torque Constant Torque HP Drives) 1 = 3., VT 5 =., no IR 1 = 1., CT 2 = 35., VT 6 =. 11 = 12.5, CT 3 = 4., VT 7 = 2.5, CT 12 = 15., CT 4 = 45., VT 8 = 5., CT 13 = 17.5, CT 9 = 7.5, CT 14 = 2., CT A85 [Start Boost]./25.%.1% 2.5% Only active when A84 [Boost Select] and A125 [Torque Perf Mode] are set to.

14 English-14 No. Parameter Min/Max Display/Options Default A86 [Break Voltage]./1.%.1% 25.% Only active when A84 [Boost Select] and A125 [Torque Perf Mode] are set to. A87 [Break Frequency]./4. Hz.1 Hz 15. Hz Only active when A84 [Boost Select] and A125 [Torque Perf Mode] are set to. A88 [Maximum Voltage] 2/Rated Volts 1 VAC Rated Volts A89 [Current Limit 1].1/(Drive Amps 1.8).1 Amps Amps 1.5 A9 [Motor OL Select] /2 = No Derate 1 = Min Derate 2 = Max Derate A91 [PWM Frequency] 2./16. khz.1 khz 4. khz A92 [Auto Rstrt Tries] /9 1 A93 [Auto Rstrt Delay]./3. Secs.1 Secs 1. Secs A94 [Start At PowerUp] /1 = Disabled 1 = Enabled A95 [Reverse Disable] /1 = Rev Enabled 1 = Rev Disabled A96 [Flying Start En] /1 = Disabled 1 = Enabled A97 [Compensation] /3 = Disabled 2 = Mechanical 1 1 = Electrical 3 = Both A98 [SW Current Trip]./(Drive Amps 2).1 Amps. (Disabled) A99 [Process Factor].1/ A1 [Fault Clear] /2 = Ready/Idle 1 = Reset Fault 2 = Clear Buffer A11 [Program Lock] /9999 = Unlocked 1 = Locked A12 [Testpoint Sel] 4/FFFF 1 Hex 4 A13 [Comm Data Rate] /5 = 12 3 = 96 3 Power to drive must be cycled before any 1 = 24 4 = 19.2K changes will affect drive operation. 2 = 48 5 = 38.4K A14 [Comm Node Addr] 1/ Power to drive must be cycled before any changes will affect drive operation. A15 [Comm Loss Action] /3 = Fault 2 = Stop 1 = Coast Stop 3 = Continu Last A16 [Comm Loss Time].1/6. Secs.1 5. A17 [Comm Format] /2 = RTU 8-N-1 1 = RTU 8-E-1 Power to drive must be cycled before any changes will affect drive operation. A18 [Language] 1/1 1 = English 2 = Français 3 = Español 4 = Italiano 5 = Deutsch 2 = RTU 8-O-1 6 = Reserved 7 = Português 8 = Reserved 9 = Reserved 1 = Nederlands A11 [Anlg In -1V Lo]./1.%.1%.% A111 [Anlg In -1V Hi]./1.%.1% 1.% A112 [Anlg In4-2mA Lo]./1.%.1%.% A113 [Anlg In4-2mA Hi]./1.%.1% 1.% A114 [Slip FLA]./1. Hz.1 Hz 2. Hz A118 [Current Limit 2].1/(Drive Amps 1.8).1 Amps Amps 1.5 A119 [Skip Frequency] /4 Hz 1 Hz Hz A12 [Skip Freq Band]./3. Hz.1 Hz. Hz A121 [Stall Fault Time] /5 = 6 Seconds 1 = 12 Seconds 2 = 24 Seconds A122 [Analog In Loss] /6 = Disabled 1 = Fault (F29) 2 = Stop 3 = Zero Ref 3 = 36 Seconds 4 = 48 Seconds 5 = Flt Disabled 4 = Min Freq Ref 5 = Max Freq Ref 6 = Int Freq Ref A123 [1V Bipolar Enbl] /1 = Uni-Polar In 1 = Bi-Polar In A124 [Var PWM Disable] /1 = Enabled 1 = Disabled A125 [Torque Perf Mode] /1 = V/Hz 1 = Sensrls Vect 1 A126 [Motor NP FLA] Drive Amps.1/2.1 Amps Rated Amps 1

15 To clear a fault, press the Stop key, cycle power or set A1 [Fault Clear] to 1 or 2. English-15 No. Parameter Min/Max Display/Options Default A127 [Autotune] /2 = Ready/Idle 2 = Rotate Tune 1 = Static Tune A128 [IR Voltage Drop]./23. VAC.1 VAC Rated Volts A129 [Flux Current Ref]./[Motor NP Volts].1 Amps Rated Amps A13 [PID Trim Hi]./ A131 [PID Trim Lo]./ A132 [PID Ref Sel] /8 = PID Disabled 5 = Setpnt, Trim 1 = PID Setpoint 2 = -1V Input 3 = 4-2mA Input 4 = Comm Port 6 = -1V, Trim 7 = 4-2mA, Trim 8 = Comm, Trim A133 [PID Feedback Sel] /2 = -1V Input 2 = Comm Port 1 = 4-2mA Input A134 [PID Prop Gain]./ A135 [PID Integ Time]./999.9 Secs.1.1 A136 [PID Diff Rate]./99.99 (1/Secs).1.1 A137 [PID Setpoint]./1.%.1%.% A138 [PID Deadband]./1.%.1%.% A139 [PID Preload]./4. Hz.1 Hz. Hz A14- A147 A15- A157 [Stp Logic -7] 1/BAFF 4 Digits For a list of digit options, refer to the PowerFlex 4 User Manual on the CD supplied with the drive. F1 [Stp Logic Time -7]./999.9 Secs.1 Secs 3. Secs Fault Codes No. Fault Description F2 Auxiliary Input (1) Check remote wiring. F3 Power Loss Monitor the incoming AC line for low voltage or line power interruption. F4 UnderVoltage (1) Monitor the incoming AC line for low voltage or line power interruption. F5 OverVoltage (1) Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. F6 Motor Stalled (1) Increase [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A89 [Current Limit]. F7 Motor Overload (1) An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P33 [Motor OL Current]. F8 Heatsink OvrTmp (1) Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded 4 C (14 F) for IP 3/NEMA 1/UL Type 1 installations or 5 C (122 F) for Open type installations. Check fan. F12 HW OverCurrent (1) Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current. F13 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition. F29 Analog In Loss An analog input is configured to fault on signal loss. A signal loss has occurred. F33 Auto Rstrt Tries Correct the cause of the fault and manually clear. F38 Phase U to Gnd Check the wiring between the drive and motor. Check motor for grounded phase. F39 Phase V to Gnd Replace drive if fault cannot be cleared. F4 Phase W to Gnd F41 Phase UV Short Check the motor and drive output terminal wiring for a shorted condition. F42 Phase UW Short Replace drive if fault cannot be cleared. F43 Phase VW Short F48 Params Defaulted The drive was commanded to write default values to EEPROM. Clear the fault or cycle power to the drive. Program the drive parameters as needed. F63 SW OverCurrent (1) Check load requirements and A98 [SW Current Trip] setting. F64 Drive Overload Reduce load or extend Accel Time. F7 Power Unit Cycle power. Replace drive if fault cannot be cleared. F8 Autotune Failure The autotune function was either cancelled by the user of failed. F81 Comm Loss If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required. Check connection. An adapter was intentionally disconnected. Turn off using A15 [Comm Loss Action]. F1 Parameter Checksum Restore factory defaults. F122 I/O Board Fail Cycle power. Replace drive if fault cannot be cleared. (1) Auto-Reset/Run type fault. Configure with parameters A92 and A93.

16 English-16 Drive Dimensions PowerFlex 4 Frames Ratings are in kw and (HP) Frame 12V AC 1-Phase 24V AC 1-Phase 24V AC 3-Phase 48V AC 3-Phase B.4 (.5).75 (1.) 1.1 (1.5) PowerFlex 4 AC Drive.4 (.5).75 (1.) 1.5 (2.).4 (.5).75 (1.) 1.5 (2.) C 2.2 (3.) 5.5 (7.5) 7.5 (1.) A D C 2.2 (3.) 3.7 (5.).4 (.5).75 (1.) 1.5 (2.) 5.5 (7.5) 7.5 (1.) Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). 2.2 (3.) 4. (5.) E B F Frame A B C D E F B 1 (3.94) C 13 (5.1) 18 (7.9) 26 (1.2) 136 (5.35) 18 (7.1) 87 (3.43) 116 (4.57) 168 (6.61) 246 (9.7) 87.4 (3.44) Ship Weight 2.2 (4.9) 4.3 (9.5) A 5.5 (.22) Communication, RFI Filter, IP 3/NEMA 1/UL Type 1 Option Kits B 79.1 (3.11) 64.1 (2.52) 4.6 (1.6) 25.6 (1.1) 22.2 (.87) 17. (4.21) 66. (2.6) 24. (.94) 28.5 (1.12) 22.2 (.87) C 74.3 (2.93) 19.9 (4.33) (4.38) (5.99) Dimension Option D B Frame Drive C Frame Drive A Comm Cover 25 (.98) 25 (.98) B EMC Line Filter 5 (1.97) (1) C EMC Line Filter 229 (9.2) (1) D IP3/NEMA 1/UL 33 (1.3) 6 (2.36) Type 1 IP3/NEMA 1/UL 64 (2.52) 6 (2.36) Type 1 for Comm Cover B Frame - 22-JBAB 77.5 (3.5) 5. (1.97) 22.5 (.89) 22.2 (.87) 15.3 (4.15) 76.3 (3.) (5.29) C Frame - 22-JBAC 18.7 (4.28) 92.2 (3.63) 69.2 (2.72) 45.7 (1.8) 22.2 (.87) 22.2 (.87) (5.7) 19.8 (4.32) 28.5 (1.12) (7.8) (1) Not available at print. B Frame - 22-JBCB (used with Comm Cover) C Frame - 22-JBCC (used with Comm Cover) U.S. Allen-Bradley Drives Technical Support Tel: (1) , Fax: (1) , [email protected], Online: Publication 22B-QS1A-EN-P October 22 Copyright 22 Rockwell Automation, Inc. All rights reserved. Printed in Taiwan.