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

ii
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
ZZ
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.