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
ZZ
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.