Rockwell Automation Allen-Bradley PowerFlex 4 User manual

Adjustable
Frequency AC
Drive
FRN 2.xx
User Manual
www.abpowerflex.com
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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 Allen-Bradley Sales Office or online at http://www.ab.com/manuals/gi )
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 the Allen-Bradley Company 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, the Allen-Bradley Company cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Allen-Bradley Company 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 the Allen-Bradley Company is prohibited.
Throughout this manual we use notes to make you aware of safety considerations.
Attentions help you:
• identify a hazard
• avoid the hazard
• recognize the consequences
Important: Identifies information that is especially important for successful
application and understanding of the product.
DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation.
PLC is a registered trademark of Rockwell Automation.
ControlNet is a trademark of ControlNet International, Ltd.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
!
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss.
Shock Hazard labels may be located on or inside the drive to alert
people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the drive to alert
people that surfaces may be at dangerous temperatures.
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Summary of Changes
The information below summarizes the changes to the PowerFlex 4 User
Manual since the last release.
Description of New or Updated Information See Page(s)
Minimum mounting clearances between drive reduced to 25 mm (1.0 in.). 1-2
Expanded information on branch circuit protective devices. 1-7
New information on I/O wiring including additional wiring examples. 1-13 – 1-16
Expanded specifications information. A-2
Section on RS485 (DSI) Protocol added. C-1 – C-5
The following parameter descriptions or values have changed:
P037 [Stop Mode] – Description changed
A084 [Start Boost] – New default value for 5 HP drives
A107 [Comm Format] – Description changed
3-10
3-19
3-24
The following parameters have been added:
d020 [0-10V Analog Input]
d021 [4-20mA Analog Input]
A110 [0-10V Analog Input Low]
A111 [0-10V Analog Input High]
A112 [4-20mA Analog Input Low]
A113 [4-20mA Analog Input High]
A114 [Slip Compensation]
3-7
3-7
3-24
3-25
3-25
3-25
3-25
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soc-2
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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 . . . . . 1-17
EMC Instructions . . . . . . . . . . . . . . . . . . 1-19
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. . 3-26
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-5
Appendix C
RS485 (DSI) Protocol
Index
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ii
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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 …
Industrial Automation Wiring
and Grounding Guidelines
1770-4.1 www.ab.com/manuals/gi
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-SB001A-EN-E www.ab.com/manuals/dr
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1 www.ab.com/manuals/gi
A Global Reference Guide for
Reading Schematic Diagrams
0100-2.10 www.ab.com/manuals/ms
Guarding Against Electrostatic
Damage
8000-4.5.2 www.ab.com/manuals/dr
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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
Shall Required and necessary
Should Recommended
Should Not Not Recommended
Drive Frame Sizes
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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.
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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
4 RS485
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP 20 (NEMA Type Open)
22A - A 1P5 N 1 1 4
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Comm Slot
Output Current @ 100-120 Input or 200-240V Input
Code Amps kW (HP)
1P5 1.5 0.2 (0.25)
2P3 2.3 0.37 (0.5)
4P5 4.5 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12 2.2 (3.0)
017 17.5 3.7 (5.0)
Code Rating
0 No Filter
1 Integral EMI Filter
Output Current @ 380-480V Input
Code Amps kW (HP)
1P4 1.4 0.37 (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)
Code
22A PowerFlex 4
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Chapter
1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 4 Drive.
Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.
1. Press and hold in the tabs on each side of the cover.
2. Pull the cover out and up to release.
For information on… See page For information on… See page
Opening the Cover 1-1 Fuses and Circuit Breakers 1-6
Mounting Considerations 1-2 Power Wiring 1-8
AC Supply Source Considerations 1-3 I/O Wiring
Recommendations
1-11
General Grounding Requirements 1-4 EMC Instructions 1-19
!
ATTENTION: The following information is merely a guide for proper
installation. The Allen-Bradley Company cannot assume responsibility
for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.
Opening the Cover
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1-2 Installation/Wiring
• Mount the drive upright on a flat, vertical and level surface.
– Install on 35 mm DIN Rail.
or
– Install with screws.
Table 1.A Screw Mounting Recommendations
• 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
Refer to Appendix B for mounting dimensions.
Ambient Operating Temperatures
Table 1.B Enclosure and Clearance Requirements
Debris Protection
A plastic top panel is included with the drive. Install the panel to prevent
debris from falling through the vents of the drive housing during
installation. Remove the panel for IP 20/Open Type applications.
Storage
• Store within an ambient temperature range of -40° to +85°C.
• Store within a relative humidity range of 0% to 95%,
non-condensing.
• Do not expose to a corrosive atmosphere.
Mounting Considerations
Minimum Panel Thickness Screw Size Mounting Torque
1.9 mm (0.0747 in.) m4 x 0.7 (#8-32) 1.56-1.96 Nm (14-17 lb.-in.)
Ambient Temperature Enclosure Rating Minimum Mounting
Clearances
Minimum Maximum
-10°C (14°F)
40°C (104°F)
IP 20/Open Type Use Mounting Option A
IP 30/NEMA 1/UL Type 1
(1)
(1)
Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.
Use Mounting Option B
50°C (122°F) IP 20/Open Type Use Mounting Option B
25 mm
(1.0 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Mounting Option A
No clearance required
between drives.
Mounting Option B
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Installation/Wiring 1-3
Ungrounded Distribution Systems
Disconnecting MOVs
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures 1.1 and 1.2.
1. Turn the screw counterclockwise to loosen.
2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Figure 1.1 Jumper Location (A Frame Shown)
Figure 1.2 Phase to Ground MOV Removal
AC Supply Source Considerations
!
ATTENTION: PowerFlex 4 drives contain protective MOVs that are
referenced to ground. These devices should be disconnected if the drive
is installed on an ungrounded distribution system.
Important:
Tighten screw after
jumper removal.
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper
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1-4 Installation/Wiring
Input Power Conditioning
The drive is suitable for direct connection to input power within the rated
voltage of the drive (see Appendix A). Listed in Table 1.C are certain
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in
Table 1.C, install one of the devices listed under the heading
Corrective
Action on the line side of the drive.
Important: Only one device per branch circuit is required. It should be
mounted closest to the branch and sized to handle the total
current of the branch circuit.
Table 1.C Input Power Conditions
The drive Safety Ground - (PE) must be connected to system ground.
Ground impedance must conform to the requirements of national and
local industrial safety regulations and/or electrical codes. The integrity
of all ground connections should be periodically checked.
Figure 1.3 Typical Grounding
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) • Install Line Reactor
(1)
• or Isolation Transformer
(1)
Refer to
Appendix B
for accessory ordering information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors
Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of normal
line to line voltage
• Remove MOV jumper to ground.
• or Install Isolation Transformer
with grounded secondary if
necessary.
Ungrounded distribution system
General Grounding Requirements
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
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Installation/Wiring 1-5
Ground Fault Monitoring
If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.
Safety Ground - (PE)
This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with national
and local industrial safety regulations and/or electrical codes.
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
Shield Termination - SHLD
Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding
point for the cable shield.
When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.
RFI Filter Grounding
Using single phase drives with integral filter, or an external filter with
any drive rating, may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded
AC supply systems and be permanently installed and solidly
grounded (bonded) to the building power distribution ground. Ensure
that the incoming supply neutral is solidly connected (bonded) to the
same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should
be periodically checked.
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1-6 Installation/Wiring
The PowerFlex 4 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.
Fusing
The PowerFlex 4 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide. Other devices which meet the
requirements of UL508C and UL489 with similar trip characteristics
may be used in order to meet local or national electrical codes.
Bulletin 140 Manual Motor Starters/UL489 Circuit Breakers
When using Bulletin 140 manual motor starters or UL489 rated circuit
breakers, the guidelines listed below must be followed in order to meet
the NEC requirements for branch circuit protection.
•Bulletin 140 manual motor starters can be used in single and group
motor applications.
•In single motor applications, a fuse or UL489 rated circuit breaker is
required ahead of the Bulletin 140 manual motor starter.
•In group motor installations, the Bulletin 140 can be used for
protection of an individual motor within the group and “one set” of
fuses or a UL489 rated circuit breaker serves as the Branch Circuit
Protective Device for the entire “Group Installation”.
•If the installation is not required to meet NEC requirements, Bulletin
140M manual motor starters can be used in single and group motor
applications without additional short circuit protection. Refer to the
technical support literature for the 140M for more details.
Fuses and Circuit Breakers
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in this section.
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Installation/Wiring 1-7
Table 1.D Minimum Recommended Branch Circuit Protective Devices
Voltage
Rating
Drive Rating
kW (HP)
Fuse Rating(1)
Amps
(1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or
equivalent.
140M Motor
Protectors
Catalog No.
Recommended
MCS Contactors
Catalog No.
120V AC –
1-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
10
15
30
140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
100-C09
100-C12
100-C23
240V AC –
1-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
10
10
15
30
140M-C2E-B63
140M-C2E-B63
140M-C2E-C16
140M-D8E-C20
100-C09
100-C09
100-C12
100-C23
240V AC –
3-Phase
0.2 (0.25)
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
3
6
10
15
25
35
140M-C2E-B25
140M-C2E-B40
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-F8E-C25
100-C09
100-C09
100-C09
100-C12
100-C16
100-C23
480V AC –
3-Phase
0.37 (0.5)
0.75 (1.0)
1.5 (2.0)
2.2 (3.0)
3.7 (5.0)
3
6
10
15
15
140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16
100-C09
100-C09
100-C09
100-C09
100-C16
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1-8 Installation/Wiring
Motor Cable Types Acceptable for 200-600 Volt Installations
General
A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.).
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of
15 mils and should not have large variations in insulation concentricity.
Shielded
Power Wiring
!
ATTENTION: National Codes and standards (NEC, VDE, BSI, etc.)
and local codes outline provisions for safely installing electrical
equipment. Installation must comply with specifications regarding wire
types, conductor sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal injury and/or equipment
damage.
!
ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.
Location Rating/Type Description
Standard
(Option 1)
600V, 75°C or 90°C (167°F
or 194°F) RHH/RHW-2
Belden 29501-29507 or
equivalent
•Four tinned copper conductors with XLPE insulation
•Foil shield and tinned copper drain wire with 85% braid
coverage
•PVC jacket
Standard
(Option 2)
Tray rated 600V, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2
Shawflex 2ACD/3ACD or
equivalent
•Three tinned copper conductors with XLPE insulation
•5 mil single helical copper tape (25% overlap min.)
with three bare copper grounds in contact with shield
•PVC jacket
Class I & II;
Division I & II
Tray rated 600V, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2
•Three bare copper conductors with XLPE insulation
with impervious corrugated continuously welded
aluminum armor
•Black sunlight resistant PVC jacket overall
•Three copper grounds on #10 AWG and smaller
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Installation/Wiring 1-9
Reflected Wave Protection
The drive should be installed as close to the motor as possible.
Installations with long motor cables may require the addition of external
devices to limit voltage reflections at the motor (reflected wave
phenomena). See Table 1.E for recommendations.
The reflected wave data applies to all frequencies 2 to 16 kHz.
For 240V ratings, reflected wave effects do not need to be considered.
Table 1.E Maximum Cable Length Recommendations
Output Disconnect
The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.
Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only(1)
(1) Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.
1000 Vp-p 15 meters (49 feet)
1200 Vp-p 40 meters (131 feet)
1600 Vp-p 170 meters (558 feet)
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1-10 Installation/Wiring
Power Terminal Block
The drive utilizes a finger guard over the power wiring terminals. To
remove:
1. Press in and hold the locking tab.
2. Slide finger guard down and out.
Replace the finger guard when wiring is complete.
Figure 1.4 Power Terminal Block (A Frame Shown)
Table 1.F Power Terminal Block Specifications
V/T2T/L3S/L2R/L1 U/T1 W/T3
BR+ BR-
Terminal Description
R/L1, S/L2 1-Phase Input
R/L1, S/L2, T/L3 3-Phase Input
U/T1 To Motor U/T1
=
Switch any two motor
leads to change
forward direction.
V/T2 To Motor V/T2
W/T3 To Motor W/T3
BR+, BR- Dynamic Brake Resistor Connection
[0.75 kW (1 HP) ratings and higher]
Safety Ground - PE
Frame Maximum Wire Size (1)
(1) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Minimum Wire Size(1) Torque
A 3.3 mm2(12 AWG) 0.8 mm2(18 AWG)
1.7-2.2 N-m (16-19 lb.-in.)
B 5.3 mm2(10 AWG) 1.3 mm2 (16 AWG)
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