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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