Rockwell Automation Allen Bradley PowerFlex40 User manual

Adjustable
Frequency AC
Drive
FRN 1.xx - 7.xx
User Manual
www.abpowerflex.com
22B-UM001.book Page 1 Tuesday, May 30, 2017 5:22 PM

PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.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 and DriveExecutive are trademarks 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.
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Summary of Changes
Manual Updates
The information below summarizes the changes to the PowerFlex 40
User Manual since the June 2013 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the August 2008 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the April 2008 release.
The information below summarizes the changes to the PowerFlex 40
User Manual since the January 2007 release.
Description of New or Updated Information Page(s)
Certifications for Australian RCM and CE Directives updated. 1-25,
A-3
Certifications for EAC, KCC, and NSF/ANSI added. A-3
Description of New or Updated Information Page(s)
Minimum Enclosure Volume column and new footnotes added. 1-9, 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)
Description of A056 revised. 3-17
Description of A059/A062 revised. 3-19
Fault description for F3 revised. 4-3
A table row for electrical specifications added. A-4
Graphic for the “Network Wiring” section revised. C-1
Second last paragraph in the “Network Wiring” section revised. C-2
Text in the “Writing (06) Logic Command Data” section revised. C-4
Frequency source for logic command 001 of bits 14, 13, and 12 corrected. C-4
Text in the “Writing (06) Reference” section revised. C-5
Description of New or Updated Information Page(s)
Input description and attention text for Multiple Digital Input Connection
example corrected.
1-22
New method of changing speed reference for IP66, NEMA/UL Type 4X rated
drives described.
2-2
Description for Up Arrow and Down Arrow keys revised. 2-4
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soc-2
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Parameter Updates
The following parameters have been updated with firmware version 6.xx.
The following parameters have been updated with firmware version 5.xx.
New Parameter
The following parameter has been added with firmware version 5.xx.
Fault description for F3 revised. 4-3
Graphic for the “Network Wiring” section revised. C-1
Descriptions for bits 6, 7, and 15 of register address 8192 (Logic Command)
updated.
C-4
New information on reading register address 8192 added. C-4
New information on reading register address 8193 added. C-5
Graphic for the “Connecting an RS-485 Network” section corrected. D-4
New method for inverting sign of PID error added. F-6
Parameter Number Description Page
[Relay Out Sel] A055 Function of option 20, ParamControl,
changed.
Option 24, MsgControl, added.
3-16
[Relay Out Sel] A058, A061 Function of option 20, ParamControl,
changed.
Option 24, MsgControl, added.
3-18
Parameter Number Description Page
[Control Source] d012 Options 7 and 8 added. 3-5
[Start Source] P036 Description revised for option 6. 3-10
[Relay Out Sel] A055 Description revised for option 20. 3-16
[Relay Out Level] A056 Description revised. 3-17
[Opto Outx Sel] A058, A061 Description revised for option 20. 3-18
[Opto Outx Level] A059, A062 Description revised. 3-19
[Internal Freq] A069 Default value for IP66, NEMA/
UL Type 4X drives is 0.0 Hz.
Default value for IP20 rated drives is
60.0 Hz.
3-22
[PID Trim Hi] A130 Description revised. 3-38
[PID Trim Lo] A131 Description revised. 3-38
Parameter Number Description Page
[PID Invert Error] A167 New 3-44
Description of New or Updated Information Page(s)
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-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 . . . . . . . . . . . . . 1-3
AC Supply Source Considerations . . . . . . 1-5
General Grounding Requirements . . . . . . 1-7
Fuses and Circuit Breakers . . . . . . . . . . . . 1-8
Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-10
IP66, NEMA/UL Type 4X Installations . 1-14
I/O Wiring Recommendations . . . . . . . . 1-14
Start and Speed Reference Control . . . . . 1-23
EMC Instructions . . . . . . . . . . . . . . . . . . 1-25
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad. . . . . . . . . . . . . . . . . . . . . 2-4
Viewing and Editing Parameters. . . . . . . . 2-5
Remote HIM Menu Structure . . . . . . . . . . 2-6
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-9
Advanced Program Group. . . . . . . . . . . . 3-14
Parameter Cross Reference – by Name. . 3-45
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-7
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2Table of Contents
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-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 One Temporary Peripheral . . . D-3
Connecting One Temporary Peripheral and
One Permanent Peripheral . . . . . . . . . . . D-3
Connecting Two Permanent Peripherals . . D-4
Connecting an RS-485 Network . . . . . . . . D-4
Appendix E StepLogic, Basic Logic and
Timer/Counter Functions
StepLogic Using Timed Steps . . . . . . . . . . E-2
StepLogic Using Basic Logic Functions . . E-3
Timer Function . . . . . . . . . . . . . . . . . . . . . E-4
Counter Function. . . . . . . . . . . . . . . . . . . . E-6
Appendix F PID Set Up
PID Loop . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
PID Reference and Feedback . . . . . . . . . . F-4
Analog PID Reference Signals . . . . . . . . . F-5
Index
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PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-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 40 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-TD001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
100-2.10
Guarding Against Electrostatic
Damage
8000-4.5.2
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P-2 Overview
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
•In this manual we refer to the PowerFlex 40 Adjustable Frequency
AC Drive as; drive, PowerFlex 40 or PowerFlex 40 Drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Similar PowerFlex 40 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
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Overview P-3
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
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.
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P-4 Overview
PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual
Publication 22B-UM001I-EN-E
Catalog Number Explanation
Code Voltage Ph.
V 120V AC 1
A 240V AC 1
B 240V AC 3
D 480V AC 3
E 600V AC 3
Code Version
3 No Brake IGBT
4 Standard
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP20, NEMA/UL Type Open
C Panel Mount - IP66, NEMA/UL Type 4X
F Flange Mount - IP20, NEMA/UL Type Open
H Replacement Plate Drive - IP20, NEMA/UL Type Open
- Contact factory for ordering information.
1-3 4 5 6-8 9 10 11 12 (1) 13-14
22B - A 1P5 N 1 1 4 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional
Output Current
@ 100-120V 50/60 Hz Input
Code Amps kW (HP)
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
6P0 6.0 1.1 (1.5)
Code Rating
0 Not Filtered
1Filtered
Output Current
@ 380-480V 50/60 Hz 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)
010 10.5 4.0 (5.0)
012 12 5.5 (7.5)
017 17 7.5 (10)
024 24 11 (15)
Code
22B PowerFlex 40
Additional accessories, options and adapters are available. See Appendix B for details.
Output Current
@ 500-600V 50/60 Hz Input
Code Amps kW (HP)
1P7 1.7 0.75 (1.0)
3P0 3.0 1.5 (2.0)
4P2 4.2 2.2 (3.0)
6P6 6.6 4.0 (5.0)
9P9 9.9 5.5 (7.5)
012 12.2 7.5 (10)
019 19 11 (15)
Code Purpose
AA Reserved for
thru custom firmware
ZZ
Output Current
@ 200-240V 50/60 Hz Input
Code Amps kW (HP)
2P3 2.3 0.4 (0.5)
5P0 5.0 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12 2.2 (3.0)
017 17.5 3.7 (5.0)
024 24 5.5 (7.5)
033 33 7.5 (10)
(1) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 40
drives are equipped with RS485 communication.
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