Adjustable Frequency AC Drive FRN 1.xx - 4.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. 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. Important: Identifies information that is critical for successful application and understanding of the product. 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 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. Summary of Changes The information below summarizes the changes to the PowerFlex 40 User Manual since the October 2005 release. Parameter Updates The following parameters have been added or updated with firmware version 4.xx. Parameter Number Description Page [Speed Reference] P038 Default value for IP66, NEMA/UL 3-12 Type 4X rated drives is option 1 “InternalFreq”. [Comm Write Mode] A164 New 3-43 [Anlg Loss Delay] A165 New 3-43 [Analog In Filter] A166 New 3-43 [Relay Out Sel] A055 Option added. 3-15 [Opto Outx Sel] A058, A061 Option added. 3-17 [Analog Out Sel] A065 Options added. 3-20 [Anlg In 0-10V Lo] A110 3-32 [Anlg In 0-10V Hi] A111 Parameter setting can be changed 3-32 [Anlg In4-20mA Lo] A112 while drive is running. 3-32 [Anlg In4-20mA Hi] A113 3-33 [Comm Write Mode] A164 Revised description. 3-43 IP66, NEMA/UL Type 4X Enclosure Additions Description of New or Updated Information Page(s) Enclosure code added to Catalog Number Explanation P-4 Cover removal and installation instructions P-1 MOV jumper location P-5 Conduit entry plate plug installation P-14 Dimension drawing B-7 soc-2 The information below summarizes the changes to the PowerFlex 40 User Manual since the February 2005 release. Description of New or Updated Information See Page(s) Attention statement on bus regulation added. P-3 Attention statement clarified. 1-5 240V AC – 3-Phase 3.7 kW (5.0 Hp) drive fuse rating revised to 30 amps. 1-9, A-2 Footnote added to Table 1.F indicating that stranded or solid core wire is 1-15 acceptable for signal and I/O wiring. Analog Input, PTC wiring example added. 1-18 The following parameters have been added: P043 [Motor OL Ret] 3-13 A163 [DB Threshold] 3-42 Option 27 “EM Brk Rlse” added to parameters A051-A054 [Digital Inx Sel]. 3-14 Attention statement added to parameter A082 [DB Resistor Sel]. 3-24 Parameter A117 [Bus Reg Mode], new description provided. 3-33 Parameter A129 [Flux Current Ref] maximum value corrected to 3-36 [Motor NP FLA] Explanation of Electronic Motor Overload Protection clarified. A-4 Watts Loss table added. A-5 Two footnotes regarding Flange Mount drives added to Table B.A. B-1 Communication Adapters, External Comm Options, Compact I/O added to B-6 Table B.I. External brake resistor circuitry diagram added. B-13 Catalog Numbers for Frame B EMC Line Filters corrected. B-15 Catalog Numbers for Frame C EMC Line Filters corrected. B-16 Modbus Function Code 16 added. C-2 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. . . . . . . . . . . . . . . . . . . . . 2-3 Viewing and Editing Parameters. . . . . . . . 2-4 Remote HIM Menu Structure. . . . . . . . . . 2-5 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. . 3-44 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 Appendix C RS485 (DSI) Protocol Appendix D RJ45 DSI Splitter Cable Appendix E StepLogic™, Basic Logic and Timer/Counter Functions Appendix F PID Set Up Index 2 Table of Contents 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. 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? 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. Reference Materials The following manuals are recommended for general drive information: Title Publication Available Online at … Wiring and Grounding DRIVES-IN001… Guidelines for Pulse Width Modulated (PWM) AC Drives Preventive Maintenance of DRIVES-TD001… Industrial Control and Drive System Equipment Safety Guidelines for the SGI-1.1 www.rockwellautomation.com/ Application, Installation and literature Maintenance of Solid State Control A Global Reference Guide for 100-2.10 Reading Schematic Diagrams Guarding Against Electrostatic 8000-4.5.2 Damage P-2 Overview Manual Conventions • 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: P031[Motor NP Volts] Name Number Group d = Display Group P = Basic Program Group A = Advanced Program Group • The following words are used throughout the manual to describe an action: 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 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. 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-4 Overview Catalog Number Explanation 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 Code Code Version 22B PowerFlex 40 3 No Brake IGBT 4 Standard Code Rating 0 Not Filtered Code Voltage Ph. 1 Filtered V 120V AC 1 A 240V AC 1 Code Interface Module Code Purpose B 240V AC 3 1 Fixed Keypad AA Reserved for D 480V AC 3 thru custom firmware E 600V AC 3 ZZ 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. Output Current Output Current @ 100-120V 50/60 Hz Input @ 200-240V 50/60 Hz Input Code Amps kW (HP) Code Amps kW (HP) 2P3 2.3 0.4 (0.5) 2P3 2.3 0.4 (0.5) 5P0 5.0 0.75 (1.0) 5P0 5.0 0.75 (1.0) 6P0 6.0 1.1 (1.5) 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) Output Current Output Current @ 380-480V 50/60 Hz Input @ 500-600V 50/60 Hz Input Code Amps kW (HP) Code Amps kW (HP) 1P4 1.4 0.4 (0.5) 1P7 1.7 0.75 (1.0) 2P3 2.3 0.75 (1.0) 3P0 3.0 1.5 (2.0) 4P0 4.0 1.5 (2.0) 4P2 4.2 2.2 (3.0) 6P0 6.0 2.2 (3.0) 6P6 6.6 4.0 (5.0) 010 10.5 4.0 (5.0) 9P9 9.9 5.5 (7.5) 012 12 5.5 (7.5) 012 12.2 7.5 (10) 017 17 7.5 (10) 019 19 11 (15) 024 24 11 (15) (1) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 40 drives are equipped with RS485 communication. Additional accessories, options and adapters are available. See Appendix B for details.