Allen-Bradley PowerFlex 4M User Manual
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Allen-Bradley PowerFlex 4M User Manual

Frn 1 series, frn 2 series, adjustable frequency ac drive
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Summary of Contents for Allen-Bradley PowerFlex 4M

  • Page 1 Adjustable Frequency AC Drive FRN 1.xx - 2.xx User Manual www.abpowerflex.com...
  • Page 2 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. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual...
  • Page 3 Description for bits 6, 7, and 15 of register address 8192 updated. Information on reading register address 8193 clarified. Figure C.1, Network Wiring Diagram, updated. Guidelines on standard RS485 wiring practices added. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 4 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 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 5: Table Of Contents

    Product Selection ....B-1 Product Dimensions ....B-6 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 6 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...

  • Page 7: Who Should Use This Manual

    Safety Guidelines for the SGI-1.1 www.rockwellautomation.com/ Application, Installation and literature Maintenance of Solid State Control A Global Reference Guide for 0100-2.10 Reading Schematic Diagrams Guarding Against Electrostatic 8000-4.5.2 Damage PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 8: Manual Conventions

    Overview Manual Conventions • 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: P101 [Motor NP Volts] Name...

  • Page 9: General Precautions

    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. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 10: Catalog Number Explanation

    17.5 3.7 (5.0) 18.0 7.5 (10.0) 25.0 5.5 (7.5) 24.0 10.0 (15.0) 33.0 7.5 (10.0) Additional accessories, options and adapters are available. See Appendix B for details. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 11: Installation/Wiring

    Opening the Cover 1. Press and hold in the tabs on each side of the cover. 2. Pull the cover out and up to release. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 12: Mounting Considerations

    Horizontal Clearance between drives Minimum Maximum 0 mm and greater -10°C (14°F) 40°C (104°F) 25 mm and greater -10°C (14°F) 50°C (122°F) Drive enclosure is rated IP20, NEMA/UL Type Open. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 13: Ac Supply Source Considerations

    2. Pull the jumper completely out of the drive chassis. 3. Tighten the screw to keep it in place. Figure 1.1 Jumper Location (Frame A shown) Important: Tighten screw after jumper removal. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 14 Phase to ground voltage exceeds 125% of normal • or Install Isolation Transformer line to line voltage with grounded secondary if Ungrounded distribution system necessary. Appendix B Refer to for accessory ordering information. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 15: General Grounding Requirements

    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. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 16 Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 17: Fuses And Circuit Breakers

    Fusing The PowerFlex 4M has been UL tested and approved for use with input fuses. The ratings in the table that follows are the maximum recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide.
  • Page 18 When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 19: Power Wiring

    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. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 20 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. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 21 Drive will not power up without a jumper or inductor connected. U/T1 To Motor U/T1 Switch any two motor leads to change forward V/T2 To Motor V/T2 direction. W/T3 To Motor W/T3 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 22 When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present - the motor will coast to a stop. An auxiliary braking method may be required. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 23: I/O Wiring Recommendations

    To improve noise immunity, the I/O terminal block Common must be connected to ground terminal/protective earth. If using the RS485 (DSI) port, I/O Terminal 16 should also be connected to ground terminal/protective earth. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 24 Digital Input 2 Preset Freq Program with t202 [Digital In2 Sel]. t202 Drive supplied power for digital inputs. +24V DC – Maximum output current is 100mA. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 25 [Digital In1 Sel] = 3 “Aux Fault” t221 [Relay Out Sel] = 10 “Above Anlg V” t222 [Relay Out Level] = % Voltage Trip PTC (hot) × 100 Trip PTC (hot) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 26 Each digital input draws 6 mA. closed at the same time, an undetermined state could occur. 2 Wire SNK Control - Internal Supply (SNK) Run FWD/Run REV Stop-Run Forward Stop-Run Reverse PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 27 Direction Mode]. I/O Terminal 03 +24V Common determines direction. Each digital input draws 6 mA. 3 Wire SNK Control - Internal Supply (SNK) Reversing Stop Start Direction PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 28 I/O Terminal 13 (potentiometer wiper) should be daisy-chained to each drive. All drives must be powered up for the analog signal to be read correctly. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 29: Start And Speed Reference Control

    Preset Inputs Active Start and Direction commands come from P106 [Start Source]. Run as specified by P108 [Speed Reference]. Start and Direction commands come from P106 [Start Source]. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 30 Preset Frequency. by [Preset Freq x] See A410-A413 [Preset Freq 0-3] t201 or t202 = 4 page 3-21. P109 [Accel Time 1]/P110 [Decel Time 1] are used. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 31: Emc Instructions

    • Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 32 Keep wire length as short as possible between the enclosure entry point and the EMI filter. Integral EMI filters are available on 240V, 1-Phase drives and 380V, 3-Phase drives. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 33 Installations on a public low voltage power network may require additional external harmonic mitigation. • Other drive ratings meet the current harmonic requirements of EN61000-3-2 without additional external mitigation. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 34 1-24 Installation/Wiring Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 35: Prepare For Drive Start-Up

    Chapter Start Up This chapter describes how to start up the PowerFlex 4M Drive. To simplify drive setup, the most commonly programmed parameters are organized in a single Basic Program Group. Important: Read the General Precautions section before proceeding. ATTENTION: Power must be applied to the drive to perform the following start-up procedures.
  • Page 36 Variable Torque Fan/Pump Applications For improved motor tuning performance when using a premium efficient motor on a variable torque load, set A453 [Boost Select] to option 2 “35.0, VT”. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 37: Integral Keypad

    Scroll through groups and parameters. Increase/decrease the value of a flashing digit. Down Arrow Enter Advance one step in programming menu. Save a change to a parameter value. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 38: Viewing And Editing Parameters

    HERTZ that group will flash. PROGRAM FAULT 5. Press the Up Arrow or Down Arrow to scroll through the parameters in the group. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 39 [Output Frequency] is displayed. Press Enter or Sel to enter the group menu again. The Basic Program Group (page 3-8) contains the most commonly changed parameters. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 40 Start Up Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 41: Programming And Parameters

    = Stop drive before changing this parameter. = 32 bit parameter. Parameters marked 32 bit will have two parameter numbers when using RS485 communications and programming software. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 42: Parameter Organization

    Maximum Voltage A457 DB Duty Cycle A428 Program Lock A458 Testpoint Sel A459 Start At PowerUp A433 Reverse Disable A434 Motor NP FLA A461 Flying Start En A435 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 43: Display Group

    0/Drive Rated Volts Display: 0.1 VAC d005 [DC Bus Voltage] Present DC bus voltage level. Values Default Read Only Min/Max: Based on Drive Rating Display: 1 VDC PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 44 [Process Factor] or by A438 [Process Time Lo] and A439 [Process Time Hi]. Output Process Process Freq Factor Display Values Default Read Only Min/Max: 0.00/9999 Display: 0.01 – 1 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 45 When this bit is a 1 the drive can be started. When this bit is a 0 the drive will stop. Values Default Read Only Min/Max: Display: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 46 Main Control Board software version. Values Default Read Only Min/Max: 1.00/99.99 Display: 0.01 d017 [Drive Type] Used by Rockwell Automation field service personnel. Values Default Read Only Min/Max: 1001/9999 Display: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 47 Read Only Min/Max: 0.0/100.0% Display: 0.1% d022 [Drive Temp] Present operating temperature of the drive power section. Values Default Read Only Min/Max: 0/120 degC Display: 1 degC PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 48: Basic Program Group

    A438 Stop drive before changing this parameter. Sets the highest frequency the drive will output. Values Default 60 Hz Min/Max: 0/400 Hz Display: 1 Hz PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 49 When using option 5 “Comm Port”, if the drive is using a network for control and the user’s program is maintaining a “Start” or “Jog” command without sending a “Stop command”, the drive will start automatically when power is cycled. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 50 • Standard DC Injection Braking for value set in A424 Brake Time]. • Drive shuts off if current limit is exceeded. Stop input also clears active fault. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 51 Values Default 10.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs P105 [Maximum Freq] Speed P109 or A401 P110 or A402 Time [Accel Time x] [Decel Time x] PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 52 Options 0 “Idle State” (Default) • After the reset function is complete, this parameter will set 1 “Reset Defaults” itself back to “0”. • Causes an F48 Params Defaulted fault. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 53: Terminal Block Group

    12 “Jog Reverse” Drive accelerates to A404 [Jog Frequency] according to A405 [Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start will override this command. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 54 Analog inversion can be accomplished by setting this value larger than t214 [Anlg In4-20mA Hi] or by setting t201 t202 [Digital Inx Sel] to option 15 “Anlg Invert”. Values Default 0.0% Min/Max: 0.0/ 100.0% Display: 0.1% PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 55 Enables the output to be controlled by bit 6 of the logic command word. See Writing (06) Logic Command Data on page C-4 for more information. 14-22 Reserved PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 56 [Relay Out Sel] is 6, 7, 8, 10 or 11. t221 Setting t222 Min/Max 0/400 Hz 0/180% 0/815 Volts 0/100% Values Default Min/Max: As above Display: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 57: Communications Group

    Stops drive via coast to stop. 2 “Stop” Stops drive via P107 [Stop Mode] setting. 3 “Continu Last” Drive continues operating at communication commanded speed saved in RAM. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 58 Do not create a program that frequently uses configurable outputs to write parameter data to NVS unless C307 [Comm Write Mode] is set to option 1. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 59: Advanced Program Group

    Values Default 20.0 Secs Min/Max: 0.1/600.0 Secs Display: 0.1 Secs P105 [Maximum Freq] Speed P109 or A401 P110 or A402 Time [Accel Time x] [Decel Time x] PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 60 EEPROM memory. If the ESC key is used before the Enter key, the frequency will return to the original value following the normal accel/decel curve. Values Default 60.0 Hz Min/Max: 0.0/400.0 Hz Display: 0.1 Hz PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 61 Sets the frequency at which the drive will not operate. A setting of 0 disables this parameter. Values Default 0 Hz Min/Max: 0/400 Hz Display: 1 Hz PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 62 Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter A425 Brake Level]. Values Default 0.0 Secs Min/Max: 0.0/99.9 Secs (A setting of 99.9 = Continuous) Display: 0.1 Secs PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 63 Figure B.3 on page B-7, or equivalent, must be supplied. Values Default Min/Max: Display: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 64 1 “Rev Disabled” A435 [Flying Start En] Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM. Options 0 “Disabled” (Default) 1 “Enabled” PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 65 [Maximum Freq]. When set to a value other than zero, d010 [Process Display] indicates the duration of the process. Values Default 0.00 Min/Max: 0.00/ 99.99 Display: 0.01 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 66 2 “Max Derate” No Derate Min Derate Max Derate % of P102 [Motor NP Hertz] % of P102 [Motor NP Hertz] % of P102 [Motor NP Hertz] PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 67 A448 [SW Current Trip] Related Parameter(s): P103 Enables/disables a software instantaneous (within 100 ms) current trip. Values Default 0.0 (Disabled) 0.0/(Drive Rated Amps × 2) Min/Max: Display: 0.1 Amps PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 68 Sets the time between restart attempts when A451 [Auto Rstrt Tries] is set to a value other than zero. Values Default 1.0 Secs Min/Max: 0.0/120.0 Secs Display: 0.1 Secs PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 69 9 “7.5, CT” 10 “10.0, CT” 11 “12.5, CT” 12 “15.0, CT” 13 “17.5, CT” 14 “20.0, CT” 1/2 [Motor NP Volts] Settings 5-14 % P102 [Motor NP Hertz] PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 70 A461 [Motor NP FLA] Set to the motor nameplate rated full load amps. Values Default Drive Rated Amps 0.1/(Drive Rated Amps × 2) Min/Max: Display: 0.1 Amps PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 71: Parameter Cross Reference - By Name

    Advanced Program 3-30 Motor NP Hertz P102 Basic Program Motor NP Volts P101 Basic Program Motor OL Current P103 Basic Program Motor OL Ret P111 Basic Program 3-12 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 72 3-32 Programming and Parameters Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 73: Troubleshooting

    Chapter Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 4M drive. Included is a listing and description of drive faults (with possible solutions, when applicable). For information on… See page… For information on… See page… Drive Status...
  • Page 74 (Type 2) that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 75: Fault Descriptions

    4-1 for a description of fault types. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 76 Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared. page 4-1 for a description of fault types. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 77: Common Symptoms And Corrective Actions

    [Digital Inx Select] to option 5 “Local” and activate the input. I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install not present. jumper. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 78 [Digital Inx Select]. • Check P108 [Speed Reference] for the source of the speed reference. Reprogram as necessary. • Review the Speed Reference Control chart on page 1-19. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 79 • Check all fuses and disconnects. Jumper between I/O Terminals None Install jumper or connect DC Bus P2 and P1 not installed and/or Inductor. DC Bus Inductor not connected. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 80 Troubleshooting Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 81: Supplemental Drive Information

    AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH. Typical designations include; Type J - JKS, LPJ, DFJ Type T - JJS, JJN Type RK1 - LPS, KTS, KTN PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 82 Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/ 277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 83 Internal brake IGBT included with power ratings 5.5 kW (7.5 HP) and 7.5 kW (10.0 HP) for 240V, 3-phase drives and 5.5 kW (7.5 HP), 7.5 kW (10.0 HP) and 11.0 kW (15.0 HP) for 480V, 3-phase drives. See Appendix B for ordering information. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 84 0.98 across entire speed range Maximum Short Circuit Rating: 100,000 Amps Symmetrical Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit breaker Transistor Type: Isolated Gate Bipolar (IGBT) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 85 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 5.5 (7.5) 7.5 (10) 380–480V, 3-Phase 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 5.5 (7.5) 7.5 (10) 11 (15) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 86 Supplemental Drive Information Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 87: Accessories And Dimensions

    22F-B012N103 17.5 22F-B017N103 25.0 22F-B025N104 10.0 33.0 22F-B033N104 480V 50/60 Hz 22F-D1P5N103 3-Phase 0.75 22F-D2P5N103 22F-D4P2N103 22F-D6P0N103 22F-D8P7N103 13.0 22F-D013N104 10.0 18.0 22F-D018N104 11.0 15.0 24.0 22F-D024N104 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 88 Alternative resistors may be used, however care must be taken when making a selection. Refer to the PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001…. Requires two resistors wired in parallel. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 89 240V 50/60 Hz 0.85 32RB001 3-Phase 10.0 40RB001 480V 50/60 Hz 3.75 18RB004 3-Phase 10.0 25RB005 11.0 15.0 2.68 32RB003 Use MTE RB Series or equivalent inductors. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 90 This filter is suitable for use with a cable length up to 100 meters (328 feet) for Class A and 25 meters (82 feet) for Class B environments. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 91 Compatibility: Windows 98, ME, NT 4.0 (Service Pack 3 or later), 2000 and XP See www.ab.com/drives/driveexplorer.htm for supported devices. For pricing information, refer to the PowerFlex 4-Class Price List, Publication 22-PL001…. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 92: Product Dimensions

    Accessories and Dimensions Product Dimensions Table B.I PowerFlex 4M Panel Mount Drives – Ratings are in kW and (HP) 120V AC – 1-Phase 240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase 0.2 (0.25) 0.2 (0.25) 0.2 (0.25) 0.4 (0.5)
  • Page 93 Figure B.3 Recommended External Brake Resistor Circuitry T (L3) Note: Applicable to Frame C drives only. S (L2) Three-Phase AC Input R (L1) Power Off Power On Power Source DB Resistor Thermostat PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 94 4.9 (11) 1321-3R25-B 183 (7.20) 147 (5.80) 89 (3.50) 60 (2.35) 76 (3.00) 6.4 (14) 1321-3R35-A 193 (7.60) 146 (5.76) 91 (3.60) 66 (2.60) 76 (3.00) 6.3 (14) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 95 Catalog Numbers: 22F-RF010-AL; 22F-RF9P5-AS, 22F-RF9P5-AL; 22F-RF6P0-AS, 22F-RF6P0-AL 72.0 (2.83) 50.0 (1.97) 31.0 (1.22) 54.0 (2.13) 229.0 (9.02) 218.5 (8.60) 218.5 (8.60) 19.0 5.5 (0.22) (0.75) 24.0 (0.94) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 96 Catalog Numbers: 22F-RF025-BL; 22F-RF021-BS, 22F-RF021-BL; 22F-RF012-BS, 22F-RF012-BL 101.0 (3.98) 50.0 (1.97) 27.0 (1.06) 74.0 (2.91) 229.0 (9.02) 216.0 (8.50) 216.0 (8.50) 15.0 5.5 (0.22) (0.59) 24.0 (0.94) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 97 Catalog Number: 22F-RF039-CS, 22F-RF039-CL; 22F-RF026-CS, 22F-RF026-CL 130.0 (5.12) 60.0 (2.36) 32.0 (1.26) 90.0 (3.54) 309.0 (12.17) 309.0 (12.17) 297.0 297.0 (11.69) (11.69) 5.5 (0.22) 17.0 (0.67) 30.0 (1.18) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 98 Figure B.8 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2 17.6 (0.69) (4.09) (8.66) 2.9m (3.07) (2.60) (7.64) (4.92) 60.5 (2.38) 19.1 (1.50) (0.75) (0.19) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 99 (3.66) (7.09) (2.64) (2.36) (6.06) 19.1 (3.03) (0.75) (0.19) 23.5 (0.93) Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 100 Figure B.10 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-B1 11.1 (0.44) (3.66) 25.2 (0.99) (7.09) (2.64) (2.36) (6.06) 19.1 (3.03) (0.75) (0.19) 23.5 (0.93) PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 101: Network Wiring

    PowerFlex 4M drives support the RS485 (DSI) protocol to allow efficient operation with Rockwell Automation peripherals. In addition, some Modbus functions are supported to allow simple networking. PowerFlex 4M drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode. Controller For information regarding DeviceNet or other communication protocols, refer to the appropriate user manual.
  • Page 102 (1 foot). • Network wiring should only cross power wires at a right angle. Control Terminal 16 on the PowerFlex 4M must also be connected to PE ground (there are two PE terminals on the drive). See Figure 1.5 for more information.

  • Page 103: Parameter Configuration

    RS485 (DSI) Protocol Parameter Configuration The following PowerFlex 4M parameters are used to configure the drive to operate on a network. Parameter Details Reference P106 [Start Source] Set to 5 “RS485 (DSI) Port” if Start is controlled from Page 3-9 the network.

  • Page 104: Writing (06) Logic Command Data

    RS485 (DSI) Protocol Writing (06) Logic Command Data The PowerFlex 4M drive can be controlled via the network by sending Function Code 06 writes to register address 8192 (Logic Command). P106 [Start Source] must be set to 5 “RS485 (DSI) Port” in order to accept the commands.

  • Page 105: Writing (06) Reference

    RS485 (DSI) Protocol Writing (06) Reference The Speed Reference to a PowerFlex 4M drive can be controlled via the network by sending Function Code 06 writes to register address 8193 (Reference). P108 [Speed Reference] must be set to 5 “RS485 (DSI) Port”...

  • Page 106: Reading (03) Feedback

    Returns the same data as Reading (03) Parameter d001 [Output Freq]. Reading (03) Drive Error Codes The PowerFlex 4M Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error Codes).

  • Page 107: Reading (03) And Writing (06) Drive Parameters

    For example, a decimal “1” is used to address Parameter d001 [Output Freq] and decimal “39” is used to address Parameter P109 [Accel Time 1]. Additional Information Refer to for additional information. http://www.ab.com/drives/ PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 108 RS485 (DSI) Protocol Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 109: Rj45 Dsi Splitter Cable

    Appendix RJ45 DSI Splitter Cable The PowerFlex 4M drive provides a RJ45 port to allow the connection of a single peripheral device. The RJ45 DSI Splitter Cable can be used to connect a second DSI peripheral device to the drive.

  • Page 110: Dsi Cable Accessories

    RJ45 Two-Position Terminal Block Adapter – Catalog Number: AK-U0-RJ45-TB2P (PIN 5) PIN 8 (PIN 4) PIN 1 RJ45 Adapter with Integrated Termination Resistor – Catalog Number: AK-U0-RJ45-TR1 PIN 8 PIN 1 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...

  • Page 111: Connecting An Rs-485 Network

    4 and 5 only. Both the Master (M) and Slave (S) ports on the RJ45 Splitter Cable operate as standard RS-485 ports in this configuration. PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 112 RJ45 DSI Splitter Cable Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 113 Filter, RFI, 1-6 Dimensions Frame Designations, P-2, A-1, B-6 Drive, B-6 Fuses Minimum Clearances, 1-2 Input, 1-7 Display, 2-3 Ratings, A-1 Display Group Parameters, 3-3 Distribution Systems, Ungrounded, PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 114 RWR (Reflective Wave Reducer), 1-10 Opening the Cover, 1-1 Operating Temperatures, 1-2 Safety Ground, 1-5 Operator Interface, 2-3 Shielded Power Cables, 1-10 OverVoltage Fault, 4-3 Short Circuit Protection, 1-7 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 115 Ungrounded Supply, 1-3 Unshielded Power Cables, 1-9 Watts Loss, A-5 Wiring, 1-1 Block Diagram, 1-14 I/O, 1-13 I/O Examples, 1-15, 1-18 Potentiometer, 1-15 Power, 1-9 PTC Example, 1-15 PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 116 Index-4 Notes: PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual Publication 22F-UM001D-EN-E...
  • Page 118 www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444 Europe/Middle East/Africa: Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, Level 14, Core F, Cyberport 3, 100 Cyberport Road, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Publication 22F-UM001D-EN-E –...

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