Allen-Bradley PowerFlex 40P User Manual
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Allen-Bradley PowerFlex 40P User Manual

Adjustable frequency ac drive
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Adjustable
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Summary of Contents for Allen-Bradley PowerFlex 40P

  • Page 1 Adjustable Frequency AC Drive FRN 1.xx - 3.xx User Manual www.abpowerflex.com...
  • Page 2 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.
  • Page 3 Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex 40P User Manual since the June 2013 release. Description of New or Updated Information See Page(s) Replaced ISO 13849 with EN ISO 13849-1:2008+AC:2009 1-21, 3-11, and Certification for Australian C-Tick, CE Directives, and TUV updated.
  • Page 4 soc-2 Parameter Number Description Page Fault 5 Code d311 New Parameter 3-64 Fault 6 Code d312 New Parameter 3-64 Fault 7 Code d313 New Parameter 3-64 Fault 8 Code d314 New Parameter 3-65 Fault 9 Code d315 New Parameter 3-65 Fault 10 Code d316 New Parameter...

  • Page 5: Table Of Contents

    Table of Contents Preface Overview Who Should Use this Manual? ..P-1 Reference Materials ....P-1 Manual Conventions .
  • Page 6 Table of Contents Appendix C RS485 (DSI) Protocol Network Wiring ..... C-1 Parameter Configuration ....C-3 Supported Modbus Function Codes .

  • Page 7: Who Should Use This Manual

    Preface Overview The purpose of this manual is to provide you with the basic information needed to install, start-up and troubleshoot the PowerFlex 40P Adjustable Frequency AC Drive. For information on… See page… Who Should Use this Manual? Reference Materials...

  • Page 8: Manual Conventions

    Overview Manual Conventions • In this manual we refer to the PowerFlex 40P Adjustable Frequency AC Drive as; drive, PowerFlex 40P or PowerFlex 40P Drive. • Parameter numbers and names are shown in this format: P031 [Motor NP Volts] Name...

  • Page 9: General Precautions

    Overview 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.

  • Page 10: Catalog Number Explanation

    13-14 22D - Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Version Optional Code Code Version 22D PowerFlex 40P Standard Code EMC Filter Not Filter Code Voltage 240V AC 3 480V AC 3 600V AC 3 Code HIM Version...

  • Page 11: Installation/Wiring

    Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 40P Drive. For information on… See page For information on… See page Opening the Cover Fuses and Circuit Breakers 1-7 Mounting Considerations Power Wiring AC Supply Source Considerations 1-4...

  • Page 12: Mounting Considerations

    Use Mounting Option A 40°C (104°F) -10°C (14°F) IP 30/NEMA 1/UL Type 1 Use Mounting Option B 50°C (122°F) IP 20/Open Type Use Mounting Option B Rating requires installation of the PowerFlex 40P IP 30/NEMA 1/UL Type 1 option kit.

  • Page 13: Plate Drive Installation

    Installation/Wiring 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. •...

  • Page 14: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source Considerations Ungrounded Distribution Systems ATTENTION: PowerFlex 40P drives contain protective MOVs that are referenced to ground. These devices must be disconnected if the drive is installed on an ungrounded or resistive grounded distribution system. Disconnecting MOVs...
  • Page 15 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.B 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.B, install one of the devices listed under the heading Corrective Action on the line side of the drive.

  • Page 16: General Grounding Requirements

    Installation/Wiring General Grounding Requirements 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 FAULT R/L1...

  • Page 17: Fuses And Circuit Breakers

    Fuses and Circuit Breakers The PowerFlex 40P 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.
  • Page 18 Installation/Wiring Table 1.C Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Min. Enclosure (2) (3) Rating kW (HP) Amps Protectors MCS Contactors Volume Catalog No. Catalog No. Inches 240V AC – 0.4 (0.5) 140M-C2E-B40 100-C07 1655 3-Phase 0.75 (1.0)

  • Page 19: Power Wiring

    Installation/Wiring 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.
  • Page 20 1-10 Installation/Wiring Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks.
  • Page 21 Installation/Wiring 1-11 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.D for recommendations.
  • Page 22 1-12 Installation/Wiring Power Terminal Block The power terminal block is covered by a finger guard. 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 (Typical) B Frame C Frame...

  • Page 23: Common Bus/Precharge Notes

    Installation/Wiring 1-13 Common Bus/Precharge Notes If drives with internal precharge are used with a disconnect switch to the common bus, then an auxiliary contact on the disconnect must be connected to a digital input of the drive. The corresponding input (parameter A051-A054) must be set to option 29, “Precharge Enable.”...
  • Page 24 1-14 Installation/Wiring Signal and Control Wire Types Table 1.F Recommended Signal Wire Signal Type/ Belden Wire Type(s) Min. Insulation Where Used (or equivalent) Description Rating Analog I/O & PTC 8760/9460 0.750 mm (18AWG), twisted 300V, pair, 100% shield with drain 75-90°...
  • Page 25 Installation/Wiring 1-15 Figure 1.5 Control Wiring Block Diagram Typical Typical Enable Jumper (1)(6) SRC Wiring SNK Wiring Stop Start/Run FWD Direction/Run REV Digital Common Digital Input 1 Digital Input 2 Digital Input 3 Digital Input 4 Opto Common +24V +24V DC +10V DC +10V 0-10V (or ±10V) Input...
  • Page 26 1-16 Installation/Wiring Control Wiring Block Diagram Notes Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set to “3-Wire”, “2-W Lvl Sens” or “Momt FWD/REV” control. In three wire control, I/O Terminal 01 is controlled by P037 [Stop Mode].
  • Page 27 Installation/Wiring 1-17 Table 1.I Control I/O Terminal Designations No. Signal Default Description Param. Relay N.O. Fault Normally open contact for output relay. A055 Relay Common – Common for output relay. Relay N.C. Fault Normally closed contact for output relay. A055 Analog Output Select DIP 0-10V Sets analog output to either voltage or current.
  • Page 28 1-18 Installation/Wiring Encoder Interface The PowerFlex 40P Encoder Interface can source 5 or12 volt power and accept 5, 12 or 24 volt single ended or differential inputs. +V Cm B- B A- A Table 1.J Terminal Description No. Signal Description +V 5V-12V Power Internal power source 250 mA (isolated).
  • Page 29 Installation/Wiring 1-19 Figure 1.6 Sample Encoder Wiring Connection Example Connection Example Encoder Encoder +12V DC (250 mA) Power – Power – Internal Drive External Common Power Power SHLD to SHLD External Source Power Internal (drive) Supply 12V DC, 250mA Encoder Encoder to Power Supply Signal –...
  • Page 30 1-20 Installation/Wiring Hardware Enable Circuitry I/O Terminal 01 is always a stop input. The status of this input is interpreted by drive software. If the application requires the drive to be disabled without software interpretation, a hardware enable configuration can be utilized. This is done by removing the ENBL enable jumper and wiring the enable input to I/O Terminal 1 (see below).
  • Page 31 Installation/Wiring 1-21 User Installed DriveGuard Safe-Off Option (Series B) The DriveGuard Safe-Off Option (Series B) board, when used with suitable safety components, provides protection according to EN ISO 13849-1:2008+AC:2009; Performance Level d (Safety Category 3) for safe off and protection against restart. The PowerFlex safe off option is just one safety control system.
  • Page 32 1-22 Installation/Wiring I/O Wiring Examples Input/Output Connection Example Potentiometer P038 [Speed Reference] = 2 “0-10V Input” 1-10k Ohm Pot. Recommended (2 Watt minimum) Analog Input Bipolar Unipolar (Voltage) Unipolar (Current) 0 to +10V, 100k ohm P038 [Speed Reference] P038 [Speed Reference] P038 [Speed Reference] impedance...
  • Page 33 Installation/Wiring 1-23 Input/Output Connection Example 2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Non-Reversing P036 [Start Source] = 2, 3 or 4 Stop-Run Input must be active for Stop-Run the drive to run. When input is opened, the +24V Common drive will stop as specified by...
  • Page 34 1-24 Installation/Wiring Input/Output Connection Example 3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Non-Reversing P036 [Start Source] = 1 Stop Stop A momentary input will start the drive. A stop Start Start input to I/O Terminal 01 will stop the drive as specified by P037...
  • Page 35 Installation/Wiring 1-25 Input/Output Connection Example Opto Output (1 & 2) Opto-Output 1 A058 [Opto Out1 Sel] determines Opto-Output 1 (I/O Terminal 17) operation. A061 [Opto Out2 Sel] determines Opto-Output 2 (I/O Terminal 18) operation. When using Opto-Output with an +24V Common inductive load such as Each Opto-Output is rated...
  • Page 36 1-26 Installation/Wiring Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input Connections Customer Inputs can be wired per External Supply (SRC). Customer Inputs Optional Ground Connection When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives.

  • Page 37: Start And Speed Reference Control

    Installation/Wiring 1-27 Start and Speed Reference Control The drive speed command can be obtained from a number of different sources. The source is P038 [Speed Reference]. However, when A051 A054 [Digital Inx Sel] is normally determined by set to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, or if A132 is not set to P038 [Speed Reference] will be overridden.
  • Page 38 1-28 Installation/Wiring Accel/Decel Selection The Accel/Decel rate can be obtained by a variety of methods. The default rate is determined by P039 [Accel Time 1] and P040 [Decel Time 1]. Alternative Accel/Decel rates can be made through digital inputs, RS485 (DSI) communications and/or parameters. See the chart below for the override priority.

  • Page 39: Emc Instructions

    Installation/Wiring 1-29 EMC Instructions CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Drives comply with the EN standards listed below when installed according to the User Manual.
  • Page 40 1-30 Installation/Wiring Essential Requirements for CE Compliance Conditions 1-3 listed below must be satisfied for PowerFlex drives to meet the requirements of EN61800-3:2004+A1:2012. 1. Grounding as described in Figure 1.8. Refer to page 1-7 additional grounding recommendations. 2. Output power, control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.
  • Page 41 Installation/Wiring 1-31 EN61000-3-2 • 0.75 kW (1 HP) 240V 3-Phase drives are suitable for installation on a private low voltage power network. 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.
  • Page 42 1-32 Installation/Wiring Notes:...

  • Page 43: Prepare For Drive Start-Up

    Chapter Start Up This chapter describes how to start up the PowerFlex 40P 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 44 Start Up Applying Power to the Drive 6. Apply AC power and control voltages to the drive. Start, Stop, Direction and Speed Control Factory default parameter values allow the drive to be controlled from comms. No programming is required to start, stop, change direction and control speed directly from comms.

  • Page 45: Display/Fault Reset

    Start Up Display/Fault Reset Menu Description Basic Display Group (View Only) Commonly viewed drive operating conditions. Advanced Display Group (View Only) Consists of advanced drive operating conditions. FAULT Fault Designator Consists of list of codes for specific fault conditions. Displayed only when fault is present.
  • Page 46 Start Up Notes:...

  • Page 47: Programming And Parameters

    Chapter Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 40P parameters. Parameters are programmed (viewed/edited) using either a DSI Remote HIM or PC programming tools (DriveExplorer™ or DriveTools SP™ software), a personal computer and a serial converter module.

  • Page 48: Parameter Organization

    Programming and Parameters Parameter Organization Refer to page 3-66 for an alphabetical listing of parameters. Basic Display Group Output Voltage b004 Contrl In Status b013 Analog In 4-20mA b021 DC Bus Voltage b005 Dig In Status b014 Output Power b022 Drive Status b006 Comm Status...

  • Page 49: Basic Display Group

    Programming and Parameters Basic Display Group b001 [Output Freq] Related Parameter(s): b002, b010, P034, P035, P038 Output frequency present at T1, T2 & T3 (U, V & W). Values Default: Read Only Min/Max: 0.00/P035 [Maximum Freq] Display: 0.01 Hz b002 [Commanded Freq] Related Parameter(s): b001, b013, P034, P035, P038 Value of the active frequency command.
  • Page 50 Programming and Parameters Basic Display Group (continued) b006 [Drive Status] Related Parameter(s): A095 Present operating condition of the drive. 1 = Condition True, 0 = Condition False Running Bit 0 Forward Bit 1 Accelerating Bit 2 Decelerating Bit 3 Values Default: Read Only Min/Max:...
  • Page 51 Programming and Parameters Basic Display Group (continued) b012 [Control Source] Related Parameter(s): P036, P038, A051-A054 Displays the active source of the Start Command and Speed Command which are normally defined by the settings of P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital inputs.
  • Page 52 Status of the communications ports. 1 = Condition True, 0 = Condition False Receiving Data Bit 0 Transmitting Data Bit 1 RS485 (DSI) Based Option Connected Bit 2 (Allen-Bradley devices only.) Communication Error Occurred Bit 3 Values Default: Read Only Min/Max: Display: b016 [Control SW Ver] Main Control Board software version.
  • Page 53 Programming and Parameters Basic Display Group (continued) b018 [Elapsed Run Time] Accumulated time drive is outputting power. Time is displayed in 10 hour increments. Values Default: Read Only Min/Max: 0/9999 Hrs Display: 1 = 10 Hrs b019 [Testpoint Data] Related Parameter(s): A102 The present value of the function selected in A102...
  • Page 54 Programming and Parameters Basic Display Group (continued) b024 [Drive Temp] Present operating temperature of the drive power section. Values Default: Read Only Min/Max: 0/120 degC Display: 1 degC b025 [Counter Status] The current value of the counter when counter is enabled. Values Default: Read only...

  • Page 55: Basic Program Group

    Programming and Parameters Basic Program Group P031 [Motor NP Volts] Related Parameter(s): b004, A084, A085, A086, A087 Stop drive before changing this parameter. Set to the motor nameplate rated volts. Values Default: Based on Drive Rating Min/Max: 20/Drive Rated Volts Display: 1 VAC P032 [Motor NP Hertz]...
  • Page 56 3-10 Programming and Parameters Basic Program Group (continued) P036 [Start Source] Related Parameter(s): b012, P037 Stop drive before changing this parameter. Sets the control scheme used to start the drive and controls the behavior of I/O Terminals 01, 02, and 03.
  • Page 57 Programming and Parameters 3-11 Basic Program Group (continued) P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082, A105, A160 Active stop mode for all stop sources [e.g. run forward (I/O Terminal 02), run reverse (I/O Terminal 03), RS485 port] except as noted below. Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start Source] is set for...
  • Page 58 3-12 Programming and Parameters Basic Program Group (continued) P038 [Speed Reference] Related Parameter(s): b001, b002, b012, b020, b021, P039,P040, A051-A054, A069, A070-A077, A110, A111, A112, A113, A123, A132, A140-A147, A150-A157 Sets the source of the speed reference to the drive. The drive speed command can be obtained from a number of different sources.
  • Page 59 Programming and Parameters 3-13 Basic Program Group (continued) P039 [Accel Time 1] Related Parameter(s): P038, P040, A051-A054, A067, A070-A077, A140-A147 Sets the rate of acceleration for all speed increases. Maximum Freq Accel Rate Accel Time Values Default: 10.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs...
  • Page 60 3-14 Programming and Parameters Basic Program Group (continued) P042 [Voltage Class] Stop drive before changing this parameter. Sets the voltage class of 600V drives. Options 2 “Low Voltage” 480V 3 “High Voltage” (Default) 600V P043 [Motor OL Ret] Related Parameter(s): P033 Enables/disables the Motor Overload Retention function.

  • Page 61: Advanced Program Group

    Programming and Parameters 3-15 Advanced Program Group A051 [Digital In1 Sel] Related Parameter(s): b012, b014, P038, P039, P040, A067, A068, A070-A077, A078, A079, A118, A140-A147 (I/O Terminal 05) A052 [Digital In2 Sel] (I/O Terminal 06) Stop drive before changing this parameter. A053 [Digital In3 Sel] (I/O Terminal 07) A054 [Digital In4 Sel]...
  • Page 62 3-16 Programming and Parameters A051 - 12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079 A054 [Jog Accel/Decel] and ramps to stop when input becomes Options inactive. A valid start will override this command. (Cont.) 13 “10V In Ctrl” Selects 0-10V or ±10V control as the frequency reference.
  • Page 63 Programming and Parameters 3-17 A051 - 29 “Precharge En” Forces drive into precharge state. Typically controlled by auxiliary contact on the disconnect at the DC input to the A054 drive. If this input is assigned, it must be energized for the Options pre-charge relay to close and for the drive to run.
  • Page 64 3-18 Programming and Parameters Advanced Program Group (continued) A055 [Relay Out Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157, A160, A161 Sets the condition that changes the state of the output relay contacts. Options 0 “Ready/Fault” Relay changes state when power is applied. This indicates that the drive is ready for operation.
  • Page 65 Programming and Parameters 3-19 A055 19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In Loss] for desired action when input loss occurs. Options (Cont.) 20 “ParamControl” Enables the output to be controlled over network communications by writing to A056 [Relay Out Level].
  • Page 66 3-20 Programming and Parameters Advanced Program Group (continued) A058 [Opto Out1 Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157 A061 [Opto Out2 Sel] Determines the operation of the programmable opto outputs. Options 0 “Ready/Fault” Opto outputs are active when power is applied. This indicates that the drive is ready for operation.
  • Page 67 Programming and Parameters 3-21 • Power Factor angle has exceeded the value set in A058, 18 “Above PF Ang” A059 A061 A062 [Opto Outx Level]. • Use A059 or A062 to set threshold. Options (Cont.) 19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In Loss] for desired action when input loss occurs.
  • Page 68 3-22 Programming and Parameters Advanced Program Group (continued) A064 [Opto Out Logic] Determines the logic (Normally Open/NO or Normally Closed/NC) of the opto outputs. A064 Option Opto Out1 Logic Opto Out2 Logic NO (Normally Open) NO (Normally Open) NC (Normally Closed) NO (Normally Open) NO (Normally Open) NC (Normally Closed)
  • Page 69 Programming and Parameters 3-23 Advanced Program Group (continued) A066 [Analog Out High] Related Parameter(s): A065 Scales the Maximum Output Value for the A065 [Analog Out Sel] source setting. Examples: A066 Setting A065 Setting A065 Max. Output Value 1 “OutCurr 0-10” 5V for 200% Drive Rated Output Current 8 “OutPowr 0-20”...
  • Page 70 3-24 Programming and Parameters Advanced Program Group (continued) A069 [Internal Freq] Related Parameter(s): P038, A162 Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “InternalFreq”. When enabled, this parameter will change the frequency command in “real time”. A051 A054 [Digital Inx Sel] is set to 16 “MOP Up”...
  • Page 71 Programming and Parameters 3-25 Advanced Program Group (continued) A070 [Preset Freq 0] Related Parameter(s): P038, P039, P040, A051-A053, A067, A068, A140-A147, A150-A157 A071 [Preset Freq 1] A072 [Preset Freq 2] A073 [Preset Freq 3] A074 [Preset Freq 4] A075 [Preset Freq 5] A076 [Preset Freq 6] A077 [Preset Freq 7] Values...
  • Page 72 3-26 Programming and Parameters Advanced Program Group (continued) A079 [Jog Accel/Decel] Related Parameter(s): A078, A051-A054 Sets the acceleration and deceleration time when a jog command is issued. Values Default: 10.0 Secs Min/Max: 0.1/600.0 Secs Display: 0.1 Secs A080 [DC Brake Time] Related Parameter(s): P037, A051-A054, A081 Sets the length of time that DC brake current is “injected”...
  • Page 73 Programming and Parameters 3-27 Advanced Program Group (continued) A082 [DB Resistor Sel] Related Parameter(s): P037 Stop drive before changing this parameter. Enables/disables external dynamic braking. Setting Min/Max “Disabled” “Normal RA Res” (5% Duty Cycle) – Refer to Table B.C on page B-2.
  • Page 74 3-28 Programming and Parameters Advanced Program Group (continued) A084 [Boost Select] Related Parameter(s): b004, P031, P032, A085, A086, A087, A125 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve. Active when A125 [Torque Perf Mode] = 0 “V/Hz”.
  • Page 75 Programming and Parameters 3-29 Advanced Program Group (continued) A085 [Start Boost] Related Parameter(s): P031, P032, P034, P035, A084, A086, A087, A088, A125 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve when A084 [Boost Select] = 0 “Custom V/Hz”...
  • Page 76 3-30 Programming and Parameters Advanced Program Group (continued) A088 [Maximum Voltage] Related Parameter(s): b004, A085, A086, A087 Sets the highest voltage the drive will output. Values Default: Drive Rated Volts Min/Max: 20/Drive Rated Volts Display: 1 VAC A089 [Current Limit 1] Related Parameter(s): P033, A118 Maximum output current allowed before current limiting occurs.
  • Page 77 Programming and Parameters 3-31 Advanced Program Group (continued) A091 [PWM Frequency] Related Parameter(s): A124 Sets the carrier frequency for the PWM output waveform. The chart below provides derating guidelines based on the PWM frequency setting. Important: Ignoring derating guidelines can cause reduced drive performance. Values Default: 4.0 kHz...
  • Page 78 3-32 Programming and Parameters Advanced Program Group (continued) A094 [Start At PowerUp] Stop drive before changing this parameter. Enables/disables a feature that allows a Start or Run command to automatically cause the drive to resume running at commanded speed after drive input power is restored. Requires a digital input configured for Run or Start and a valid start contact.
  • Page 79 Programming and Parameters 3-33 Advanced Program Group (continued) A098 [SW Current Trip] Related Parameter(s): P033 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 A099 [Process Factor] Related Parameter(s): b010 Scales the output frequency value displayed by...
  • Page 80 3-34 Programming and Parameters Advanced Program Group (continued) A103 [Comm Data Rate] Related Parameter(s): b015 Sets the serial port rate for the RS485 (DSI) port. Important: Power to drive must be cycled before any changes will affect drive operation. Options 0 “1200” 1 “2400”...
  • Page 81 Programming and Parameters 3-35 Advanced Program Group (continued) A107 [Comm Format] Related Parameter(s): b015 Selects the protocol (RTU only), data bits (8 data bits only), parity (None, Even, Odd), and stop bits (1 stop bit only) used by the RS485 port on the drive. Refer to Appendix C for details on using the drive communication features.
  • Page 82 3-36 Programming and Parameters Advanced Program Group (continued) A110 [Anlg In 0-10V Lo] Related Parameter(s): b020, P034, P038, A122, A123 Stop drive before changing this parameter. Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038 [Speed Reference].

  • Page 83: Related Parameter(S): P033, A051-A054

    Programming and Parameters 3-37 Advanced Program Group (continued) A113 [Anlg In4-20mA Hi] Related Parameter(s): b021, P035, P038 Stop drive before changing this parameter. Sets the analog input level that corresponds to P035 [Maximum Freq] if a 4-20mA input is used by P038 [Speed Reference].

  • Page 84: Values Default

    3-38 Programming and Parameters Advanced Program Group (continued) A119 [Skip Frequency] Related Parameter(s): A120 Sets the frequency at which the drive will not operate. A setting of 0 disables this parameter. Values Default: 0 Hz Min/Max: 0/500 Hz Display: 1 Hz A120 [Skip Freq Band] Related Parameter(s): A119...

  • Page 85: Options 0 "Disabled

    Programming and Parameters 3-39 Advanced Program Group (continued) A122 [Analog In Loss] Related Parameter(s): A110, A111, A132 Selects drive action when an input signal loss is detected. Signal loss is defined as an analog signal less than 1V or 2mA. The signal loss event ends and normal operation resumes when the input signal level is greater than or equal to 1.5V or 3mA.

  • Page 86: Drive Rated Amps

    3-40 Programming and Parameters Advanced Program Group (continued) A126 [Motor NP FLA] Related Parameter(s): A127 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 A127 [Autotune] Related Parameter(s): A125, A126, A128, A129 Stop drive before changing this parameter.
  • Page 87 Programming and Parameters 3-41 Advanced Program Group (continued) A129 [Flux Current Ref] Related Parameter(s): A127 Value of amps for full motor flux. Values Default: Based on Drive Rating Min/Max: 0.00/[Motor NP FLA] Display: 0.01 Amps A130 [PID Trim Hi] Sets the maximum positive value that is added to a PID reference when PID trim is used. Values Default: 60.0 Hz...
  • Page 88 3-42 Programming and Parameters Advanced Program Group (continued) A133 [PID Feedback Sel] Select the source of the PID feedback. Refer to Appendix F for details. ATTENTION: The loss of analog input, encoder or other feedback may cause unintended speed or motion. Take appropriate precautions to guard against possible unintended speed or motion.
  • Page 89 Programming and Parameters 3-43 Advanced Program Group (continued) A137 [PID Setpoint] Provides an internal fixed value for process setpoint when the PID mode is enabled by A132 [PID Ref Sel]. Values Default: 0.0% Min/Max: 0.0/100.0% Display: 0.1% A138 [PID Deadband] Sets the lower limit of the PID output.
  • Page 90 3-44 Programming and Parameters Advanced Program Group (continued) A140 [Stp Logic 0] Related Parameter(s): P038, P039, P040, A051-A054, A055, A058, A061, A067, A068, A070-A077, A150-A157, A141 [Stp Logic 1] E248 A142 [Stp Logic 2] A143 [Stp Logic 3] A144 [Stp Logic 4] Stop drive before changing this parameter.
  • Page 91 Programming and Parameters 3-45 How StepLogic Works The StepLogic sequence begins with a valid start command. A normal sequence always begins with A140 [Stp Logic 0]. Digit 0: Logic For Next Step This digit defines the logic for the next step. When the condition is met the program advances to the next step.
  • Page 92 3-46 Programming and Parameters StepLogic Settings The logic for each function is determined by the four digits for each StepLogic parameter. The following is a listing of the available settings for each digit. Refer to Appendix E for details. Logic For Next Step Digit 0 Logic to Jump to a Different Step Digit 1...
  • Page 93 Programming and Parameters 3-47 Advanced Program Group (continued) A150 [Stp Logic Time 0] Related Parameter(s): P038, A055, A058, A061, A070-A077, A140-A147, E222 A151 [Stp Logic Time 1] A152 [Stp Logic Time 2] A153 [Stp Logic Time 3] A154 [Stp Logic Time 4] A155 [Stp Logic Time 5] A156 [Stp Logic Time 6] A157 [Stp Logic Time 7]...
  • Page 94 3-48 Programming and Parameters Advanced Program Group (continued) A161 [EM Brk On Delay] Related Parameter(s): P037 Sets the time the drive remains at minimum frequency before the relay or an opto output is de-energizing and the drive stops. The relay or opto output is typically connected to a user-supplied electromechanical brake coil relay. P037 [Stop Mode] to 8 “Ramp+EM B,CF”...

  • Page 95: Enhanced Program Group

    Programming and Parameters 3-49 Enhanced Program Group E201 [LED Display Opt] Selects which parameters can be viewed by the drive’s LED interface. E201 Option Parameter Set All Basic Display (Group b) and Advanced Display (Group d) parameters All Basic Display Group (b001-b029) parameters Basic Display Group parameters b001-b007 and b010 Basic Display Group parameter b001-b004 Values...
  • Page 96 3-50 Programming and Parameters E202 11 “Jog Forward” Drive accelerates to A078 [Jog Frequency] according to A079 Options [Jog Accel/Decel] and ramps to stop when input becomes (Cont.) inactive. A valid start will override this command. 12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079...
  • Page 97 Programming and Parameters 3-51 E202 28 “Acc/Dec Sel2” If active, can determine which Accel/Decel time will be used for Options Option all ramp rates except jog. Can (Cont.) 28 1 Description be applied to one input only. Acc/Dec 1 Acc/Dec 2 Acc/Dec 3 Acc/Dec 4 29 “Precharge En”...
  • Page 98 3-52 Programming and Parameters Enhanced Program Group (continued) E203 [Accel Time 3] Related Parameter(s): A067 E205 [Accel Time 4] Sets the rate of acceleration for all speed increases when selected by digital inputs. Refer to graphic A067 [Accel Time 2]. Maximum Freq Accel Rate Accel Time...
  • Page 99 Programming and Parameters 3-53 Enhanced Program Group (continued) E209 [Half Bus Enable] Enables/disables the power ride through function which allows the drive to maintain power to the motor at 50% drive input voltage during short-term power sag conditions. Options 0 “Disabled” (Default) 1 “Enabled”...
  • Page 100 3-54 Programming and Parameters Enhanced Program Group (continued) E212 [Traverse Dec] Related Parameter(s): E210 Sets time required for the Traverse function to decelerate from the maximum to the minimum traverse frequency. Refer to the diagram at E210 [Max Traverse]. Values Default: 0.00 Secs Min/Max:...
  • Page 101 Programming and Parameters 3-55 Enhanced Program Group (continued) E216 [Motor Fdbk Type] Stop drive before changing this parameter. Selects the encoder type. For additional information refer to Appendix E216 Option Encoder None Pulse Train Single Chan Single Check Quadrature Quad Check ATTENTION: The loss of analog input, encoder or other feedback may cause unintended speed or motion.
  • Page 102 3-56 Programming and Parameters Enhanced Program Group (continued) E220 [Ki Speed Loop] Sets the I-Gain used in the PI calculation of the speed loop. Values Default: Min/Max: 0.0/400.0 Display: E221 [Kp Speed Loop] Sets the P-Gain used in the PI calculation of the speed loop. Values Default: Min/Max:...
  • Page 103 Programming and Parameters 3-57 Enhanced Program Group (continued) E224 [Find Home Dir] Stop drive before changing this parameter. Sets the direction the drive commands when “Find Home” is issued. For additional information refer to Appendix Options 0 “Forward” (Default) 1 “Reverse” E225 [Encoder Pos Tol] Sets the “At Position”...
  • Page 104 3-58 Programming and Parameters Enhanced Program Group (continued) E230 [Step Units 0] Related Parameter(s): E226 E232 [Step Units 1] E234 [Step Units 2] E236 [Step Units 3] E238 [Step Units 4] E240 [Step Units 5] E242 [Step Units 6] E244 [Step Units 7] 32 bit parameter.
  • Page 105 Programming and Parameters 3-59 Enhanced Program Group (continued) E246 [Pos Reg Filter] Sets the error signal filter in the position regulator. For additional information refer to Appendix Values Default: Min/Max: 0/15 Display: E247 [Pos Reg Gain] Sets the gain adjustment for the position regulator. For additional information refer to Appendix Values Default:...
  • Page 106 3-60 Programming and Parameters Enhanced Program Group (continued) E248 [Enh Control Word] Allows control of positioning and other functions via parameter control for use over comms. The functions replicate the digital input options and function in the same way. For additional information refer to Appendix Important: The Find Home and Position Redefine bits must be returned to 0 following the homing...
  • Page 107 Programming and Parameters 3-61 Enhanced Program Group (continued) E249 [Cmd Stat Select] Selects velocity-specific or position/fibers-specific Command and Status Word bit definitions for use over a communication network. For additional information refer to Appendix Options 0 “Velocity” (Default) 1 “Position”...

  • Page 108: Advanced Display Group

    3-62 Programming and Parameters Advanced Display Group d301 [Drive Status 2] Present operating condition of the drive. When in Positioning mode, Bit 10 indicates positive or negative position in relation to Home. 1 = Condition True, 0 = Condition False Dir Positive Bit 0 At Position...
  • Page 109 Programming and Parameters 3-63 Advanced Display Group (continued) d305 [Speed Feedback F] Related Parameter(s): d304 Displays the value of the actual motor speed (fractional portion) whether measured by encoder/pulse train feedback or estimated. Values Default: Read Only Min/Max: 0.0/0.9 Display: d306 [Encoder Speed] Related Parameter(s): d307...
  • Page 110 3-64 Programming and Parameters d310 [Fault 4 Code] Related Parameter(s): A100 (With FRN 3.xx and later.) A code that represents the fourth most recent drive fault. The codes will appear in these parameters in the order they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.
  • Page 111 Programming and Parameters 3-65 d314 [Fault 8 Code] Related Parameter(s): A100 (With FRN 3.xx and later.) A code that represents the eighth most recent drive fault. The codes will appear in these parameters in the order they occur (b007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.

  • Page 112: Parameter Cross Reference - By Name

    3-66 Programming and Parameters Parameter Cross Reference – by Name Parameter Name Group Parameter Name Group 10V Bipolar Enbl A123 Advanced Program Encoder PPR E218 Enhanced Program Accel Time 1 P039 Basic Program Encoder Speed d306 Advanced Display Accel Time 2 A067 Advanced Program Encoder Speed F...
  • Page 113 Programming and Parameters 3-67 Parameter Name Group Parameter Name Group PID Trim Hi A130 Advanced Program Units Traveled H d308 Advanced Display PID Trim Lo A131 Advanced Program Units Traveled L d309 Advanced Display Pos Reg Filter E246 Enhanced Program Var PWM Disable A124 Advanced Program...
  • Page 114 3-68 Programming and Parameters Notes:...

  • Page 115: Troubleshooting

    Chapter Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 40P 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 116 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. The integral LED display provides visual notification of a fault condition by displaying the FAULT following. • Flashing fault number • Flashing fault indicator Press the Up Arrow key to regain control of the display.

  • Page 117: Fault Descriptions

    Troubleshooting Fault Descriptions Table 4.B Fault Types, Descriptions and Actions No. Fault Description Action Auxiliary Input Auxiliary input interlock is open. 1. Check remote wiring. 2. Verify communications programming for intentional fault. Power Loss DC bus voltage remained below 1. Monitor the incoming AC line for 85% of nominal or single phase low voltage or line power operation detected.
  • Page 118 Troubleshooting Fault Description Action F33 Auto Rstrt Tries Drive unsuccessfully attempted Correct the cause of the fault and to reset a fault and resume manually clear. running for the programmed number of A092 [Auto Rstrt Tries]. F38 Phase U to Gnd A phase to ground fault has been 1.
  • Page 119 Troubleshooting Fault Description Action F91 Encoder Loss Requires differential encoder. 1. Check Wiring. One of the 2 encoder channel 2. If P038 [Speed Reference] = 9 “Positioning” and E216 [Motor signals is missing. Fdbk Type] = 5 “Quad Check” swap the Encoder channel inputs (see page 1-18) or swap any two...

  • Page 120: Common Symptoms And Corrective Actions

    Troubleshooting Common Symptoms and Corrective Actions Motor does not Start. Cause(s) Indication Corrective Action No output voltage to the motor. None Check the power circuit. • Check the supply voltage. • Check all fuses and disconnects. Check the motor. • Verify that the motor is connected properly.
  • Page 121 Troubleshooting Drive does not Start from Start or Run Inputs wired to the terminal block. Cause(s) Indication Corrective Action Drive is Faulted Flashing red status light Clear fault. • Press and hold Up Arrow key for 3 seconds. • Cycle power •...
  • Page 122 Troubleshooting Motor and/or drive will not accelerate to commanded speed. Cause(s) Indication Corrective Action Acceleration time is excessive. None Reprogram P039 [Accel Time 1] or A067 [Accel Time 2]. Excess load or short None Compare b003 [Output Current] with acceleration times force the A089 [Current Limit 1].
  • Page 123 Troubleshooting Motor operation is unstable. Cause(s) Indication Corrective Action Motor data was incorrectly None 1. Correctly enter motor nameplate entered. data into P031, P032 and P033. 2. Enable A097 [Compensation]. 3. Use A084 [Boost Select] to reduce boost level. Drive will not reverse motor direction. Cause(s) Indication Corrective Action...
  • Page 124 4-10 Troubleshooting Notes:...

  • Page 125: Supplemental Drive Information

    Appendix Supplemental Drive Information For information on… See page… Drive, Fuse & Circuit Breaker Ratings Specifications Drive, Fuse & Circuit Breaker Ratings The tables on the following pages provide recommended AC line input fuse and circuit breaker information. See Fusing and Circuit Breakers below for UL and IEC requirements.
  • Page 126 Supplemental Drive Information Specifications Table A.A Drive Ratings Output Ratings Input Ratings Branch Circuit Protection Catalog 140M Motor Voltage Min. Enclosure Number (2) (3) kW (HP) Amps Range kVA Amps Fuses Protectors Contactors Volume (in. 200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output 22D-B2P3 0.4 (0.5) 180-264 1.15 2.5...
  • Page 127 Supplemental Drive Information Table A.B Specifications Category Specification Agency Listed to UL508C and CAN/CSA-22.2 Certification ® Certified to AS/NZS, 1997 Group 1, Class A N223 Marked for all applicable European Directives EMC Directive: 2004/108/EC: EN 61800-3:2004+A1:2012 LV Directive: 2006/95/EC: EN 61800-5-1:2007 EN 60204-1:2006+A1:2009 +AC:2010 Machine Directive: 2006/42/EC: EN 62061...
  • Page 128 Supplemental Drive Information Category Specification Electrical Voltage Tolerance: 200-240V ±10% 380-480V ±10% 460-600V ±10% Frequency Tolerance: 48-63 Hz Input Phases: Three-phase input provides full rating. Single-phase operation provides 35% rated current. Displacement Power Factor: 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...
  • Page 129 Specification Resolution: 10-bit 0 to 10V DC Analog: 1k ohm minimum 4-20mA Analog: 525 ohm maximum Table A.C PowerFlex 40P Estimated Watts Loss (Rated Load, Speed & PWM) Voltage kW (HP) External Watts Internal Watts Total Watts Loss 200–240V 0.4 (0.5) 0.75 (1.0)
  • Page 130 Supplemental Drive Information Notes:...

  • Page 131: Accessories And Dimensions

    Accessories and Dimensions Product Selection Table B.A Catalog Number Description 22D - Drive Voltage Rating Rating Enclosure Emission Class Version Table B.B PowerFlex 40P Drives IP20 Flange Drive Ratings IP20/NEMA Type Open Mount Plate Drive Output Frame Input Voltage kW HP...
  • Page 132 Accessories and Dimensions Table B.C Dynamic Brake Modules Drive Ratings Minimum Resistance Ω (1) (2) Input Voltage Catalog Number 240V 50/60 Hz AK-R2-091P500 3-Phase 0.75 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 AK-R2-047P500 AK-R2-030P1K2 10.0 AK-R2-030P1K2 480V 50/60 Hz AK-R2-360P500 3-Phase 0.75 AK-R2-360P500 AK-R2-360P500 AK-R2-120P1K2 AK-R2-120P1K2 AK-R2-120P1K2...
  • Page 133 Accessories and Dimensions Table B.D Bulletin 1321-3R Series Line Reactors Maximum Fundamental Continuous Inductance Watts Catalog Input Voltage Amps Amps Loss Number 240V 50/60 Hz 12.0 21 W 1321-3R4-D 3-Phase 0.75 1.0 29 W 1321-3R8-B 19.5 W 1321-3R8-A 1.25 26 W 1321-3R12-A 36 W 1321-3R18-A...
  • Page 134 Accessories and Dimensions Table B.F EMC Line Filters Drive Ratings S Type Filter L Type Filter Input Voltage Catalog Number Catalog Number 240V 50/60 Hz 22-RF021-BS 22-RF021-BL 3-Phase 0.75 22-RF021-BS 22-RF021-BL 22-RF021-BS 22-RF021-BL 22-RF021-BS 22-RF021-BL 22-RF021-BS 22-RF021-BL 22-RF034-CS 22-RF034-CL 10.0 22-RF034-CS 22-RF034-CL 480V 50/60 Hz...
  • Page 135 Accessories and Dimensions Table B.G Human Interface Module (HIM) Option Kits and Accessories Item Description Catalog Number LCD Display, Remote Panel Digital speed control 22-HIM-C2S Mount CopyCat capable IP66 (NEMA Type 4X/12) indoor use only Includes 2.9 meter cable LCD Display, Remote Handheld Digital speed control 22-HIM-A3 Full numeric keypad CopyCat capable...
  • Page 136 RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P DriveTools SP Software Windows based software packages that provide 9303-4DTS01ENE an intuitive means for monitoring or configuring DriveExplorer Software 9306-4EXP01ENE Allen-Bradley drives and communication adapters (CD-ROM) Version 3.01 online. or later Compatibility: DriveExecutive software 9303-4DTE01ENE Windows 95, 98, ME, NT 4.0 (Service Pack 3 or...

  • Page 137: Product Dimensions

    Accessories and Dimensions Product Dimensions Table B.K PowerFlex 40P Frames – Ratings are in kW and (HP) 240V AC – 480V AC – 600V AC – Frame 3-Phase 3-Phase 3-Phase 0.4 (0.5) 2.2 (3.0) 0.4 (0.5) 2.2 (3.0) 0.75 (1.0) 2.2 (3.0)
  • Page 138 Accessories and Dimensions Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit with Communication Option – Dimensions are in millimeters and (inches) 77.5 (3.05) 161.0 (6.34) 100.0 (3.94) 50.0 (1.97) 87.0 (3.43) 136.0 (5.35) 22.5 (0.89) ∅ 22.2 (0.87) 87.4 (3.44) FAULT FAULT...
  • Page 139 Accessories and Dimensions Figure B.3 PowerFlex 40P Flange Mount Drives – Dimensions are in millimeters and (inches) 106.3 (4.19) 94.3 63.1 (3.71) (2.48) (9.61) (8.43) 20A-DG01 FAULT FAULT (9.84) 22D-CCB 119.3 (4.70) Frame B 117.8 (4.64) 105.8 138.2 (11.81) (4.17) (5.44)
  • Page 140 B-10 Accessories and Dimensions Figure B.4 PowerFlex 40P Flange Mount Cutout Dimensions – Dimensions are in millimeters and (inches) (5.71) 23.5 (0.26) (0.93) (7.76) (8.27) (8.86) 98.5 (3.88) (0.21) (0.30) (1.22) (1.93) (0.55) (3.86) (6.30) Frame B (0.21) (6.46) (0.31) 307.5...
  • Page 141 Accessories and Dimensions B-11 Figure B.5 PowerFlex 40P Plate Drive Dimensions – Dimensions are in millimeters and (inches) (4.92) (4.41) (3.94) (3.15) (3.46) (0.37) 20A-DG01 FAULT FAULT (7.56) (7.09) (8.03) 22D-CCB (3.78) (0.21) (4.45) (3.94) Frame B (6.10) 110.5 (5.59) (4.35)
  • Page 142 B-12 Accessories and Dimensions Figure B.6 Dynamic Brake Modules – Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). Frame A Frame B 30.0 61.0 (1.18) (2.40) 17.0 60.0 31.0 59.0 (0.67) (2.36) (1.22) (2.32) 316.0 335.0 386.0 405.0 (12.44)
  • Page 143 Accessories and Dimensions B-13 Figure B.8 Bulletin 1321-3R Series Line Reactors – Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). Catalog Number Weight 1321-3R2-A 112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4) 1321-3R2-B 112 (4.40) 104 (4.10)
  • Page 144 B-14 Accessories and Dimensions Figure B.9 Frame B EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF0P8-BL; 22-RF012-BS, -BL (Series B); 22-RF021-BS, -BL (1.97) (3.94) 29.8 (3.07) (1.17) (8.54) (9.02) (8.50) 17.8 5.5 (0.22) (0.70) 24.0 (0.94)
  • Page 145 Accessories and Dimensions B-15 Figure B.10 Frame C EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF018-CS, -CL; 22-RF025-CL; 22-RF026-CS, -CL; 22-RF034-CS, (2.36) (5.12) (3.54) (1.26) (11.69) (12.17) (11.69) 5.5 (0.22) (0.67) (1.18)
  • Page 146 B-16 Accessories and Dimensions Figure B.11 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches) Catalog Number: 22-HIM-C2S (0.98) (3.66) (7.09) (2.64) (2.36) (6.06) 19.1 (3.03) (0.75) (0.19) 23.5 (0.93)
  • Page 147 Accessories and Dimensions B-17 Figure B.12 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)
  • Page 148 B-18 Accessories and Dimensions Notes:...

  • Page 149: Network Wiring

    PowerFlex 40P 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 40P 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 150 (1 foot). • Network wiring should only cross power wires at a right angle. I/O Terminal 19 (DSI Shield) on the PowerFlex 40P must also be connected to PE ground (there are two PE terminals on the drive). See Table 1.I...

  • Page 151: Parameter Configuration

    RS485 (DSI) Protocol Parameter Configuration The following PowerFlex 40P parameters are used to configure the drive to operate on a network. Parameter Details Reference P036 [Start Source] Set to 5 “Comm Port” if Start is controlled from the Page 3-10 network.

  • Page 152: Writing (06) Logic Command Data

    RS485 (DSI) Protocol Writing (06) Logic Command Data The PowerFlex 40P drive can be controlled via the network by sending Function Code 06 writes to register address 8192 (Logic Command). P036 [Start Source] must be set to 5 “Comm Port” in order to accept the commands.

  • Page 153: Writing (06) Reference

    1 = Pos Redefine 1 = Sync Enable 1 = Traverse Disable Writing (06) Reference The Speed Reference to a PowerFlex 40P drive can be controlled via the network by sending Function Code 06 writes to register address 8193 (Reference). P038 [Speed Reference] must be set to 5 “Comm Port”...

  • Page 154: Reading (03) Logic Status Data

    RS485 (DSI) Protocol Reading (03) Logic Status Data The PowerFlex 40P Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 (Logic Status). Parameter E249 [Cmd Stat Select] is used to select Velocity or Position Bit definitions.

  • Page 155: Reading (03) Feedback

    Returns the same data as Reading (03) Parameter d001 [Output Freq]. Reading (03) Drive Error Codes The PowerFlex 40P Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error Codes).

  • Page 156: Reading (03) And Writing (06) Drive Parameters

    RS485 (DSI) Protocol Reading (03) and Writing (06) Drive Parameters To access drive parameters, the Modbus register address equals the parameter number. For example, a decimal “1” is used to address Parameter d001 [Output Freq] and decimal “39” is used to address Parameter P039 [Accel Time 1].

  • Page 157: Connectivity Guidelines

    Appendix RJ45 DSI Splitter Cable The PowerFlex 40P 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 158: Dsi Cable Accessories

    RJ45 DSI Splitter Cable DSI Cable Accessories RJ45 Splitter Cable – Catalog Number: AK-U0-RJ45-SC1 Slave Port Master Port PIN 1 PIN 8 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 –...

  • Page 159: Connecting One Temporary Peripheral

    RJ45 DSI Splitter Cable Connecting One Temporary Peripheral DSI / MDI Drive DSI / MDI Hand Held Serial Converter Parameter 1 [Adapter Cfg] set to "Auto" (default) or "Master" and connected to Master port (M) on RJ45 Splitter Cable Parameter 9 [Device Type] set to "Auto" (default) or "Master"...

  • Page 160: Connecting Two Permanent Peripherals

    RJ45 DSI Splitter Cable Connecting Two Permanent Peripherals NEMA 1 Bezel with DSI / MDI Hand Held NEMA 4 Panel Mount Unit DSI / MDI Drive Parameter 9 [Device Type] set to "Master" and connected to Master port (M) on RJ45 Splitter Cable Parameter 9 [Device Type] set to "Slave"...

  • Page 161: Velocity Steplogic™, Basic Logic And Timer/Counter Functions

    Appendix Velocity StepLogic™, Basic Logic and Timer/Counter Functions Four PowerFlex 40P logic functions provide the capability to program simple logic functions without a separate controller. • Velocity StepLogic Function Steps through up to eight preset speeds based on programmed logic.

  • Page 162: Velocity Steplogic Using Timed Steps

    Velocity StepLogic™, Basic Logic and Timer/Counter Functions Velocity StepLogic Using Timed Steps To activate this function, set parameter P038 [Speed Reference] to 6 “Stp Logic”. Three parameters are used to configure the logic, speed reference and time for each step. •...

  • Page 163: Velocity Steplogic Using Basic Logic Functions

    Velocity StepLogic™, Basic Logic and Timer/Counter Functions Velocity StepLogic Using Basic Logic Functions Digital input and digital output parameters can be configured to use logic to transition to the next step. Logic In1 and Logic In2 are defined by programming parameters A051-A054 [Digital Inx Sel] to option 23 “Logic In1”...

  • Page 164: Timer Function

    Velocity StepLogic™, Basic Logic and Timer/Counter Functions Timer Function Digital inputs and outputs control the timer function and are configured with parameters A051-A054 [Digital Inx Sel] set to 18 “Timer Start” and 20 “Reset Timer”. Digital outputs (relay and opto type) define a preset level and indicate when the level is reached.
  • Page 165 Velocity StepLogic™, Basic Logic and Timer/Counter Functions Output Frequency Start Relay Out Photo Eye Digital In1 Counter In Digital In2 Reset Counter Limit Switch Note that a “Reset Timer” input is not required for this example since the “Timer Start” input both clears and starts the timer.

  • Page 166: Counter Function

    Velocity StepLogic™, Basic Logic and Timer/Counter Functions Counter Function Digital inputs and outputs control the counter function and are configured with parameters A051-A054 [Digital Inx Sel] set to 19 “Counter In” and 21 “Reset Countr”. Digital outputs (relay and opto type) define a preset level and indicate when the level is reached.
  • Page 167 Velocity StepLogic™, Basic Logic and Timer/Counter Functions Velocity StepLogic Parameters Table E.A Code Descriptions for Parameters A140-A147 Digit 3 Digit 2 Digit 1 Digit 0 Table E.B Digit 3 – Defines the action during the step currently executing. Accel/Decel StepLogic Output Setting Parameters Used State...
  • Page 168 Velocity StepLogic™, Basic Logic and Timer/Counter Functions Table E.D Digit 1 – Defines what logic must be met to jump to a step other than the very next step. Setting Description Logic Skip Step (jump immediately) SKIP Step based on the time programmed in the respective [Stp Logic Time x] TIMED parameter.

  • Page 169: Encoder Usage And Position Steplogic Application

    Encoder Usage and Position StepLogic Application Encoder Usage The PowerFlex 40P includes a pulse-train/encoder input. When E216 [Motor Fdbk Type] is set to a value other than zero, the drive is set to use an encoder. The drive will use the encoder in several ways depending on the settings of other parameters.

  • Page 170: Wiring Notes

    E216 [Motor Fdbk Type] is set to option 5 “Quad Check”. Positioning Overview The PowerFlex 40P includes a simple position regulator which can be used in a variety of position applications without the need for multiple limit switches or photo-eyes. This can be used as a stand-alone controller for simple applications (up to 8 positions) or in conjunction with a controller for more flexibility.

  • Page 171: Common Guidelines For All Applications

    Encoder Usage and Position StepLogic Application Common Guidelines for All Applications The position regulator can be configured for operation appropriate for a variety of applications. Certain parameters will need to be adjusted in all cases. P038 [Speed Reference] must be set to option 9 “Positioning”. E216 [Motor Fdbk Type] must be set to the match the feedback device.
  • Page 172 E217 [Motor NP Poles] must be set to match the number of motor poles on the motor driven by the PowerFlex 40P drive. E218 [Encoder PPR] must be set to match the number of pulses per revolution of the encoder used (i.e., 1024 PPR Encoder).

  • Page 173: Positioning Operation

    Encoder Usage and Position StepLogic Application Positioning Operation Parameter E222 [Positioning Mode] must be set to properly match the desired operation of the positioning function. E222 [Positioning Mode] Options 0 “Time Steps” uses Step Logic times. This mode ignores the Step Logic settings and moves through the steps (Step 0 to Step 7 and back to Step 0) based on the times programmed into A150-A157...
  • Page 174 Encoder Usage and Position StepLogic Application In all position modes, the following parameters will control the characteristics at each step: E230-E244 [Step Units x] These are the number value to the left of the decimal (whole number) of the 8 positions desired for an application, beginning with Step 0 (E230) and continuing with each step until Step 7 (E244).
  • Page 175 Encoder Usage and Position StepLogic Application A140-A147 [Stp Logic x] – When a positioning mode is selected that utilizes the Step Logic functions these parameters allow additional flexibility and control various aspects of each step. Note that in Positioning mode these parameters have a different function than when used for normal velocity Step Logic.

  • Page 176: Homing Routine

    Encoder Usage and Position StepLogic Application E247 [Pos Reg Gain] is a single adjustment for increasing or decreasing the responsiveness of the position regulator. For faster response, the filter should be reduced and/or the gain should be increased. For smoother response with less overshoot, the filter should be increased and/or the gain should be reduced.

  • Page 177: Encoder And Position Feedback

    Encoder Usage and Position StepLogic Application E223 [Find Home Freq] This parameter sets the frequency the drive will use while it is moving to the home position during the automatic homing routine. E224 [Find Home Dir] This parameter sets the direction the drive will use while it is moving to the home position during the automatic homing routine.

  • Page 178: Use Over Communications

    F-10 Encoder Usage and Position StepLogic Application d308 [Units Traveled] Parameter d308 [Units Traveled H] and d309 [Units Traveled L] indicate the current position of the system in terms of units away from Home. Parameter d308 is the number value to the left of the decimal (whole number) and d309 is the number to the right of the decimal (the portion less than 1).

  • Page 179: Setup Notes

    Encoder Usage and Position StepLogic Application F-11 E248 [Enh Control Word] This parameter allows many of the positioning functions to be completed via parameter control using an explicit message. This allows the operation over communications instead of with hardware inputs. The bits have the same functions as the digital input options of the same name.
  • Page 180 F-12 Encoder Usage and Position StepLogic Application Notes:...

  • Page 181: Pid Loop

    Appendix PID Set Up PID Loop The PowerFlex 40P has a built-in PID (proportional, integral, differential) control loop. The PID loop is used to maintain a process feedback (such as pressure, flow or tension) at a desired set point. The PID loop works by subtracting the PID feedback from a reference and generating an error value.
  • Page 182 PID Set Up Exclusive Control In Exclusive Control, the Speed Reference becomes 0, and the PID Output becomes the entire Freq Command. Exclusive Control is used when A132 [PID Ref Sel] is set to option 1, 2, 3, 4 or 5. This configuration does not require a master reference, only a desired set point, such as a flow rate for a pump.
  • Page 183 PID Set Up Trim Control In Trim Control, the PID Output is added to the Speed Reference. In Trim mode, the output of the PID loop bypasses the accel/decel ramp as shown. Trim Control is used when A132 [PID Ref Sel] is set to option 6, 7, 8, 9 or 10.

  • Page 184: Pid Reference And Feedback

    2 “Comm Port” The reference word from a communication network (see Appendix C of the PowerFlex 40P User Manual for details on the reference word) such as Modbus RTU or DeviceNet becomes the PID Feedback. The value sent over the network is scaled so that P035 [Maximum Freq] x 10 = 100% Feedback.

  • Page 185: Analog Pid Reference Signals

    PID Set Up Analog PID Reference Signals Parameters A110 [Anlg In 0-10V Lo] and A111 [Anlg In 0-10V Hi] are used to scale or invert an analog PID Reference or PID Feedback. Examples Scale Function For a 0-5 volt signal, the following parameter settings are used so that a 0 volt signal = 0% PID Reference and a 5 volt signal = 100% PID Reference.
  • Page 186 PID Set Up PID Deadband Parameter A138 [PID Deadband] is used to set a range, in percent, of the PID Reference that the drive will ignore. Example • [PID Deadband] is set to 5.0 • The PID Reference is 25.0% •...
  • Page 187 PID Set Up PID Gains The proportional, integral, and differential gains make up the PID regulator. • A134 [PID Prop Gain] The proportional gain (unitless) affects how the regulator reacts to the magnitude of the error. The proportional component of the PID regulator outputs a speed command proportional to the PID error.
  • Page 188 PID Set Up Guidelines for Adjusting the PID Gains 1. Adjust the proportional gain. During this step it may be desirable to disable the integral gain and differential gain by setting them to 0. After a step change in the PID Feedback: –...
  • Page 189 PID Set Up The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains. Figure G.1 Unstable PID Reference PID Feedback Time Figure G.2 Slow Response – Over Damped PID Reference PID Feedback Time Figure G.3 Oscillation –...
  • Page 190 G-10 PID Set Up Notes:...

  • Page 191: Plate Drive Installation Instructions

    Plate Drive Installation Instructions Introduction The PowerFlex 40P is available in a plate drive version without heatsink. This is designed to allow mounting to a customer supplied heatsink. This may be a large heatsink to be shared by multiple drives, a large thermal mass that is part of a system, or some other heat-sinking system.

  • Page 192: Heatsink Thermal Capacity

    Plate Drive Installation Instructions Heatsink Thermal Capacity The heatsink provided must have the thermal capacity to cool the drive under worst-case loading conditions as well as for short duration overload conditions in the application. Refer to Table A.C on page A-5 for estimated watts loss data.

  • Page 193: Heatsink Surface And Flatness Requirements

    Plate Drive Installation Instructions Heatsink Surface and Flatness Requirements The drive comes with a thermal pad designed to provide a good interface between the drive and heatsink. However, in order for this to function properly the mounting surface for the plate drive must be clean and free of dirt, oil, and debris.

  • Page 194: Mounting Dimensions And Requirements

    Plate Drive Installation Instructions Mounting Dimensions and Requirements Refer to Figure B.5 on page B-11 for plate drive dimensions and mounting hole locations. Use the pattern illustrated in Step 3 below to gradually tighten all mounting bolts to the recommend torque of 2.0 N-m (18 lb.-in.). Isopropyl Alcohol 2.0 N-m...
  • Page 195 Index Drive, B-7 Minimum Clearances, 1-2 AC Supply DIP Switch Locations, 1-15 Ground, 1-6 Discharging Bus Capacitors, P-3 Source, 1-4 Display, 2-3 Ungrounded, 1-4 Distribution Systems, Ungrounded, Advanced Display Group Parameters, 3-62 Drive Frame Size, P-2, B-7 Advanced Program Group Drive Grounding, 1-6 Parameters, 3-15 Drive Overload Fault, 4-4...
  • Page 196 Index-2 Phase to Ground Short, 4-4 Motor Overload Fault, 4-3 Motor Stalled Fault, 4-3 Power Loss, 4-3 motor starter, 1-7 Power Unit, 4-4 Mounting Options and Clearances, SW OverCurrent, 4-4 UnderVoltage, 4-3 MOVs, 1-4 Filter, RFI, 1-7 Frame Designations, P-2, A-1, B-7 Fuses Opening the Cover, 1-1 Input, 1-7...
  • Page 197 Index-3 Repeated Start/Stop Precautions, 1-13 RFI, see EMC/RFI RWR (Reflective Wave Reducer), 1-11 Safe Off Operation, 1-21 Safety Ground, 1-6 Shielded Power Cables, 1-9 Short Circuit Protection, 1-7 Software, 3-1 Start and Speed Reference Selection and Control, 1-27, 1-28 Start/Stop, Repeated, 1-13 Start-Up Checklist, 2-1, 2-2 Static Discharge, ESD, P-3 Status LEDs, 2-3...
  • Page 198 Index-4 Notes:...
  • Page 200 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 22D-UM001D-EN-E –...

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