Rockwell Automation Allen-Bradley PowerFlex 4 User Manual
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Rockwell Automation Allen-Bradley PowerFlex 4 User Manual

Rockwell Automation Allen-Bradley PowerFlex 4 User Manual

Adjustable frequency ac drive
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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 4

  • Page 1 Adjustable Frequency AC Drive FRN 2.xx User Manual www.abpowerflex.com...
  • Page 2 Burn Hazard labels may be located on or inside the drive to alert people that surfaces may be at dangerous temperatures. DriveExplorer, DriveTools32, and SCANport are trademarks of Rockwell Automation. PLC is a registered trademark of Rockwell Automation. ControlNet is a trademark of ControlNet International, Ltd.
  • Page 3 Summary of Changes The information below summarizes the changes to the PowerFlex 4 User Manual since the last release. Description of New or Updated Information See Page(s) Minimum mounting clearances between drive reduced to 25 mm (1.0 in.). 1-2 Expanded information on branch circuit protective devices. New information on I/O wiring including additional wiring examples.
  • Page 4 soc-2...

  • Page 5: Table Of Contents

    Table of Contents Preface Overview Who Should Use this Manual? ..P-1 Reference Materials....P-1 Manual Conventions .

  • 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 4 Adjustable Frequency AC Drive. For information on… See page… Who Should Use this Manual? Reference Materials Manual Conventions Drive Frame Sizes General Precautions...

  • Page 8: Manual Conventions

    Overview Manual Conventions • In this manual we refer to the PowerFlex 4 Adjustable Frequency AC Drive as; drive, PowerFlex 4 or PowerFlex 4 Drive. • Parameter numbers and names are shown in this format: P031 [Motor NP Volts] Name Number Group d = Display Group...

  • 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

    Overview Catalog Number Explanation Drive Dash Voltage Rating Rating Enclosure Emission Class Comm Slot Code Code Version 22A PowerFlex 4 RS485 Code Rating No Filter Integral EMI Filter Code Voltage 120V AC 1 240V AC 1 Code Interface Module 240V AC 3 Fixed Keypad 480V AC 3 Code Enclosure...

  • Page 11: Installation/Wiring

    Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 4 Drive. For information on… See page For information on… See page Opening the Cover Fuses and Circuit Breakers 1-6 Mounting Considerations Power Wiring AC Supply Source Considerations 1-3 I/O Wiring 1-11 Recommendations...

  • Page 12: Mounting Considerations

    Installation/Wiring Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. – Install on 35 mm DIN Rail. – Install with screws. Table 1.A Screw Mounting Recommendations Minimum Panel Thickness Screw Size Mounting Torque 1.9 mm (0.0747 in.) m4 x 0.7 (#8-32) 1.56-1.96 Nm (14-17 lb.-in.) •...

  • Page 13: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source Considerations Ungrounded Distribution Systems ATTENTION: PowerFlex 4 drives contain protective MOVs that are referenced to ground. These devices should be disconnected if the drive is installed on an ungrounded distribution system. Disconnecting MOVs To prevent drive damage, the MOVs connected to ground shall be disconnected if the drive is installed on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage.

  • Page 14: General Grounding Requirements

    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.C 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.C, install one of the devices listed under the heading Corrective Action on the line side of the drive.
  • Page 15 Installation/Wiring Ground Fault Monitoring If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping. Safety Ground - (PE) This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod or bus bar.

  • Page 16: Fuses And Circuit Breakers

    Installation/Wiring Fuses and Circuit Breakers The PowerFlex 4 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. ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in this section.
  • Page 17 Installation/Wiring Table 1.D Minimum Recommended Branch Circuit Protective Devices Voltage Drive Rating Fuse Rating 140M Motor Recommended Rating kW (HP) Amps Protectors MCS Contactors Catalog No. Catalog No. 120V AC – 0.2 (0.25) 140M-C2E-C10 100-C09 1-Phase 0.37 (0.5) 140M-C2E-C16 100-C12 0.75 (1.0) 140M-D8E-C20 100-C23...

  • Page 18: 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 19 Installation/Wiring 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.E for recommendations.
  • Page 20 1-10 Installation/Wiring Power Terminal Block The drive utilizes a finger guard over the power wiring terminals. 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 (A Frame Shown) R/L1 S/L2...

  • Page 21: I/O Wiring Recommendations

    Installation/Wiring 1-11 I/O Wiring Recommendations Motor Start/Stop Precautions ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor.
  • Page 22 1-12 Installation/Wiring Control Wire Types Table 1.G Recommended Control and Signal Wire Wire Type(s) Description Minimum Insulation Rating Belden 8760/9460 0.8 mm (18AWG), twisted pair, 100% 300V (or equiv.) shield with drain. 60 degrees C (140 degrees F) Belden 8770 0.8 mm (18AWG), 3 conductor, shielded for (or equiv.)
  • Page 23 Installation/Wiring 1-13 Figure 1.5 Control Wiring Block Diagram Important: I/O Terminal 01 is P036 I/O Terminal 01 [Start Source] always a coast to stop input except Stop Stop Keypad Per P037 Coast when P036 [Start Source] is set to 3-Wire Per P037 Per P037 “3-Wire”...
  • Page 24 1-14 Installation/Wiring I/O Wiring Examples Input Connection Example Potentiometer P038 [Speed Reference] = 2 “0-10V Input” 1-10k Ohm Pot. Recommended (2 Watt minimum) Analog Input Voltage Current 0 to +10V, 100k ohm P038 [Speed Reference] = 2 “0-10V P038 [Speed Reference] impedance Input”...
  • Page 25 Installation/Wiring 1-15 Input Connection Example 2 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Run FWD/Run REV P036 [Start Source] = 2, 3 Stop-Run or 4 Forward Stop-Run Input must be active for Forward the drive to run. When Stop-Run Reverse input is opened, the drive...
  • Page 26 1-16 Installation/Wiring Input Connection Example 3 Wire SRC Control - Internal Supply (SRC) External Supply (SRC) Reversing P036 [Start Source] Stop Stop A momentary input will start the drive. A stop Start input to I/O Terminal 01 Start will stop the drive as Direction Direction specified by P037...

  • Page 27: Start And Speed Reference Control

    Installation/Wiring 1-17 Start and Speed Reference Control The drive speed command can be obtained from a number of different sources. The source is normally determined by P038 [Speed Reference]. However, when A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or 6, and the digital input is active, A051 or A052 will override the speed reference commanded by P038 [Speed...
  • Page 28 1-18 Installation/Wiring Accel/Decel Selection The selection of Accel/Decel rates can be made through digital inputs, RS485 (DSI) communications and/or parameters. Jog Input A079 [Jog Accel/Decel] used. Enabled and Active: A051 or A052 = 2 Active when RS485 (DSI) Port A067 [Accel Time 2]/A068 [Decel Time 2] Controls Speed is selected by RS485 (DSI) port.

  • Page 29: Emc Instructions

    Installation/Wiring 1-19 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 30 1-20 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. 1. Grounding as described in Figure 1.6. Refer to page 1-5 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 31 Installation/Wiring 1-21 EN61000-3-2 • 0.75 kW (1 HP) 240V 1-Phase and 3-Phase drives and 0.37 kW (0.5 HP) 240V 1-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. •...
  • Page 32 1-22 Installation/Wiring Notes:...

  • Page 33: Prepare For Drive Start-Up

    Chapter Start Up This chapter describes how to start up the PowerFlex 4 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 34 Start Up Applying Power to the Drive ❏ 6. Apply AC power and control voltages to the drive. ❏ 7. Familiarize yourself with the integral keypad features (see page 2-3) before setting any Program Group parameters. Start, Stop, Direction and Speed Control Factory default parameter values allow the drive to be controlled from the integral keypad.

  • Page 35: Integral Keypad

    Start Up Integral Keypad — – ˜ Menu Description VOLTS Display Group (View Only) AMPS HERTZ Consists of commonly viewed drive operating conditions. PROGRAM FAULT š ™ Basic Program Group Consists of most commonly used programmable functions.  › œ Advanced Program Group Consists of remaining programmable functions.

  • Page 36: Viewing And Editing Parameters

    Start Up Viewing and Editing Parameters The last user-selected Display Group parameter is saved when power is removed and is displayed by default when power is reapplied. The following is an example of basic integral keypad and display functions. This example provides basic navigation instructions and illustrates how to program the first Program Group parameter.

  • Page 37: Programming And Parameters

    Chapter Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 4 parameters. Parameters are programmed (viewed/edited) using the integral keypad. As an alternative, programming can also be performed using DriveExplorer™ or DriveExecutive™ software, a personal computer and a serial converter module.

  • Page 38: Parameter Organization

    Programming and Parameters Parameter Organization A d v a n c e d P r o g r a m G B a s i c r o u p P r o g r a m G D i s p l r o u p a y G r o u p...

  • Page 39: Display Group

    Programming and Parameters Display Group d001 [Output Freq] Related Parameter(s): d002, d010, P034, P035 Output frequency present at T1, T2 & T3 (U, V & W). Values Default Read Only Min/Max: 0.0/P035 [Maximum Freq] Display: 0.1 Hz d002 [Commanded Freq] Related Parameter(s): d001, P034, P035, P038 Value of the active frequency command.
  • Page 40 Programming and Parameters Display Group (continued) d006 [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: Display:...
  • Page 41 Programming and Parameters Display Group (continued) d012 [Control Source] Related Parameter(s): P036, P038, A051, A052 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 42 Values Default Read Only Min/Max: Display: d016 [Control SW Ver] 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:...
  • Page 43 Programming and Parameters Display Group (continued) d018 [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 d019 [Testpoint Data] Related Parameter(s): A102 The present value of the function selected in A102 [Testpoint...

  • Page 44: Basic Program Group

    Programming and Parameters Basic Program Group Stop drive before changing this parameter. P031 [Motor NP Volts] Related Parameter(s): A084 Set to the motor nameplate rated volts. Values Default Based on Drive Rating Min/Max: 20/Drive Rated Volts Display: 1 VAC Stop drive before changing this parameter. P032 [Motor NP Hertz] Related Parameter(s):A084...
  • Page 45 Programming and Parameters Basic Program Group (continued) Stop drive before changing this parameter. P036 [Start Source] Related Parameter(s): d012 Sets the control scheme used to start the drive. Refer to Start and Speed Reference Control on page 1-17 for details about how other drive settings can override the setting of this parameter.
  • Page 46 3-10 Programming and Parameters Basic Program Group (continued) P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082 Active stop mode for all stop sources [e.g. keypad, 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 “3-Wire”...
  • Page 47 Programming and Parameters 3-11 Basic Program Group (continued) P038 [Speed Reference] Related Parameter(s): d012, A069, A070, A071, A072, A073 Sets the source of the speed reference to the drive. Important: When A051 or A052 [Digital Inx Sel] is set to option 2, 4, 5 or 6, and the digital input is active, A051 or A052 will override the speed reference commanded by this parameter.
  • Page 48 3-12 Programming and Parameters Basic Program Group (continued) P040 [Decel Time 1] Related Parameter(s): P038, P039, A051, A052, A068 Sets the rate of deceleration for all speed decreases. Maximum Freq Decel Rate Decel Time Values Default 10.0 Secs Min/Max: 0.1/600.0 Secs Display: 0.1 Secs [Maximum Freq]...

  • Page 49: Advanced Program Group

    Programming and Parameters 3-13 Advanced Program Group Stop drive before changing this parameter. A051 [Digital In1 Sel] Related Parameter(s): A067, A068, A070-A073, A078, A079 (I/O Terminal 5) A052 [Digital In2 Sel] (I/O Terminal 6) Selects the function for the digital inputs. Refer to the flowchart on page 1-17 for more information on speed reference control priority.
  • Page 50 3-14 Programming and Parameters A055 [Relay Out Sel] Related Parameter(s): P033, A056, A092 Sets the condition that changes the state of the output relay contacts. Options 0 “Ready” (Not Faulted) Relay changes state when power is applied. This indicates that the drive is ready for operation. Relay returns drive to Default shelf state when power is removed or a fault occurs.
  • Page 51 Programming and Parameters 3-15 Advanced Program Group (continued) 32 bit parameter. A056 [Relay Out Level] Related Parameter(s): A055 Sets the trip point for the digital output relay if the value of A055 [Relay Out Sel] is 6, 7 or 8. A055 Setting Min/Max 0/240 Hz...
  • Page 52 3-16 Programming and Parameters Advanced Program Group (continued) A069 [Internal Freq] Related Parameter(s): P038 Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal Freq”. When enabled, this parameter will change the frequency command in “real time” using the integral keypad Up Arrow or Down Arrow when in program mode.
  • Page 53 Programming and Parameters 3-17 Advanced Program Group (continued) A079 [Jog Accel/Decel] 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): A081 Sets the length of time that DC brake current is “injected”...
  • Page 54 3-18 Programming and Parameters Advanced Program Group (continued) Stop drive before changing this parameter. A082 [DB Resistor Sel] Enables/disables external dynamic braking. Setting Min/Max Disabled AB Resistor (5% Duty Cycle) No Protection (100% Duty Cycle) 3-99 Duty Cycle Limited (3% – 99% of Duty Cycle) Values Default Min/Max:...
  • Page 55 Programming and Parameters 3-19 Advanced Program Group (continued) A084 [Start Boost] Related Parameter(s): P031 Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve. Drive may add additional voltage unless Option 5 is selected. Options 1 “30.0”...
  • Page 56 3-20 Programming and Parameters Advanced Program Group (continued) A089 [Current Limit] Maximum output current allowed before current limiting occurs. Drive Rated Amps × 1.5 Values Default 0.1/(Drive Rated Amps × 1.8) Min/Max: Display: 0.1 Amps A090 [Motor OL Select] Related Parameter(s): P032 Drive provides Class 10 motor overload protection.
  • Page 57 Programming and Parameters 3-21 Advanced Program Group (continued) A092 [Auto Rstrt Tries] Sets the maximum number of times the drive attempts to reset a fault and restart. Clear a Type 1 fault and restart the drive. 1. Set A092 [Auto Rstrt Tries] to a value other than “0”. 2.
  • Page 58 3-22 Programming and Parameters Advanced Program Group (continued) Stop drive before changing this parameter. A095 [Reverse Disable] Enables/disables the function that allows the direction of motor rotation to be changed. The reverse command may come from a digital command, the keypad or a serial command. All reverse inputs including two-wire Run Reverse will be ignored with reverse disabled.
  • Page 59 [Fault x Code]) A101 [Program Lock] Protects parameters against change by unauthorized personnel. Options 0 “Unlocked” (Default) 1 “Locked” A102 [Testpoint Sel] Used by Rockwell Automation field service personnel. Values Default Min/Max: 0/FFFF Display: 1 Hex A103 [Comm Data Rate] Sets the serial port rate for the RS485 (DSI) port.
  • Page 60 3-24 Programming and Parameters Advanced Program Group (continued) A105 [Comm Loss Action] Related Parameter(s): P037, A106 Selects the drive’s response to a loss of the communication connection or excessive communication errors. Options 0 “Fault” (Default) Drive will fault on an F81 Comm Loss and coast to stop. 1 “Coast to Stop”...
  • Page 61 Programming and Parameters 3-25 A111 [0-10V Analog Input High] Related Parameter(s): d020, P035, P038 Sets the analog input level that corresponds to P035 [Maximum Freq] if a 0-10V input is used by P038 [Speed Reference]. Analog inversion can be accomplished by setting this value smaller than A110 [0-10V Analog Input Low].

  • Page 62: Parameter Cross Reference - By Name

    3-26 Programming and Parameters Parameter Cross Reference – by Name Parameter Name Group Parameter Name Group 0-10V Analog Input d020 Display Fault x Code d007-d009 Display 0-10V Analog Input High A111 Advanced Program Fault Clear A100 Advanced Program 0-10V Analog Input Low A110 Advanced Program Flying Start En A096...

  • Page 63: Troubleshooting

    Chapter Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 4 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 Fault Descriptions Faults Common Symptoms and...
  • Page 64 Troubleshooting Fault Indication Condition Display Drive is indicating a fault. VOLTS The integral keypad provides visual notification of a AMPS HERTZ fault condition by displaying the following. PRGOGRAM FAULT • Flashing fault number • Flashing fault indicator Press the Escape key to regain control of the integral keypad.

  • Page 65: Fault Descriptions

    Troubleshooting Fault Descriptions Table 4.A Fault Types, Descriptions and Actions Fault Description Action ➀ Auxiliary Input Auxiliary input interlock is open. 1. Check remote wiring. 2. Verify communications programming for intentional fault. ➁ Power Loss DC bus voltage remained below 1.
  • Page 66 Troubleshooting Fault Description Action ➁ 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]. ➁ F38 Phase U to Gnd A phase to ground fault has been 1.

  • Page 67: 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 68 Troubleshooting Drive does not Start from Integral Keypad. Cause(s) Indication Corrective Action • Set parameter P036 Integral keypad is not enabled. Green LED above Start key is [Start not illuminated. Source] to option 0 “Keypad”. • Set parameter A051 - A052 [Digital Inx Sel] to option 5 “Local”...
  • Page 69 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 [Start Boost] to reduce boost level. Drive will not reverse motor direction. Cause(s) Indication Corrective Action...
  • Page 70 Troubleshooting Notes:...

  • Page 71: 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 drive ratings and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements.
  • Page 72 Supplemental Drive Information Specifications Drive Ratings Power Output Ratings Input Ratings Branch Circuit Protection Dissipation Catalog Number Voltage 140M Motor IP20 Open kW (HP) Amps Range kVA Amps Fuses Protectors Contactors Watts 100 - 115V AC 1-Phase Input, 0 - 230V 3-Phase Output 22A-V1P5N104 0.2 (0.25) 90-126 0.75 6.0...
  • Page 73 Supplemental Drive Information Category Specification Environment Altitude: 1000 m (3300 ft) max. without derating Ambient Operating Temperature IP20: –10 to 50 degrees C (14 to 122 degrees F) NEMA 1: –10 to 40 degrees C (14 to 104 degrees F) Cooling Method Convection: 0.2 kW (0.25 HP) drive ratings, Catalog Numbers...
  • Page 74 Supplemental Drive Information Notes:...

  • Page 75: Accessories And Dimensions

    Appendix Accessories and Dimensions For information on… See page Product Selection Product Dimensions Product Selection Table B.A Catalog Number Description 22A - Drive Voltage Rating Rating Enclosure Emission Class Comm Slot Table B.B PowerFlex 4 Drives Drive Ratings Frame Input Voltage Output Current Catalog Number Size...
  • Page 76 Accessories and Dimensions Table B.C Dynamic Brake Modules Drive Ratings Input Voltage Catalog Number 120V 50/60 Hz 0.25 1-Phase 0.37 0.75 160-BMA1 240V 50/60 Hz 0.25 1-Phase 0.37 0.75 160-BMA1 160-BMA2 240V 50/60 Hz 0.25 3-Phase 0.37 0.75 160-BMA1 160-BMA2 160-BMA2 160-BMA2 480V 50/60 Hz...
  • Page 77 Accessories and Dimensions Table B.E EMC Line Filters Drive Ratings S Type Filter L Type Filter Input Voltage Catalog Number Catalog Number 120V 50/60 Hz 0.25 – 22-RF010-AL 1-Phase 0.37 – 22-RF010-AL 0.75 – 22-RF018-BL 240V 50/60 Hz 0.25 22-RF010-AL 1-Phase 0.37 22-RF010-AL...
  • Page 78 Accessories and Dimensions Table B.F Communication Option Kits Item Description Catalog Number Serial Converter Module Provides serial communication via DF1 protocol for 22-SCM-232 (RS485 to RS232) use with DriveExplorer and DriveExecutive software. Includes: DSI to RS232 serial converter (1) 1203-SFC serial cable (1) 22-RJ45CBL-C20 cable (1) DriveExplorer Lite CD (1) DSI Cable...

  • Page 79: Product Dimensions

    Accessories and Dimensions Product Dimensions Figure B.1 PowerFlex 4 Drives – Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). 5.5 (0.22) Shipping Frame Weight 80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64) 152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1) 100 (3.94)
  • Page 80 Accessories and Dimensions Figure B.3 Dynamic Brake Modules – Dimensions are in millimeters and (inches) 86.4 (2.84) (3.40) (0.55) (0.31) (0.30) (1.97) 6.86 (0.27) Mounting Holes, 4 Places (1.14) Catalog Number 160-BMA1, -BMB1 245 (9.64) 225 (8.86) 160-BMA2, -BMB2 334 (13.15) 314 (12.36) Figure B.4 Bulletin 1321-3R Series Line Reactors –...
  • Page 81 Accessories and Dimensions Figure B.5 Frame A EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL (1.97) (3.15) 29.8 (2.36) (1.17) (8.66) (8.19) 17.8 5.5 (0.22) (0.70) (0.94) Figure B.6 Frame B EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF012-BS, -BL;...
  • Page 82 Accessories and Dimensions Notes:...

  • Page 83: Rs485 (Dsi) Protocol

    RS485 (DSI) Protocol PowerFlex 4 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 4 drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.
  • Page 84 RS485 (DSI) Protocol Control Terminal 16 on the PowerFlex 4 must also be connected to PE ground (there are two PE terminals on the drive). See Figure 1.5 more information. Parameter Configuration The following PowerFlex 4 parameters are used to configure the drive to operate on a network.
  • Page 85 RS485 (DSI) Protocol Writing (06) Logic Command Data The PowerFlex 4 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 “RS485 (DSI) Port” in order to accept the commands.
  • Page 86 RS485 (DSI) Protocol Reading (03) Logic Status Data The PowerFlex 4 Logic Status data can be read via the network by sending Function Code 03 reads to register address 8448 (Logic Status). Logic Status Address (Decimal) Bit(s) Description 1 = Ready, 0 = Not Ready 1 = Active (Running), 0 = Not Active 1 = Cmd Forward, 0 = Cmd Reverse 1 = Rotating Forward, 0 = Rotating Reverse...
  • Page 87 RS485 (DSI) Protocol Reading (03) Drive Error Codes The PowerFlex 4 Error Code data can be read via the network by sending Function Code 03 reads to register address 8449 (Drive Error Codes). Logic Status Address (Decimal) Value (Decimal) Description No Fault Auxiliary Input Power Loss...
  • Page 88 RS485 (DSI) Protocol Notes:...
  • Page 89 Index Display Group Parameters, 3-3 Distribution Systems, Ungrounded, AC Supply Ground, 1-4 Drive Frame Size, P-2, B-5 Source, 1-3 Drive Grounding, 1-4 Ungrounded, 1-3 Drive Overload Fault, 4-4 Advanced Program Group Drive Ratings, P-4, A-1 Parameters, 3-13 DriveExecutive, 3-1 Ambient Temperatures, 1-2 DriveExplorer, 3-1 Armored Cable, 1-8 Auto Rstrt Tries Fault, 4-4...
  • Page 90 Index-2 General Precautions, P-3 Parameter Ground Fault, 4-3 Descriptions, 3-1 Grounding Types, 3-1 Filter, 1-5 Viewing and Editing, 2-4 General, 1-4 Parameter Checksum Fault, 4-4 Parameter Cross Reference by Name, 3-25 Heatsink OvrTmp Fault, 4-3 Parameters HW OverCurrent Fault, 4-3 Advanced Program Group, 3-13 Display Group, 3-3 Program Group, 3-8...
  • Page 91 Index-3 Start-Up Checklist, 2-1, 2-2 Static Discharge, ESD, P-3 Status LEDs, 2-3 Supply Source, AC, 1-3 SW OverCurrent Fault, 4-4 System Grounding, 1-4 Terminal Block I/O, 1-12 Power, 1-10 Three Wire Control, 1-14, 1-15 Two Wire Control, 1-14, 1-15 UnderVoltage Fault, 4-3 Ungrounded Supply, 1-3 Unshielded Power Cables, 1-8 Wiring, 1-1...
  • Page 92 Index-4 Notes:...
  • Page 94 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 SA/NV, Vorstlaan/Boulevard du Souverain 36, 1170 Brussels, Belgium, Tel: (32) 2 663 0600, Fax: (32) 2 663 0640 Asia Pacific: Rockwell Automation, 27/F Citicorp Centre, 18 Whitfield Road, Causeway Bay, Hong Kong, Tel: (852) 2887 4788, Fax: (852) 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433...

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