Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series User Manual
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Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series User Manual

Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series User Manual

Adjustable frequency ac drive
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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series

  • Page 1 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual www.abpowerflex.com...
  • Page 2 In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
  • Page 3 Summary of Changes Manual Updates The information below summarizes the changes to the PowerFlex 40 User Manual since the June 2013 release. Description of New or Updated Information Page(s) Certifications for Australian RCM and CE Directives updated. 1-25, Certifications for EAC, KCC, and NSF/ANSI added. The information below summarizes the changes to the PowerFlex 40 User Manual since the August 2008 release.
  • Page 4 soc-2 Description of New or Updated Information Page(s) Fault description for F3 revised. Graphic for the “Network Wiring” section revised. Descriptions for bits 6, 7, and 15 of register address 8192 (Logic Command) updated. New information on reading register address 8192 added. New information on reading register address 8193 added.

  • 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 40 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 40 Adjustable Frequency AC Drive as; drive, PowerFlex 40 or PowerFlex 40 Drive. • Parameter numbers and names are shown in this format: P031 [Motor NP Volts] Name Number Group d = Display Group...

  • 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 13-14 22B - Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional Code Code Version 22B PowerFlex 40 No Brake IGBT Standard Code Rating Not Filtered Code Voltage Filtered 120V AC 1 240V AC 1 Code Purpose Code Interface Module 240V AC 3...

  • Page 11: Installation/Wiring

    ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation, Inc. cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment.
  • Page 12 Installation/Wiring IP66, NEMA/UL Type 4X ATTENTION: To avoid an electric shock hazard, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)] and wait three minutes for capacitors to discharge before removing the external cover. Once the cover is removed, verify that the voltage on the bus capacitors has discharged before performing any work on the drive.

  • Page 13: Mounting Considerations

    Installation/Wiring Mounting Considerations • Mount the drive upright on a flat, vertical and level surface. Frame Screw Size Screw Torque DIN Rail M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) – B (IP66, M6 (#12-24) 3.95-4.75 N-m (35-42 lb.-in.) –...
  • Page 14 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 IP20, NEMA/UL Type Open applications. Storage • Store within an ambient temperature range of -40° to +85°C. •...

  • Page 15: Ac Supply Source Considerations

    Installation/Wiring AC Supply Source Considerations Ungrounded Distribution Systems ATTENTION: PowerFlex 40 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 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...
  • Page 16 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 17: 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 R/L1 U/T1...

  • Page 18: Fuses And Circuit Breakers

    Installation/Wiring RFI Filter Grounding Using single phase drives with integral filter, or an external filter with any drive rating, may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground.
  • Page 19 Installation/Wiring Table 1.C Minimum 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 120V AC – 0.4 (0.5) 140M-C2E-C16 100-C12 1655 1-Phase...

  • Page 20: Power Wiring

    1-10 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 21 Installation/Wiring 1-11 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 22 1-12 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.D for recommendations.
  • Page 23 Installation/Wiring 1-13 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 24: Ip66, Nema/Ul Type 4X Installations

    1-14 Installation/Wiring IP66, NEMA/UL Type 4X Installations Use the plugs supplied with IP66, NEMA/UL Type 4X rated drives to seal unused holes in the conduit entry plate. Important: Completely seat the plug inner rim for the best seal. 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...
  • Page 25 Installation/Wiring 1-15 Control Wire Types Table 1.F 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 26 1-16 Installation/Wiring Figure 1.5 Control Wiring Block Diagram Typical Typical Enable Jumper (1)(4) 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 27 Installation/Wiring 1-17 Table 1.H 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 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 29 Installation/Wiring 1-19 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 30 1-20 Installation/Wiring Input/Output Connection Example 2 Wire SNK Control - Internal Supply (SNK) Run FWD/Run REV Stop-Run Forward Stop-Run Reverse 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.
  • Page 31 Installation/Wiring 1-21 Input/Output Connection Example 3 Wire SNK Control - Internal Supply (SNK) Reversing Stop Start Direction 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.
  • Page 32 1-22 Installation/Wiring Typical Multiple Drive Connection Examples Input/Output Connection Example Multiple Digital Input Connections Customer Inputs can be wired per External Supply (SRC) examples on 1-19 and 1-20. 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 33: Start And Speed Reference Control

    Installation/Wiring 1-23 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 A054 [Digital Inx Sel] is 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 option 0, the speed reference commanded by P038 [Speed Reference] will be overridden.
  • Page 34 1-24 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 35: Emc Instructions

    Installation/Wiring 1-25 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 36 1-26 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 1-8 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 37 Installation/Wiring 1-27 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 38 1-28 Installation/Wiring Notes: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 39: Prepare For Drive Start-Up

    Chapter Start Up This chapter describes how to start up the PowerFlex 40 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 40 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 2-4) before setting any Program Group parameters. If a fault appears on power up, refer to Fault Descriptions on page 4-3 for an explanation of the fault code.
  • Page 41 Start Up TIP: You can also change the speed reference by editing the parameter A069 [Internal Freq] in program mode. For details on how to enter the program mode, see Viewing and Editing Parameters on page 2-5. Note: The default value of A069 [Internal Freq] is 0 Hz.

  • Page 42: Integral Keypad

    Start Up Integral Keypad Menu Description VOLTS Display Group (View Only) AMPS HERTZ Consists of commonly viewed drive operating conditions. PROGRAM FAULT Basic Program Group Consists of most commonly used programmable functions. Advanced Program Group Consists of remaining programmable functions. Fault Designator Consists of list of codes for specific fault conditions.

  • Page 43: 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 44: Remote Him Menu Structure

    Start Up The Basic Program Group (page 3-9) contains the most commonly changed parameters. Remote HIM Menu Structure The Menu Structure below can be accessed through the following Human Interface Module options: HIM Option Catalog Number Remote Panel Mount Small, LCD Display 22-HIM-C2S Remote Handheld, LCD Display 22-HIM-A3...
  • Page 45 Start Up Diagnostics Menu When a fault trips the drive, use this menu to access detailed data about the drive. Option Description Faults View fault queue or fault information, clear faults or clear fault queue. Device Status View status information about the drive or peripheral. Device Version View the firmware version and hardware series of components.
  • Page 46 Start Up Notes: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 47: Programming And Parameters

    Chapter Programming and Parameters Chapter 3 provides a complete listing and description of the PowerFlex 40 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 48: Parameter Organization

    Programming and Parameters Parameter Organization Refer to page 3-45 for an alphabetical listing of parameters. D i s p l A d v a a y G r P r o g r n c e d o u p a m G r o u p See page 3-14...

  • Page 49: Display Group

    Programming and Parameters Display Group d001 [Output Freq] Related Parameter(s): d002, d010, P034, P035, P038 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, d013, P034, P035, P038 Value of the active frequency command.
  • Page 50 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 51 Programming and Parameters Display Group (continued) d012 [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 Main Control Board software version. Values Default: Read Only Min/Max: 1.00/99.99 Display: 0.01 d017 [Drive Type] Used by Rockwell Automation field service personnel. Values Default: Read Only Min/Max: 1001/9999 Display: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 53 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...
  • Page 54 Programming and Parameters Display Group (continued) d024 [Drive Temp] Present operating temperature of the drive power section. Values Default: Read Only Min/Max: 0/120 degC Display: 1 degC d025 [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): d004, 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): d012, P037 Stop drive before changing this parameter. Sets the control scheme used to start the drive. Refer to Start and Speed Reference Control on page 1-23 for details about how other drive settings can override the setting of this parameter.
  • 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. 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...
  • Page 58 3-12 Programming and Parameters Basic Program Group (continued) P038 [Speed Reference] Related Parameter(s): d001, d002, d012, d020, d021, P039, P040, A051-A054, A069, A070-A077, A110-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. The source is normally determined by P038 [Speed Reference].
  • Page 59 Programming and Parameters 3-13 Basic Program Group (continued) P040 [Decel Time 1] Related Parameter(s): P038, P039, A051-A054, A068, A070-A077, A140-A147 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...

  • Page 60: Advanced Program Group

    3-14 Programming and Parameters Advanced Program Group A051 [Digital In1 Sel] Related Parameter(s): d012, d014, 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 61 Programming and Parameters 3-15 A051 - 13 “10V In Ctrl” Selects 0-10V or ±10V control as the frequency reference. A054 Start source is not changed. Options 14 “20mA In Ctrl” Selects 4-20mA control as the frequency reference. Start (Cont.) source is not changed. 15 “PID Disable”...
  • Page 62 3-16 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 63 Programming and Parameters 3-17 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” Prior to FRN 4.01, this option enables the output to be controlled over network communications by writing to A056 [Relay Out Level].
  • Page 64 3-18 Programming and Parameters Advanced Program Group (continued) A058 [Opto Out1 Sel] Related Parameter(s): P033, A059, A062, A092, A122, A123, A061 [Opto Out2 Sel] A160, A161, A140-A147, A150-A157 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 65 Programming and Parameters 3-19 • 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 66 3-20 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 67 Programming and Parameters 3-21 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 68 3-22 Programming and Parameters Advanced Program Group (continued) A068 [Decel Time 2] Related Parameter(s): P040, A051-A054, A070-A077, A140-A147 When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart on page 1-24 for details. Maximum Freq Decel Rate Decel Time...
  • Page 69 Programming and Parameters 3-23 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 70 3-24 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, A081 Sets the length of time that DC brake current is “injected”...
  • Page 71 Programming and Parameters 3-25 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 72 3-26 Programming and Parameters Advanced Program Group (continued) A084 [Boost Select] Related Parameter(s): d004, 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”. Drive may add additional voltage unless Option 5 is selected.
  • Page 73 Programming and Parameters 3-27 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 74 3-28 Programming and Parameters Advanced Program Group (continued) A088 [Maximum Voltage] Related Parameter(s): d004, 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 75 Programming and Parameters 3-29 Advanced Program Group (continued) A092 [Auto Rstrt Tries] Related Parameter(s): A055, A058, A061, A093 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.
  • Page 76 3-30 Programming and Parameters Advanced Program Group (continued) A095 [Reverse Disable] Related Parameter(s): d006 Stop drive before changing this parameter. 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 77 A101 [Program Lock] Protects parameters against change by unauthorized personnel. Options 0 “Unlocked” (Default) 1 “Locked” A102 [Testpoint Sel] Related Parameter(s): d019 Used by Rockwell Automation field service personnel. Values Default: Min/Max: 0/FFFF Display: 1 Hex A103 [Comm Data Rate]...
  • Page 78 3-32 Programming and Parameters Advanced Program Group (continued) A105 [Comm Loss Action] Related Parameter(s): d015, 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 Stop”...
  • Page 79 Programming and Parameters 3-33 Advanced Program Group (continued) A109 [Anlg Out Setpt] Related Parameter(s): A065 When A065 [Analog Out Sel] is set to option 18, 19 or 20, this parameter sets the percentage of analog output desired. Values Default: 0.0% Min/Max: 0.0/100.0% Display:...
  • Page 80 3-34 Programming and Parameters Advanced Program Group (continued) A113 [Anlg In4-20mA Hi] Related Parameter(s): d021, P035, P038 Sets the analog input level that corresponds to P035 [Maximum Freq] if a 4-20mA input is used by P038 [Speed Reference]. Analog inversion can be accomplished by setting this value smaller than A112 [Anlg In4-20mA Lo]. Values Default: 100.0%...
  • Page 81 Programming and Parameters 3-35 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: 0/400 Hz Display: 1 Hz A120 [Skip Freq Band] Related Parameter(s): A119...
  • Page 82 3-36 Programming and Parameters 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 83 Programming and Parameters 3-37 Advanced Program Group (continued) A127 [Autotune] Related Parameter(s): A125, A126, A128, A129 Stop drive before changing this parameter. Provides an automatic method for setting A128 [IR Voltage Drop] and A129 [Flux Current Ref], which affect sensorless vector performance. Parameter A126 [Motor NP FLA] must be set to the motor nameplate full load amps before running the Autotune procedure.
  • Page 84 3-38 Programming and Parameters Advanced Program Group (continued) A130 [PID Trim Hi] Sets the maximum positive value that is added to the speed reference when PID trim is used. Values Default: 60.0 Min/Max: 0.0/400.0 Display: A131 [PID Trim Lo] Sets the maximum positive value that is subtracted from the PID reference when PID trim is used. Values Default: Min/Max:...
  • Page 85 Programming and Parameters 3-39 Advanced Program Group (continued) A135 [PID Integ Time] Sets the value for the PID integral component when the PID mode is enabled by A132 [PID Ref Sel]. Values Default: 0.1 Secs Min/Max: 0.0/999.9 Secs Display: 0.1 Secs A136 [PID Diff Rate] Sets the value for the PID differential component when the PID mode is enabled by A132 [PID Ref Sel].
  • Page 86 3-40 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] A142 [Stp Logic 2] A143 [Stp Logic 3] Stop drive before changing this parameter. A144 [Stp Logic 4] A145 [Stp Logic 5] A146 [Stp Logic 6]...
  • Page 87 Programming and Parameters 3-41 Digit 3: Step Settings This digit defines what accel/decel profile the speed command will follow and the direction of the command for the current step. In addition, if a relay or opto output (parameters A055, A058 and A061) is set to 15 “StpLogic Out”, this parameter can control the status of that output.
  • Page 88 3-42 Programming and Parameters Advanced Program Group (continued) A150 [Stp Logic Time 0] Related Parameter(s): P038, A055, A058, A061, A070-A077, A140-A147 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 89 Programming and Parameters 3-43 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 90 3-44 Programming and Parameters Advanced Program Group (continued) A164 [Comm Write Mode] Determines whether parameter changes made over communication port are saved and stored in Non-Volatile Storage (NVS) or RAM only. If they are stored in RAM, the values will be lost at power-down.

  • Page 91: Parameter Cross Reference - By Name

    Programming and Parameters 3-45 Parameter Cross Reference – by Name Parameter Name Group Parameter Name Group Jog Accel/Decel A079 Advanced Program 10V Bipolar Enbl A123 Advanced Program Jog Frequency A078 Advanced Program Accel Time 1 P039 Basic Program Language A108 Advanced Program Accel Time 2 A067...
  • Page 92 3-46 Programming and Parameters Parameter Name Group Testpoint Data d019 Display Testpoint Sel A102 Advanced Program Timer Status d026 Display Torque Current d029 Display Torque Perf Mode A125 Advanced Program Var PWM Disable A124 Advanced Program Voltage Class P042 Basic Program PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 93: Troubleshooting

    Chapter Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 40 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 94 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 95: Fault Descriptions

    Troubleshooting Fault Descriptions Table 4.A Fault Types, Descriptions and Actions Fault Description Action Auxiliary Input Auxiliary input interlock is open. 1. Check remote wiring. 2. Verify communications programming for intentional fault. Power Loss Excessive DC Bus voltage ripple. 1. Monitor the incoming line for phase loss or line imbalance.
  • Page 96 Troubleshooting page 4-1 for a description of fault types. 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].

  • Page 97: Common Symptoms And Corrective Actions

    Troubleshooting Fault Description Action F100 Parameter The checksum read from the P041 [Reset To Defalts] to Checksum board does not match the option 1 “Reset Defaults”. checksum calculated. F122 I/O Board Fail Failure has been detected in the 1. Cycle power. drive control and I/O section.
  • Page 98 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 Stop • Cycle power • Set A100 [Fault Clear] to option 1 “Clear Faults”.
  • Page 99 Troubleshooting Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action • Check No value is coming from the The drive “Run” indicator is lit d012 [Control Source] for source of the command. and output is 0 Hz. correct source.
  • Page 100 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 101: 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 102 Supplemental Drive Information Specifications Drive Ratings Output Ratings Input Ratings Branch Circuit Protection Catalog Min. Enclosure 140M Motor Voltage Number (3) (4) kW (HP) Amps Range kVA Amps Fuses Protectors Contactors Volume (in. 100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output 22B-V2P3x104 0.4 (0.5) 90-132...
  • Page 103 Supplemental Drive Information Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240 Wye or Delta, 480Y/277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner ground, or high-resistance ground systems. When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column.
  • Page 104 Supplemental Drive Information Category Specification Environment Altitude: 1000 m (3300 ft) max. without derating Maximum Surrounding Air Temperature without derating: IP20, NEMA/UL Type Open: –10 to 50° C (14 to 122° F) IP30, NEMA/UL Type 1: –10 to 40° C (14 to 104° F) Flange Mount: Heatsink: –10 to 40°...
  • Page 105 Supplemental Drive Information PowerFlex 40 Estimated Watts Loss (Rated Load, Speed & PWM) Voltage kW (HP) External Watts Internal Watts Total Watts Loss 100–120V 0.4 (0.5) 0.75 (1.0) 1.1 (1.5) 200–240V 0.4 (0.5) 0.75 (1.0) 1.1 (2.0) 2.2 (3.0) 3.7 (5.0) 5.5 (7.5) 7.5 (10) 380–480V...
  • Page 106 Supplemental Drive Information Notes: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 107: Accessories And Dimensions

    Appendix Accessories and Dimensions Product Selection Table B.A Catalog Number Description 22B - Drive Voltage Rating Rating Enclosure Emission Class Type Table B.B PowerFlex 40 Drives IP20 Flange IP66, NEMA/UL Drive Ratings IP20, NEMA/UL Type Open Mount Type 4X Output Frame Input Voltage Current Catalog Number...
  • Page 108 Accessories and Dimensions Table B.C Dynamic Brake Modules Drive Ratings Minimum Resistance Ω (1) (2) Input Voltage Catalog Number 120V 50/60 Hz AK-R2-091P500 1-Phase 0.75 AK-R2-091P500 AK-R2-091P500 240V 50/60 Hz AK-R2-091P500 1-Phase 0.75 AK-R2-091P500 AK-R2-091P500 AK-R2-047P500 240V 50/60 Hz AK-R2-091P500 3-Phase 0.75 AK-R2-091P500...
  • Page 109 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 110 Accessories and Dimensions Table B.F EMC Line Filters Drive Ratings S Type Filter L Type Filter Input Voltage Catalog Number Catalog Number 120V 50/60 Hz – 22-RF018-BL 1-Phase 0.75 – 22-RF018-BL – 22-RF018-BL 240V 50/60 Hz 22-RF018-BL 1-Phase 0.75 22-RF018-BL 22-RF018-BL 22-RF025-CL 240V 50/60 Hz...
  • Page 111 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 Panel Digital speed control 22-HIM-C2 Mount...
  • Page 112 Accessories and Dimensions Table B.I Communication Option Kits and Accessories Item Description Catalog Number Communication Embedded communication options for use with Adapters the PowerFlex 4-Class drives. Requires a Communication Adapter Cover (IP20, NEMA/UL Type 1 only. Ordered Separately) BACnet® 22-COMM-B ControlNet™...

  • Page 113: Product Dimensions

    Accessories and Dimensions Product Dimensions Table B.J PowerFlex 40 Frames – Ratings are in kW and (HP) 120V AC – 240V AC – 240V AC – 480V AC – 600V AC – Frame 1-Phase 1-Phase 3-Phase 3-Phase 3-Phase 0.4 (0.5) 0.4 (0.5) 0.4 (0.5) 2.2 (3.0)
  • Page 114 Accessories and Dimensions Figure B.3 IP30, NEMA/UL Type 1 Option Kit with Communication Option – Dimensions are in millimeters and (inches) 25.0 (0.98) 77.5 (3.05) 50.0 (1.97) 22.5 (0.89) ∅ 22.2 (0.87) 134.3 (5.29) 105.3 (4.15) 76.3 (3.00) 64.0 (2.52) Frame B - 22-JBCB 25.0 (0.98)
  • Page 115 Accessories and Dimensions Figure B.4 PowerFlex 40 Flange Mount Drives – Dimensions are in millimeters and (inches) 94.3 63.1 (3.71) (2.48) (9.61) (8.43) (9.84) Frame B 130.3 (5.13) 105.8 138.2 (11.81) (4.17) (5.44) (12.8) 22B-CCC Frame C PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 116 B-10 Accessories and Dimensions Figure B.5 PowerFlex 40 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 (12.11) 230.6...
  • Page 117 Accessories and Dimensions B-11 Figure B.6 PowerFlex 40 Replacement Plate Drive Dimensions – Dimensions are in millimeters and (inches) (4.92) (4.41) (3.15) (3.46) (0.37) (7.56) (7.09) (8.03) (3.78) (0.21) (3.94) Frame B (6.10) 123.5 (5.59) (4.86) 98.5 (3.15) (3.88) (0.37) (10.71) (11.18) (10.24)
  • Page 118 B-12 Accessories and Dimensions Figure B.7 IP66, NEMA Type/UL Type 4X – Dimensions are in millimeters and (inches) Weights are in kilograms and (pounds). (6.50) (5.75) (0.26) (1.81) (0.91) (10.63) (7.80) (9.96) (1.10) (4.88) (3.50) (0.87) 82.5 (3.25) Weight 5.2 (11.5) PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 119 Accessories and Dimensions B-13 Figure B.8 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) 60.0 17.0 31.0 59.0 (0.67) (2.36) (1.22) (2.32) 316.0 335.0 386.0 405.0 (12.44)
  • Page 120 B-14 Accessories and Dimensions Figure B.10 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 121 Accessories and Dimensions B-15 Figure B.11 Frame B EMC Line Filters – Dimensions are in millimeters and (inches) Catalog Numbers: 22-RF8P0-BL, 22-RF012-BS, -BL (Series B); 22-RF018-BS; 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) PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual...
  • Page 122 B-16 Accessories and Dimensions Figure B.12 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) PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 123 Accessories and Dimensions B-17 Figure B.13 Remote (Panel Mount) Small 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) PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 124 B-18 Accessories and Dimensions Figure B.14 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) (0.19) (3.03) 19.1 (0.75) 23.5 (0.93) PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 125: Network Wiring

    RS485 (DSI) Protocol PowerFlex 40 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 40 drives can be multi-dropped on an RS485 network using Modbus protocol in RTU mode.
  • Page 126 Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 40 RJ45 socket must not be connected because they contain power, etc. for other Rockwell Automation peripheral devices. Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+”...

  • Page 127: Parameter Configuration

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

  • Page 128: Writing (06) Logic Command Data

    RS485 (DSI) Protocol Writing (06) Logic Command Data The PowerFlex 40 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 129: Writing (06) Reference

    RS485 (DSI) Protocol Writing (06) Reference The Speed Reference to a PowerFlex 40 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 “RS485 (DSI) Port”...

  • Page 130: Reading (03) Feedback

    RS485 (DSI) Protocol Reading (03) Feedback The Feedback (Output Frequency) from the PowerFlex 40 drive can be read via the network by sending Function Code 03 reads to register address 8451 (Feedback). Feedback Address (Decimal) Description A xxx.x decimal value where the decimal point is fixed. For example, a decimal 8451 “123”...

  • Page 131: 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 132 RS485 (DSI) Protocol Notes: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 133: Rj45 Dsi Splitter Cable

    Appendix RJ45 DSI Splitter Cable The PowerFlex 40 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. Connectivity Guidelines ATTENTION: Risk of injury or equipment damage exists.

  • Page 134: 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 135: 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 136: 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 137: Steplogic, Basic Logic And Timer/Counter Functions

    Appendix StepLogic, Basic Logic and Timer/Counter Functions Four PowerFlex 40 logic functions provide the capability to program simple logic functions without a separate controller. • StepLogic™ Function Steps through up to eight preset speeds based on programmed logic. Programmed logic can include conditions that need to be met from digital inputs programmed as “Logic In1”...

  • Page 138: Steplogic Using Timed Steps

    StepLogic, Basic Logic and Timer/Counter Functions 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. • Logic is defined using parameters A140-A147 [Stp Logic x]. •...

  • Page 139: Steplogic Using Basic Logic Functions

    StepLogic, Basic Logic and Timer/Counter Functions 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 140: Timer Function

    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 141 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. PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 142: Counter Function

    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 Counter”. Digital outputs (relay and opto type) define a preset level and indicate when the level is reached.
  • Page 143 StepLogic, Basic Logic and Timer/Counter Functions 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 Commanded Direction...

  • Page 144: Logic In1

    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 145: Pid Loop

    Appendix PID Set Up PID Loop The PowerFlex 40 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 146 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 or 4. This configuration does not require a master reference, only a desired set point, such as a flow rate for a pump.
  • Page 147 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 5, 6, 7 or 8.

  • Page 148: Pid Reference And Feedback

    PID Set Up PID Reference and Feedback Parameter A132 [PID Ref Sel] is used to enable the PID mode (A132 ¦ 0 “PID Disabled”) and to select the source of the PID Reference. If A132 [PID Ref Sel] is not set to 0 “PID Disabled”, PID can still be disabled by select programmable digital input options (parameters A051-A054) such as “Jog”, “Local”...

  • Page 149: 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. Important: Firmware version FRN 2.xx also allows PID Feedback scaling from an analog input. Examples Scale Function For a 0-5 volt signal, the following parameter settings are used so that a 0...
  • Page 150 PID Set Up Invert Function For a 4-20mA signal, the following parameter settings are used so that a 20mA signal = 0% PID Reference and a 4mA signal = 100% PID Reference. • A112 [Anlg In 4-20mA Lo] = 100.0% •...
  • Page 151 PID Set Up PID Preload The value set in A139 [PID Preload], in Hertz, will be pre-loaded into the integral component of the PID at any start or enable. This will cause the drive’s frequency command to initially jump to that preload frequency, and the PID loop starts regulating from there.
  • Page 152 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 153 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 154 F-10 PID Set Up The following figures show some typical responses of the PID loop at different points during adjustment of the PID Gains. Figure F.1 Unstable PID Reference PID Feedback Time Figure F.2 Slow Response – Over Damped PID Reference PID Feedback Time Figure F.3 Oscillation –...
  • Page 155 Index Drive, B-7 Minimum Clearances, 1-3 AC Supply Direction Ground, 1-7 of Drive, 2-2 Source, 1-5 of Motor, 1-13 Ungrounded, 1-5 Discharging Bus Capacitors, P-3, 1-2 Acceleration Rate, 1-24 Disconnecting Output Power, 1-12 Advanced Program Group Parameters, 3-14 Display, 2-4 Ambient Temperatures, 1-3 Display Group Parameters, 3-3 Analog Input Loss Fault, F29, 4-3...
  • Page 156 Index-2 Params Defaulted, F48, 4-4 Phase Short, F41-F43, 4-4 Keypad, 2-4 Phase to Ground Short, F38-F40, Power Loss, F3, 4-3 LEDs, 2-4 Power Unit, F70, 4-4 SVC Autotune, F80, 4-4 Menu Structure, 2-6 SW OverCurrent, F63, 4-4 Minimum Clearances, 1-3 UnderVoltage, F4, 4-3 Monitor File, 3-3 File...
  • Page 157 Index-3 Program Group, 3-9 Static Discharge, ESD, P-3 Params Defaulted Fault, F48, 4-4 Status LEDs, 2-4 PE Ground, 1-7 Supply Source, AC, 1-5 Phase Short Fault, F41-F43, 4-4 SVC Autotune Fault, F80, 4-4 Phase to Ground Fault, F38-F40, 4-4 SW OverCurrent Fault, F63, 4-4 Potentiometer, Wiring, 1-18 System Grounding, 1-7 Power Cables and Wiring, 1-10...
  • Page 158 Index-4 Notes: PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 160 U.S. Allen-Bradley Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives Publication 22B-UM001I-EN-E – June 2017 Supersedes 22B-UM001H-EN-E - June 2013 Copyright © 2017 Rockwell Automation, Inc. All rights reserved.

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