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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

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PowerFlex 4 Adjustable
Frequency AC Drive
Bulletin Number 22A
Firmware Revision 7.xxx
User Manual
Original Instructions

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 4

  • Page 1 PowerFlex 4 Adjustable Frequency AC Drive Bulletin Number 22A Firmware Revision 7.xxx User Manual Original Instructions...
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 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 PowerFlex 4 Adjustable Frequency AC Drive User Manual, publication 22A-UM001J-EN-E. Description of New or Updated Information See Pages Minimum Enclosure Volume column and new footnotes added Drive, Fuse & Circuit Breaker Ratings topic updated Electronic Motor Overload Protection description updated Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 4 Attention statement added to Multiple Digital Input Connections wiring example Parameter P043 [Motor OL Ret] added Attention statement added to parameter A082 [DB Resistor Sel] External Comm Options, Compact I/O added to Table 20 Modbus function code 16 added Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 5: Table Of Contents

    Product Selection ....83 Product Dimensions ....87 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 6 ........109 Index Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 7: Who Should Use This Manual

    SGI-1.1 devices or packaged assemblies incorporating solid-state components. Industrial Automation Wiring and Grounding Provides general guidelines for installing a Guidelines, publication 1770-4.1 Rockwell Automation industrial system. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 8: Manual Conventions

    Similar PowerFlex 4 drive sizes are grouped into frame sizes to simplify spare parts ordering, dimensioning, and so on. A cross reference of drive catalog numbers and their respective frame sizes is provided in Appendix Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 9: General Precautions

    1 minute. If this condition is unacceptable, the bus regulator must be disabled (see parameter A117). In addition, installing a properly sized dynamic brake resistor will provide equal or better performance in most cases. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 10: Catalog Number Explanation

    1.5 (2.0) 1.5 (2.0) 2.2 (3.0) 12.0 2.2 (3.0) 3.7 (5.0) 17.5 3.7 (5.0) Position 12 of the Catalog Number now indicates drive type. All PowerFlex 4 drives are equipped with RS-485 communication. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • 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: Mounting Considerations

    -10 °C (14 °F) IP30/NEMA 1/UL Type 1 Use Mounting Option B 50 °C (122 °F) IP20/Open Type Use Mounting Option B Rating requires installation of the PowerFlex 4 IP30/NEMA 1/UL Type 1 option kit. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 13: Ac Supply Source Considerations

    2. Pull the jumper completely out of the drive chassis. 3. Tighten the screw to keep it in place. Figure 1 – Jumper Location (A Frame Shown) Important: Tighten screw after jumper removal. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 14: Input Power Conditioning

    (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. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 15: Ground Fault Monitoring

    AC supply systems and be permanently installed and solidly grounded (bonded) to the building power distribution ground. Ensure that the incoming supply neutral is solidly connected (bonded) to the same building power distribution ground. Grounding must not rely on Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 16: Fuses And Circuit Breakers

    • Bulletin 140M/140MT can be used in single and group motor applications. • Bulletin 140M/140MT can be used up stream from the drive without the need for fuses. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 17 0.4 (0.5) 140M-C2E-B40 100-C09 1655 140MT-C3E-B40 100-E09 0.75 (1.0) 140M-C2E-C10 100-C09 1655 140MT-C3E-C10 100-E09 1.5 (2.0) 140M-C2E-C16 100-C12 1655 140MT-C3E-C16 100-E12 2.2 (3.0) 140M-C2E-C16 100-C16 1655 140MT-C3E-C16 100-E16 3.7 (5.0) 140M-F8E-C25 100-C23 1655 100-E26 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 18: Power Wiring

    For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross coupled” power leads. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 19 Division I and II 75 °C or 90 °C (167 °F or 194 °F) three bare copper grounds in contact with shield RHH/RHW-2 • PVC copper grounds on 6 mm (10 AWG) and smaller Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 20 If it is necessary to disconnect power to the motor with the drive outputting power, an auxiliary contact should be used to simultaneously disable drive control run commands. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 21: Power Terminal Block

    Torque 3.3 mm (12 AWG) 0.8 mm (18 AWG) 1.7…2.2 N•m (16…19 lb•in) 5.3 mm (10 AWG) 1.3 mm (16 AWG) Maximum/Minimum sizes that the terminal block accepts. These sizes are not recommendations. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 22: I/O Wiring Recommendations

    (PE) terminal and are designed to greatly reduce common mode interference. ATTENTION: Driving the 4…20 mA analog input from a voltage source could cause component damage. Verify proper configuration prior to applying input signals. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 23: I/O Terminal Block

    To improve noise immunity, the I/O terminal block Common must be connected to ground terminal/protective earth. If using the RS-485 (DSI) port, I/O Terminal 16 should also be connected to ground terminal/protective earth. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 24 0…10V In (3) Not Active P038 (input impedance = 100 kΩ) or potentiometer wiper. For 0…10V In or 4…20 mA In. Electronically isolated with Analog Common – – analog inputs from digital I/O. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 25: I/O Wiring Examples

    Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11. A051 [Digital In1 Sel] = 3 “Aux Fault” A055 [Relay Out Sel] = 10 “Above Anlg V” A056 [Relay Out Level] = % Voltage Trip PTC (hot) × 100 Trip PTC (hot) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 26 Run Reverse inputs are Each digital input draws 6 mA. closed at the same time, an undetermined state could occur. 2-wire SNK Control - Internal supply (SNK) Run FWD/Run REV Stop-Run Forward Stop-Run Reverse Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 27 P037 [Stop Direction Direction Mode]. I/O Terminal 03 determines direction. +24V Common Each digital input draws 6 mA. 3-wire SNK Control - Internal supply (SNK) Reversing Stop Start Direction Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 28 I/O Terminal 14 common together for all drives. I/O Terminal 14 common and I/O Terminal 13 (potentiometer wiper) should be daisy chained to each drive. All drives must be powered up for the analog signal to be read correctly. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 29: Start And Speed Reference Control

    A071…A073 [Preset Freq 1…3]. A051 / A052 Preset Inputs Active Start and Direction commands come from P036 [Start Source]. Run as specified by P038 [Speed Reference]. Start and Direction commands come from P036 [Start Source]. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 30 Speed is controlled determined by the active Preset Frequency. by [Preset Freq x] See A070…A073 [Preset Freq 0…3] A051 or A052 = 4 page P039 [Accel Time 1]/P040 [Decel Time 1] are used. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 31: Emc Instructions

    • Use of line filters in ungrounded systems is not recommended. • Conformity of the drive with CE EMC requirements does not guarantee an entire machine installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 32: Essential Requirements For Ce Compliance

    First Environment Unrestricted Distribution installations require a shielded enclosure. Keep wire length as short as possible between the enclosure entry point and the EMI filter. Integral EMI filters are available on 240V, 1-phase drives. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 33 Installations on a public low voltage power network may require additional external harmonic mitigation. • Other drive ratings meet the current harmonic requirements of EN61000-3-2 without additional external mitigation. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 34 Chapter 1 Installation/Wiring Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 35: Prepare For Drive Start-Up

    (I/O Terminals 01 and 11) to allow starting from the keypad. If the control scheme is changed to Sink (SNK), the jumper must be removed from I/O Terminals 01 and 11 and installed between I/O Terminals 01 and 04. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 36: Integral Keypad

    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. Displayed only when fault is present. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 37: Viewing And Editing Parameters

    This key is always active. Controlled by parameter P037 [Stop Mode]. 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. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 38 If pressing Esc does not change the display, then d001 [Output Frequency] is displayed. Press Enter or Sel to enter the group menu. The Basic Program Group (page 46) contains the most commonly changed parameters. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 39: Programming And Parameters

    1, the feature is on or the condition is true. Some parameters are marked as follows. = Stop drive before changing this parameter. = 32-bit parameter. Parameters marked 32-bit will have two parameter numbers when using RS-485 communications and programming software. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 40: Parameter Organization

    Anlg In 0-10V Hi A111 Anlg In 4-20mA Lo A112 Anlg In 4-20mA Hi A113 Slip Hertz @ FLA A114 Process Time Lo A115 Process Time Hi A116 Bus Reg Mode A117 Comm Write Mode A118 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 41: Display Group

    Output voltage present at terminals T1, T2, and T3 (U, V, and W). Values Default Read Only Min/Max: 0/Drive Rated Volts Display: 1 VAC d005 [DC Bus Voltage] Present DC bus voltage level. Values Default Read Only Min/Max: Based on Drive Rating Display: 1 VDC Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 42 The output frequency scaled by A099 [Process Factor] or by A115 [Process Time Lo] and A116 [Process Time Hi]. Output Process Process Freq Factor Display Values Default Read Only Min/Max: 0.00/9999 Display: 0.01/1 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 43 The stop input must be present in order to start the drive. When this bit is a 1 the drive can be started. When this bit is a 0 the drive will stop. Values Default Read Only Min/Max: Display: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 44 [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: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 45 The present value of the current at I/O Terminal 15 (0.0% = 4mA, 100.0% = 20mA). Values Default Read Only Min/Max: 0.0/100.0% Display: 0.1% d024 [Drive Temp] Present operating temperature of the drive power section. Values Default Read Only Min/Max: 0/120 °C Display: 1 °C Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 46: Basic Program Group

    Related Parameters: d001, d002, d013, P034, A078, A111, A113, A115 Stop drive before changing this parameter. Sets the highest frequency the drive will output. Values Default 60 Hz Min/Max: 0/240 Hz Display: 1 Hz Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 47 On firmware revisions 1.03 and later, once a stop input is received, the start command must transition from high to low to high for the drive to start. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 48 DC Injection Braking Stop with Auto Shutoff • Standard DC Injection Braking for value set in A080 Brake Time] • Drive shuts off if current limit is exceeded. Stop input also clears active fault. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 49 Maximum Freq Accel Rate Accel Time Values Default 10.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs P035 [Maximum Freq] Speed P039 or A067 P040 or A068 Time [Accel Time x] [Decel Time x] Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 50 Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor overload counter is saved at power-down and restored at power-up. A change to this parameter setting resets the counter. Options 0 “Disabled” (Default) 1 “Enabled” Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 51: Advanced Program Group

    A valid start overrides this command. 12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079 [Jog Accel/Decel] and ramps to stop when input becomes inactive. A valid start overrides this command. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 52 Enables the output to be controlled over network communications by writing to A056 [Relay Out Level]. (0 = Off, 1 = On.) 21 “NonRec Fault”” Value set in A092 [Auto Rstrt Tries] is exceeded. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 53 Maximum Freq Accel Rate Accel Time Values Default 20.0 Secs Min/Max: 0.0/600.0 Secs Display: 0.1 Secs P035 [Maximum Freq] Speed P039 or A067 P040 or A068 Time [Accel Time x] [Decel Time x] Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 54 EEPROM memory. If the ESC key is used before the Enter key, the frequency will return to the original value following the normal accel/decel curve. Values Default 60.0 Hz Min/Max: 0.0/240.0 Hz Display: 0.1 Hz Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 55 Display: 0.1 Hz A079 [Jog Accel/Decel] Related Parameters: A051, A052, A078 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 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 56 ATTENTION: If a hazard of injury due to movement of equipment or material exists, an auxiliary mechanical braking device must be used. ATTENTION: This feature should not be used with synchronous or permanent magnet motors. Motors may be demagnetized during braking. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 57 Total Time = 10 + 5 = 15 Seconds Target/2 1/2 S Curve Time Accel Time 1/2 S Curve Time 2.5 Seconds 10 Seconds 2.5 Seconds Total Time to Accelerate = Accel Time + S Curve Time Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 58 1/2 [Motor NP Volts] Settings 5-14 % P032 [Motor NP Hertz] A088 [Maximum Voltage] Sets the highest voltage the drive will output. Values Default Drive Rated Volts Min/Max: 20/Drive Rated Volts Display: 1 VAC Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 59 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 Min/Max: 2.0/16.0 kHz Display: 0.1 kHz Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 60 ATTENTION: Equipment damage and/or personal injury may result if this parameter is used in an inappropriate application. Do not use this function without considering applicable local, national and international codes, standards, regulations or industry guidelines. Options 0 “Disabled” (Default) 1 “Enabled” Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 61 0.0/(Drive Rated Amps × 2) Min/Max: Display: 0.1 Amps A099 [Process Factor] Related Parameter: d010 Scales the value displayed by d010 [Process Display]. Output Process Process Freq Factor Display Values Default 30.0 Min/Max: 0.1/999.9 Display: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 62 [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]...
  • Page 63 Important: Power to drive must be cycled before any changes will affect drive operation. Options 0 “RTU 8-N-1” (Default) 1 “RTU 8-E-1” 2 “RTU 8-O-1” 3 “RTU 8-N-2” 4 “RTU 8-E-2” 5 “RTU 8-O-2” Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 64 Analog inversion can be accomplished by setting this value larger than A113 [Anlg In4-20mA Hi] or by setting A051…A052 [Digital Inx Sel] to option 26 “Anlg Invert”. Values Default 0.0% Min/Max: 0.0/100.0% Display: 0.1% Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 65 Controls the operation of the drive voltage regulation, which is normally operational at decel or when the bus voltage rises. See the Attention statements on page 9 for important information on bus regulation. Options 0 “Disabled” “Enabled” (Default) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 66 Do not create a program that frequently uses configurable outputs to write parameter data to NVS unless A164 [Comm Write Mode] is set to option 1. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 67: Parameter Cross Reference - By Name

    Stop Mode P037 Basic Program Drive Temp d024 Display SW Current Trip A098 Advanced Program Drive Type d017 Display Testpoint Data d019 Display Elapsed Run Time d018 Display Testpoint Sel A102 Advanced Program Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 68 Chapter 3 Programming and Parameters Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 69: Troubleshooting

    Non-resettable This type of fault may require drive or motor repair, or is caused by wiring or programing errors. The cause of the fault must be corrected before the fault can be cleared. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 70: Fault Indication

    (Type 2) that indicate possible drive component malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user selected programming. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 71: Fault Descriptions

    Check the motor and external wiring has been detected at one or to the drive output terminals for a more of the drive output grounded condition. terminals. page 69 for a description of fault types. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 72 F122 I/O Board Fail Failure has been detected in the 1. Cycle power. drive control and I/O section. 2. Replace drive if fault cannot be cleared. page 69 for a description of fault types. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 73: Common Symptoms And Corrective Actions

    Source] to option 0 “Keypad”. • Set parameter A051…A052 [Digital Inx Select] to option 5 “Local” and activate the input. I/O Terminal 01 “Stop” input is None Wire inputs correctly and/or install not present. jumper. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 74 Verify settings A051…A052 [Digital Inx Select]. • Check P038 [Speed Reference] for the source of the speed reference. Reprogram as necessary. • Review the Speed Reference Control chart on page Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 75 Digital input is incorrectly None Check input wiring. See Figure wired. Motor wiring is improperly None Switch two motor leads. phased for reverse. Reverse is disabled. None Check A095 [Reverse Disable]. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 76 Chapter 4 Troubleshooting Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 77: Supplemental Drive Information

    Typical designations include, but may not be limited to the following; Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH. Typical designations include; Type CC - KTK-R, FNQ-R Type J - JKS, LPJ Type T - JJS, JJN Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 78: Specifications

    1655 140MT-C3E-B40 100-E09 140M-C2E-B63 100-C09 22A-D4P0N104 1.5 (2.0) 340…528 4.0 1655 140MT-C3E-B63 100-E09 140M-C2E-C10 100-C09 22A-D6P0N104 2.2 (3.0) 340…528 5.9 1655 140MT-C3E-C10 100-E09 140M-C2E-C16 100-C16 22A-D8P7N104 3.7 (5.0) 340…528 8.6 1655 140MT-C3E-C16 100-E16 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 79 When using a Manual Self-protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations may require a larger enclosure. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 80 200% Overload capability for up to 3 seconds Electronic Motor Overload Provides class 10 motor overload protection Protection according to NEC article 430 and motor over-temperature protection according to NEC article 430.126 (A) (2). UL 508C File 29572. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 81: Product Environmental Information

    0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) 380…480V 0.4 (0.5) 0.75 (1.0) 1.5 (2.0) 2.2 (3.0) 3.7 (5.0) Product Environmental Information Rockwell Automation maintains current product environmental information on its website at: rok.auto/certifications. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 82 Appendix A Supplemental Drive Information Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 83: Accessories And Dimensions

    22A-D1P4N104 22A-D1P4F104 3-phase 0.75 2.3 A 22A-D2P3N104 22A-D2P3F104 No Filter 4.0 A 22A-D4P0N104 22A-D4P0F104 6.0 A 22A-D6P0N104 22A-D6P0F104 8.7 A 22A-D8P7N104 22A-D8P7F104 Replacement Plate drives are also available. Contact factory for ordering information. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 84 29 W 1321-3R-12-B Catalog numbers listed are for 3% impedance open style units. NEMA Type 1 and 5% impedance reactor types are also available. See the 1321 Power Conditioning Products Technical Data, publication 1321-TD001. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 85 Description Frame Catalog Number IP30/NEMA 1/UL Type 1 Kit Field installed kit. Converts drive to IP30/NEMA 1/ 22-JBAA UL Type 1 enclosure. Includes conduit box with 22-JBAB mounting screws and plastic top panel. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 86 Compatibility: Microsoft Windows 7, Windows 10, and Windows Server 2019 package) You can download DriveTool SP software package at rok.auto/pcdc. Requires Connected Components Workbench software version 20.01.00 or earlier. Requires Connected Components Workbench software version 20.01.00 or later. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 87: Product Dimensions

    213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9) Overall height of drive with IP30/NEMA 1/UL Type 1 option kit installed Overall height of standard IP20/Open Type drive Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 88 64.1 (2.33) (2.52) 40.0 40.6 ∅ 22.2 ∅ 22.2 (1.57) (1.60) (0.87) (0.87) 20.7 25.6 (0.81) (1.01) 109.3 109.9 (4.30) (4.33) 75.3 74.3 (2.96) (2.93) Frame A - 22-JBAA Frame B - 22-JBAB Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 89 Accessories and Dimensions Figure 9 – PowerFlex 4 Flange Mount Drives Dimensions are in millimeters and (inches). Frame A 92.8 54.7 (3.65) (2.15) (6.89) (5.71) (8.27) Frame B 94.3 63.1 (3.71) (2.48) (9.61) (8.43) (9.84) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 90 Dimensions are in millimeters and (inches). Frame A (0.31) (4.49) (0.21) (7.68) (7.05) 97.5 (3.84) (0.31) (0.63) (1.93) (3.86) (5.12) Frame B (5.71) 23.5 (0.26) (0.93) (7.76) (8.27) (8.86) 98.5 (3.88) (0.21) (0.30) (0.55) (1.22) (1.93) (3.86) (6.30) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 91 Dimensions are in millimeters and (inches). Frame A 104.8 (4.13) (3.62) (1.97) (3.46) (0.24) (6.42) (5.98) (6.89) 81.5 (3.21) (0.21) (3.15) Frame B (4.92) (4.41) (3.15) (3.46) (0.37) (7.56) (7.09) (8.03) (3.78) (0.21) (3.94) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 92 AK-R2-091P500, AK-R2-047P500, AK-R2-360P500 AK-R2-030P1K2, AK-R2-120P1K2 Figure 13 – Recommended External Brake Resistor Circuitry 3-phase AC input (Input contactor) M R (L1) S (L2) T (L3) Power off Power on Power source DB resistor thermostat Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 93 85 (3.35) 63 (2.48) 51 (2.00) 4.9 (11) 1321-3R12-A 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 4.1 (9) 1321-3R18-A 152 (6.00) 133 (5.25) 79 (3.10) 54 (2.13) 51 (2.00) 4.1 (9) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 94 Figure 16 – Frame B EMC Line Filters Dimensions are in millimeters and (inches). Catalog Numbers: 22-RF012-BS, 22-RF012-BL (Series B); 22-RF018-BS; 22-RF021-BS, 22-RF012-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) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 95 Catalog Number: 22-RF025-CL (2.36) (5.12) (3.54) (1.26) (11.69) (12.17) (11.69) 5.5 (0.22) (0.67) (1.18) Important: The piggyback mounting option cannot be used with frame B PowerFlex 4 drives and frame C EMC line filters. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 96 Accessories and Dimensions Figure 18 – Remote (Panel Mount) HIM Dimensions are in millimeters and (inches). Catalog Number: 22-HIM-C2 17.6 (0.69) (4.09) (8.66) 2.9m (3.07) (2.60) (7.64) (4.92) 60.5 (2.38) 19.1 (1.50) (0.75) (0.19) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 97 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) Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 98 Accessories and Dimensions Figure 20 – 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) Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 99: Network Wiring

    RS-485 (DSI) Protocol PowerFlex 4 drives support the RS-485 (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 RS-485 network using Modbus protocol in RTU mode.
  • Page 100 Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on the PowerFlex 4 RJ45 socket must not be connected because they contain power, and so on. for other Rockwell Automation peripheral devices. Wiring terminations on the master controller will vary depending on the master controller used and “TxRxD+”...

  • Page 101: Parameter Configuration

    +1. For example, Logic Command may be register address 8192 for some master devices (for example, ProSoft 3150-MCM SLC™ Modbus scanner) and 8193 for others (for example, PanelView™). Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 102: Writing (06) Logic Command Data

    011 = Freq. Source = Comms (Addr 8193) 14,13,12 100 = A070 [Preset Freq 0] 101 = A071 [Preset Freq 1] 110 = A072 [Preset Freq 2] 111 = A073 [Preset Freq 3] Not Used Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 103: Writing (06) Reference

    A xxx.x decimal value where the decimal point is fixed. For example, a decimal 8451 “123” equals 12.3 Hz and “300” equals 30.0 Hz. Returns the same data as Reading (03) Parameter d001 [Output Freq]. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 104: Reading (03) Drive Error Codes

    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]. Additional Information Visit www.rockwellautomation.com/en-us/products/hardware/ allen-bradley/vfd.html for additional information. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 105: Rj45 Dsi Splitter Cable

    • If two peripherals will be powered up at the same time, one must be configured as the “Master” and connected to the Master port (M) and the other must be connected as the “Slave” and connected to the Slave port (S). Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 106: Dsi Cable Accessories

    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 Catalog Number: AK-U0-RJ45-TR1 PIN 8 PIN 1 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...

  • Page 107: Connecting An Rs-485 Network

    Customer supplied RJ45 male-to-RJ45 male cables with wires connected at pins 4 and 5 only. Both the master (M) and slave (S) ports on the RJ45 splitter Cable operate as standard RS-485 ports in this configuration. Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 108 Appendix D RJ45 DSI Splitter Cable Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 109 Name, 67 SW OverCurrent, 72 UnderVoltage, 71 Filter, RFI, 15 Dimensions Frame Designations, 8, 77, 87 Drive, 87 Fuses Minimum Clearances, 12 Input, 16 Discharging Bus Capacitors, 9 Ratings, 77 Display, 37 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 110 RWR (Reflective Wave Reducer), 20 MOVs, 13 Safety Ground, 15 Opening the Cover, 11 Shielded Power Cables, 19 Operating Temperatures, 12 Short Circuit Protection, 16 Operator Interface, 36 Software, 39 OverVoltage Fault, 71 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 111 System Grounding, 14 Block Diagram, 24 I/O, 22 I/O Examples, 25, 28 Terminal Block Potentiometer, 25 I/O, 23 Power, 18 Power, 21 PTC Example, 25 Three Wire Control, 25, 28 Two Wire Control, 25, 28 Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 112 Index Notes: Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 113 PowerFlex 4 Adjustable Frequency AC Drive User Manual Rockwell Automation Publication 22A-UM001L-EN-E - September 2024...
  • Page 114 At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, Compact I/O, Connected Components Workbench, DriveExecutive, DriveTools, expanding human possibility, PanelView, PowerFlex, Rockwell Automation, SLC, and TechConnect are trademarks of Rockwell Automation, Inc.
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