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

Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series
160 pages
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Adjustable
Frequency AC
Drive
FRN 1.xx - 7.xx
User Manual
www.abpowerflex.com
22B-UM001.book Page 1 Tuesday, May 30, 2017 5:22 PM

Table of Contents

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Rockwell Automation Allen-Bradley PowerFlex 40 FRN Series Specifications

General IconGeneral
Output Voltage0 to Input Voltage
Output Frequency Range0 to 400 Hz
Control MethodSensorless Vector Control
Enclosure TypeIP20 (NEMA/UL Type Open)
Overload Capacity150% for 60 seconds
Control InputsDigital inputs, Analog inputs
BrakingDynamic braking (optional DB resistor required)
Protection FeaturesOvervoltage, Undervoltage, Overcurrent, Ground Fault, Short Circuit

Summary

Important User Information

Safety Warnings

Identifies practices or circumstances that can cause an explosion or lead to injury, death, or damage.

Hazard Labels

Alerts users to potential shock or burn hazards present on or inside the equipment.

General Precautions

Catalog Number Explanation

Installation and Wiring

Opening the Cover

Provides instructions for opening the drive's cover for IP20, NEMA/UL Type Open enclosures.

IP66, NEMA;UL Type 4 X Cover Installation

Details cover removal and installation steps for IP66, NEMA/UL Type 4X enclosures.

Mounting Considerations

Discusses upright mounting, environmental protection, and minimum clearances for the drive.

AC Supply Source Considerations

Explains precautions for ungrounded systems and disconnecting MOV protective devices.

Input Power Conditioning

Lists input power conditions and corrective actions for proper drive operation.

General Grounding Requirements

Details safety ground, motor ground, and shield termination requirements.

Fuses and Circuit Breakers

Provides guidance on recommended fuses, circuit breakers, and their ratings.

Power Wiring

Provides instructions and recommendations for motor cable types and wiring practices.

Recommended Shielded Wire

Lists specific types of shielded wire recommended for drive installations.

Power Terminal Block

Describes the power terminal block, its connections, and specifications.

I;O Wiring Recommendations

Offers important points and precautions for I/O wiring, including motor start/stop.

Control Wiring Block Diagram

Illustrates typical control wiring configurations for various start/stop and direction methods.

I;O Wiring Examples

Provides wiring examples for different input/output configurations.

Start Up

Prepare For Drive Start-Up

Lists essential checks and procedures to perform before applying power to the drive.

Integral Keypad

Details the LED indicators, keys, and menu structure of the drive's integral keypad.

Viewing and Editing Parameters

Provides step-by-step instructions for navigating and modifying drive parameters.

Remote HIM Menu Structure

Describes the menu structure accessible via remote Human Interface Modules.

Diagnostics Menu

Menu for accessing detailed drive fault information and status.

Parameters Menu

Menu for accessing and displaying drive parameters in various lists.

Memory Storage Menu

Menu for saving or recalling drive configuration data (HIM sets).

Programming and Parameters

About Parameters

Explains the types of parameters (ENUM, Numeric, Bit) and their markings.

Parameter Organization

Lists parameters organized by Display, Basic, and Advanced Program Groups.

Display Group

Describes parameters related to monitoring drive status and output values.

Basic Program Group

Details parameters commonly used for drive configuration and setup.

Advanced Program Group

Details advanced parameters for fine-tuning drive functions and performance.

A055 [Relay Out Sel]

Sets the condition that changes the state of the output relay contacts.

A056 [Relay Out Level]

Sets the trip point for the digital output relay based on selected conditions.

A058 [Opto Out1 Sel]

Determines the operation of the programmable opto output 1.

A059 [Opto Out1 Level]

Determines the on/off point for opto output 1 based on selected conditions.

A067 [Accel Time 2]

Sets the rate of acceleration for all speed increases except jog.

A068 [Decel Time 2]

Sets the rate of deceleration for all speed decreases except jog.

A069 [Internal Freq]

Provides the frequency command when the speed reference is set to internal frequency.

A070 [Preset Freq 0]

Provides a fixed frequency command value when digital inputs are set to Preset Frequencies.

A079 [Jog Accel;Decel]

Sets the acceleration and deceleration time when a jog command is issued.

A084 [Boost Select]

Sets boost voltage and redefines the Volts per Hz curve for motor performance.

A085 [Start Boost]

Sets boost voltage and redefines Volts per Hz curve for custom V/Hz mode.

A089 [Current Limit 1]

Sets maximum output current allowed before current limiting occurs.

A090 [Motor OL Select]

Selects the derating factor for the I2t overload function for motor protection.

A092 [Auto Rstrt Tries]

Sets the maximum number of attempts to reset a fault and restart the drive.

A093 [Auto Rstrt Delay]

Sets the time between restart attempts after a fault.

A100 [Fault Clear]

Resets a fault and clears the fault queue, primarily for network communications.

A103 [Comm Data Rate]

Sets the serial port data rate for the RS485 (DSI) port.

A104 [Comm Node Addr]

Sets the drive node address for the RS485 (DSI) port in a network connection.

A105 [Comm Loss Action]

Selects the drive's response to communication connection loss or errors.

A106 [Comm Loss Time]

Sets the time before implementing the communication loss action.

A107 [Comm Format]

Sets transmission mode, data bits, parity, and stop bits for the RS485 (DSI) port.

A110 [Anlg In 0-10 V Lo]

Sets the analog input level corresponding to minimum frequency for 0-10V input.

A111 [Anlg In 0-10 V Hi]

Sets the analog input level corresponding to maximum frequency for 0-10V input.

A112 [Anlg In4-20 mA Lo]

Sets the analog input level corresponding to minimum frequency for 4-20mA input.

A113 [Anlg In4-20 mA Hi]

Sets the analog input level corresponding to maximum frequency for 4-20mA input.

A117 [Bus Reg Mode]

Controls the operation of the drive voltage regulation.

A118 [Current Limit 2]

Sets maximum output current allowed when current limiting is active.

A122 [Analog In Loss]

Selects drive action when an analog input signal loss is detected.

A123 [10 V Bipolar Enbl]

Enables or disables bipolar control for analog inputs.

A125 [Torque Perf Mode]

Enables or disables sensorless vector control operation.

A126 [Motor NP FLA]

Sets the motor nameplate rated full load amps.

A127 [Autotune]

Provides an automatic method for setting motor parameters for sensorless vector.

A130 [PID Trim Hi]

Sets the maximum positive value added to speed reference in PID trim mode.

A131 [PID Trim Lo]

Sets the maximum positive value subtracted from speed reference in PID trim mode.

A132 [PID Ref Sel]

Enables PID mode and selects the source of the PID reference.

A133 [PID Feedback Sel]

Selects the source of the PID feedback signal.

A134 [PID Prop Gain]

Sets the proportional gain for the PID loop.

A135 [PID Integ Time]

Sets the integral gain for the PID loop.

A136 [PID Diff Rate]

Sets the differential gain for the PID loop.

A137 [PID Setpoint]

Provides an internal fixed value for the process setpoint in PID mode.

A138 [PID Deadband]

Sets the range, in percent, of the PID reference that the drive will ignore.

A139 [PID Preload]

Sets the value used to preload the integral component on start or enable.

A140 [Stp Logic 0]

Parameter for defining the first step in StepLogic programming.

Digit 3: Step Settings

Defines accel/decel, output state, and command direction for StepLogic steps.

Digit 2 Settings

Defines conditions for jumping to a specific StepLogic step or ending the program.

Digit 1 and Digit 0 Settings

Defines logic conditions for transitioning between StepLogic steps.

A150 [Stp Logic Time 0]

Sets the time to remain in each StepLogic step when timed transitions are used.

A160 [EM Brk Off Delay]

Sets time before relay/opto output energizes for electromagnetic brake control.

A161 [EM Brk On Delay]

Sets time before relay/opto output de-energizes for electromagnetic brake control.

A163 [DB Threshold]

Sets the DC bus voltage threshold for Dynamic Brake operation.

A164 [Comm Write Mode]

Determines if parameter changes are saved to NVS or RAM only.

A165 [Anlg Loss Delay]

Sets time after power-up before analog signal loss is detected.

A166 [Analog In Filter]

Sets level of additional filtering for analog input signals.

A167 [PID Invert Error]

Changes the sign of the PID error for specific control behaviors.

Parameter Cross Reference - by Name

An alphabetical listing of parameters, their numbers, groups, and page references.

Troubleshooting

Drive Status

Explains how drive condition or state is monitored and indicated via the keypad.

Faults

Defines faults as conditions that stop the drive and categorizes them by type.

Fault Indication

Describes how faults are visually indicated on the drive's integral keypad.

Manually Clearing Faults

Provides steps for manually clearing faults after addressing the cause.

Automatically Clearing Faults

Details procedures for automatically clearing specific fault types and restarting.

Auto Restart (Reset;Run)

Explains the feature allowing automatic fault reset and start attempts.

Fault Descriptions

Lists fault types, their descriptions, and recommended actions for resolution.

Common Symptoms and Corrective Actions

Provides troubleshooting guidance for common drive issues and their solutions.

Drive does not Start from Start or Run Inputs wired to the terminal block.

Troubleshooting steps for drives not starting via terminal block inputs.

Drive does not Start from Integral Keypad.

Troubleshooting steps for drives not starting via the integral keypad.

Drive does not respond to changes in speed command.

Troubleshooting steps for issues related to speed command response.

Motor and;or drive will not accelerate to commanded speed.

Troubleshooting steps for problems with motor acceleration.

Motor operation is unstable.

Troubleshooting steps for issues related to unstable motor operation.

Drive will not reverse motor direction.

Troubleshooting steps for issues with motor direction control.

Drive does not power up.

Troubleshooting steps for when the drive fails to power up.

Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings

Provides recommended AC line input fuse and circuit breaker information.

Specifications

Lists technical specifications for the PowerFlex 40 drive series.

Input;Output Ratings

Details electrical ratings for digital and analog inputs/outputs.

Approvals

Lists safety and regulatory approvals for the drive.

Control Output

Details specifications for programmable output relays and opto outputs.

Protective Features

Lists protective features including overload, overvoltage, and overcurrent protection.

Environment

Lists environmental specifications such as altitude, temperature, and atmosphere.

Control

Lists control specifications like carrier frequency, accuracy, and I/O ranges.

Electrical

Lists electrical specifications such as voltage tolerance and input phases.

Accessories and Dimensions

Product Selection

Provides a table for selecting PowerFlex 40 drives based on ratings and enclosure.

Table B.C Dynamic Brake Modules

Lists dynamic brake module part numbers, resistance, and weight.

Table B.D Bulletin 1321-3 R Series Line Reactors

Lists line reactor part numbers, dimensions, and weight.

Table B.E DC Bus Inductors

Lists DC bus inductor part numbers and MTE catalog numbers.

Table B.F EMC Line Filters

Lists EMC line filter part numbers based on drive ratings and cable length.

Table B.G Human Interface Module (HIM) Option Kits and Accessories

Lists catalog numbers for HIM options, accessories, and cables.

Table B.H IP30;NEMA 1;UL Type 1 Kit

Lists part numbers for IP30/NEMA 1/UL Type 1 kits for drives and communication options.

Table B.I Communication Option Kits and Accessories

Lists catalog numbers for communication adapters, cables, and software.

Product Dimensions

Provides a table of drive ratings and dimensions by frame size.

Figure B.1 IP20, NEMA;UL Type Open

Shows dimensions for IP20, NEMA/UL Type Open drives.

Figure B.2 IP30, NEMA;UL Type 1 Option Kit without Communication Option

Shows dimensions for IP30/NEMA 1/UL Type 1 kits.

Figure B.4 PowerFlex 40 Flange Mount Drives

Shows dimensions for PowerFlex 40 Flange Mount drives.

Figure B.5 PowerFlex 40 Flange Mount Cutout Dimensions

Shows cutout dimensions for PowerFlex 40 Flange Mount drives.

Figure B.6 PowerFlex 40 Replacement Plate Drive Dimensions

Shows dimensions for PowerFlex 40 Replacement Plate drives.

Figure B.7 IP66, NEMA Type;UL Type 4 X - Dimensions

Shows dimensions for IP66, NEMA Type/UL Type 4X drives.

Figure B.8 Dynamic Brake Modules - Dimensions

Shows dimensions for Dynamic Brake Modules.

Figure B.10 Bulletin 1321-3 R Series Line Reactors - Dimensions

Shows dimensions for Bulletin 1321-3R Series Line Reactors.

Figure B.11 Frame B EMC Line Filters - Dimensions

Shows dimensions for Frame B EMC Line Filters.

Figure B.12 Frame C EMC Line Filters - Dimensions

Shows dimensions for Frame C EMC Line Filters.

Figure B.13 Remote (Panel Mount) Small HIM - Dimensions

Shows dimensions for Remote (Panel Mount) Small HIM.

Figure B.14 NEMA Type 1 Bezel - Dimensions

Shows dimensions for NEMA Type 1 Bezel.

RS485 (DSI) Protocol

Network Wiring

Describes the network wiring configuration for RS485 (DSI) protocol.

Parameter Configuration

Lists PowerFlex 40 parameters used to configure the drive for network operation.

Supported Modbus Function Codes

Lists Modbus function codes supported by the drive's peripheral interface.

Writing (06) Logic Command Data

Details how to write logic commands via the network using Function Code 06.

Writing (06) Reference

Details how to write speed references via the network using Function Code 06.

Reading (03) Logic Status Data

Details how to read logic status data via the network using Function Code 03.

Reading (03) Feedback

Details how to read drive feedback (output frequency) via the network.

Reading (03) Drive Error Codes

Details how to read drive error codes via the network using Function Code 03.

Reading (03) and Writing (06) Drive Parameters

Explains how to access and modify drive parameters via Modbus register addresses.

RJ45 DSI Splitter Cable

Connectivity Guidelines

Guidelines for connecting peripherals using the RJ45 DSI splitter cable.

DSI Cable Accessories

Lists various DSI cable accessories like splitter cables and adapters.

Connecting One Temporary Peripheral

Wiring example for connecting a single temporary peripheral to the drive.

Connecting One Temporary Peripheral and One Permanent Peripheral

Wiring example for connecting one temporary and one permanent peripheral.

Connecting Two Permanent Peripherals

Wiring example for connecting two permanent peripherals to the drive.

Connecting an RS-485 Network

Wiring example for connecting multiple drives to an RS-485 network.

StepLogic, Basic Logic and Timer;Counter Functions

StepLogic Function

Sequences preset speeds based on programmed logic, digital inputs, and timers.

Basic Logic Function

Uses digital inputs and outputs for basic logic functions like AND, OR, NOR.

Timer Function

Uses digital inputs and outputs to control timer functions for timed outputs.

Counter Function

Uses digital inputs and outputs to control counter functions for counting events.

StepLogic Using Timed Steps

Details configuring StepLogic using speed references and time for each step.

StepLogic Using Basic Logic Functions

Explains using digital inputs and outputs for logic transitions in StepLogic.

Timer Function

Explains how inputs and outputs control the timer function and its parameters.

Counter Function

Explains how inputs and outputs control the counter function and its parameters.

StepLogic Parameters

Provides code descriptions for StepLogic parameters.

Digit 3: Step Settings

Defines accel/decel, output state, and command direction for StepLogic steps.

Digit 2 Settings

Defines conditions for jumping to a specific StepLogic step or ending the program.

Digit 1 and Digit 0 Settings

Defines logic conditions for transitioning between StepLogic steps.

PID Set Up

PID Loop

Explains the built-in PID control loop and its function in maintaining a process set point.

Exclusive Control

Describes PID configuration where PID output becomes the entire frequency command.

Trim Control

Describes PID configuration where PID output is added to the speed reference.

PID Reference and Feedback

Explains how to select PID reference sources and PID feedback sources.

Analog PID Reference Signals

Explains how to scale analog signals for PID reference.

Invert Function

Explains inverting PID error sign for 4-20mA signals.

PID Deadband

Explains setting a range the drive ignores for PID output.

PID Preload

Explains setting a preload value for the PID integral component on start or enable.

PID Limits

Explains parameters to limit PID output frequency in trim mode.

PID Gains

Details the proportional, integral, and differential gains of the PID regulator.

Guidelines for Adjusting the PID Gains

Step-by-step guide for tuning PID proportional, integral, and differential gains.

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