Rockwell Automation Allen Bradley PowerFlex40 User Manual

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

Rockwell Automation Allen Bradley PowerFlex40 Specifications

General

Output Voltage	0 to Input Voltage
Amperage Range	2.3-32 A
Control Method	Sensorless Vector
Communication Options	EtherNet/IP
Enclosure Type	IP20 (Open Type)
Storage Temperature	-40…70 °C (-40…158 °F)
Relative Humidity	5-95% (non-condensing)
Dimensions	Varies by model (refer to datasheet)
Weight	Varies by model (refer to datasheet)

Summary

User Information and Safety

Safety Information and Warnings

Details crucial safety information, hazards, and precautions for operating the drive.

Preface

Overview and Manual Scope

Introduces the manual's purpose, scope, and intended audience.

Who Should Use this Manual?

Identifies the intended audience and required qualifications for using this manual.

Reference Materials

Lists recommended supporting documentation and resources for drive information.

Manual Conventions and Drive Frame Sizes

General Precautions

Safe Handling and Installation Precautions

Covers high voltage capacitor discharge, ESD control, qualified personnel, and installation hazard warnings.

Bus Regulator Function Considerations

Explains the bus regulator's function and potential side effects during operation.

Catalog Number Explanation

Chapter 1 Installation/Wiring

Installation and Wiring Overview

Introduces the chapter's focus on mounting and wiring the PowerFlex 40 Drive.

Opening the Drive Cover

Provides instructions on how to access the drive's internal components by removing the cover.

IP66, NEMA/UL Type 4X Cover Installation

Details the procedure for installing the cover for IP66/NEMA 4X enclosures.

Mounting Considerations

Outlines mounting clearances, orientation, and acceptable ambient temperature ranges.

Debris Protection and Storage Guidelines

Explains debris protection during installation and provides recommendations for drive storage.

AC Supply Source Considerations

Details AC supply source requirements, grounding practices, and MOV disconnection.

Input Power Conditioning

Details necessary power conditioning based on input power quality to prevent damage.

General Grounding Requirements

Explains safety ground, motor ground, and shield termination requirements for proper grounding.

RFI Filter Grounding and Protection Devices

Addresses RFI filter grounding and the selection of fuses and circuit breakers for branch circuit protection.

Power Wiring and Cable Types

Covers power wiring guidelines, acceptable motor cable types, and shielded cable recommendations.

Unshielded and Shielded Cable Usage

Describes the use and limitations of unshielded wire and the benefits of shielded cable for noise immunity.

Recommended Shielded Wire Specifications

Provides specific examples and specifications for recommended shielded wire types.

Reflected Wave Protection and Output Disconnect

Discusses limiting voltage reflections and advises against routine output power disconnection.

Power Terminal Block

Details the power terminal block layout, connections, and specifications for different drive frames.

IP66/NEMA 4X Installations and I/O Wiring

Provides installation notes for IP66/NEMA 4X drives and guidance for I/O wiring.

Motor Start/Stop Control Precautions

Highlights critical safety points and wiring practices for motor start/stop control.

Control Wire and I/O Terminal Specifications

Lists recommended control wire types, I/O terminal block specs, and maximum wiring length recommendations.

2-Wire Control Wiring Examples

Shows wiring for 2-wire control (SRC/SNK) with and without reversing operation.

3-Wire Control Wiring Examples

Illustrates wiring for 3-wire control (SRC/SNK) with and without reversing and direction control.

Opto and Analog Output Configuration

Explains the configuration and use of opto outputs and setup of analog outputs for providing drive status.

Typical Multiple Drive Connection Examples

Shows how to connect multiple digital and analog inputs to the drive for synchronized control.

Start and Speed Reference Control

Explains how to obtain the drive speed command from various sources and control logic.

Accel/Decel Selection

Details methods for selecting acceleration and deceleration rates based on various inputs and parameters.

EMC Instructions

Provides guidance for maintaining EMC compliance during installation, including CE conformity notes.

Essential Requirements for CE Compliance

Lists the critical conditions that must be met for PowerFlex drives to comply with EN61800-3 standards.

Chapter 2 Start Up

Start Up Overview

Introduces the chapter on starting up the PowerFlex 40 Drive, organizing parameters into groups.

Prepare For Drive Start-Up

Outlines essential checks and procedures to perform before applying power to the drive for the first time.

Applying Power and Basic Control

Details applying power, controlling the drive via keypad, and changing speed references.

Variable Torque Fan/Pump Application Tuning

Provides parameter setting recommendations for optimizing fan/pump applications.

Integral Keypad Interface

Provides an overview of the drive's integral keypad, including LED indicators and key functions.

LED Indicators and Keypad Buttons

Explains the meaning of each LED indicator and the purpose of each button on the integral keypad.

Viewing and Editing Parameters

Provides a step-by-step guide on navigating and modifying drive parameters using the integral keypad.

Remote HIM Menu Structure

Illustrates the hierarchical menu structure accessible through remote Human Interface Modules.

Drive Menu Navigation

Explains navigation through Diagnostics, Parameters, Device Select, Memory Storage, and HIM Setup menus.

Chapter 3 Programming and Parameters

About Parameters

Introduces the different types of parameters (ENUM, Numeric, Bit) and their characteristics.

Parameter Organization

Shows how parameters are grouped into Display, Basic Program, and Advanced Program categories.

Display Group Parameters Explained

Details parameters that display drive status, output values, and fault codes.

Basic Program Group Parameters

Motor Configuration Parameters

Covers parameters for setting motor voltage, frequency, current, and minimum/maximum frequencies.

Start, Stop, and Speed Reference Configuration

Details parameters for configuring start source, stop mode, speed reference, and acceleration/deceleration times.

Parameter Reset and Motor Overload Retention

Covers resetting parameters and configuring motor overload retention.

Advanced Program Group Parameters

Digital Input Configuration (A051-A054)

Selects functions for digital inputs, enabling flexible control logic and sequences.

Output Relay and Opto Configuration

Configures relay and opto outputs, setting conditions, levels, and logic for status signaling.

Speed and Motion Control Parameters

Covers parameters for acceleration/deceleration times, jog settings, DC braking, and boost settings.

Communication and Fault Handling Parameters

Details parameters for communication settings, fault clearing, and auto-restart functions.

PID Control Configuration

Covers PID loop setup, reference/feedback selection, gains, and tuning guidelines.

Chapter 4 Troubleshooting

Troubleshooting Overview and Faults

Explains drive status, fault types, indications, and manual/automatic clearing procedures.

Common Symptoms and Corrective Actions

Addresses common drive issues and their solutions, such as motor starting, acceleration, and power-up failures.

Motor Does Not Start

Details troubleshooting steps for a motor that does not start, covering power, control signals, and programming.

Drive Does Not Start from Terminal Block Inputs

Troubleshoots issues with terminal block wiring, incorrect programming, and sink/source settings.

Drive Does Not Respond to Speed Command Changes

Guides on diagnosing issues with speed command sources, incorrect references, and programming limits.

Motor or Drive Will Not Accelerate to Commanded Speed

Covers excessive acceleration time, load issues, improper boost settings, and torque performance mismatches.

Drive Does Not Power Up

Covers checks for no input power, incorrect jumper settings, or missing DC bus inductors.

Supplemental Drive Information

Drive Ratings, Specifications, and Protection

Lists drive ratings, electrical/environmental specifications, and protective features.

Fuse and Circuit Breaker Recommendations

Specifies recommended fuse types and circuit breaker requirements for branch circuit protection.

Accessories and Dimensions

Product Selection Guide

Provides a table for selecting PowerFlex 40 drives based on catalog number descriptions and configurations.

Drive Dimensions by Enclosure Type

Shows dimensional drawings and weights for various drive enclosure types (IP20, IP30, Flange, Replacement Plate, IP66).

RS485 (DSI) Protocol

Network Wiring and Configuration Parameters

Explains RS485 DSI network wiring, parameter configuration, and supported Modbus function codes.

Logic Command, Reference, and Status Data Writing/Reading

Details writing commands and reading status/error codes via network communication.

RJ45 DSI Splitter Cable

Connectivity Guidelines and Peripheral Connections

Provides guidelines for connecting peripherals using the RJ45 DSI splitter cable, including network configurations.

StepLogic, Basic Logic and Timer/Counter Functions

StepLogic Functionality and Timed Steps

Describes programming sequential operations using logic, speed references, and timed steps for automated processes.

Basic Logic, Timer, and Counter Functions

Explains using digital inputs/outputs for logic functions, timed operations, and event counting.

PID Set Up

PID Loop Configuration and Control Modes

Explains the built-in PID control loop, covering exclusive and trim control modes.

PID Reference, Feedback, and Gains

Details selecting PID reference/feedback sources, gains, and provides tuning guidelines.

PID Tuning Procedure

Provides a step-by-step process for tuning PID gains (Proportional, Integral, Differential) for optimal performance.