Allen-Bradley PowerFlex40 User Manual
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Allen-Bradley PowerFlex40 User Manual

Adjustable frequency ac drive
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Aotewell Ltd
HongKong|UK|China [email protected]
www.abpowerflex.com
www.aotewell.com
Industry Automation
Adjustable
Frequency AC
Drive
FRN 1.xx - 7.xx
User Manual
+86-755-8660-6182
Table of Contents
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Summary of Contents for Allen-Bradley PowerFlex40

  • Page 1 Aotewell Ltd www.aotewell.com Industry Automation Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual HongKong|UK|China [email protected] www.abpowerflex.com +86-755-8660-6182...
  • Page 2 Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be at dangerous temperatures. Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks of Rockwell Automation, Inc. DriveExplorer and DriveExecutive are trademarks of Rockwell Automation, Inc. HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual...
  • Page 3 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 4 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation Table of Contents Preface Overview Who Should Use this Manual? ..P-1 Reference Materials ....P-1 Manual Conventions .

  • Page 6: Table Of Contents

    Aotewell Ltd www.aotewell.com Industry Automation 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?

    Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 8: Manual Conventions

    Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 9: General Precautions

    Aotewell Ltd www.aotewell.com Industry Automation 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)].

  • Page 10: Catalog Number Explanation

    Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 11: Opening The Cover

    Aotewell Ltd www.aotewell.com Industry Automation Chapter Installation/Wiring This chapter provides information on mounting and wiring the PowerFlex 40 Drive. For information on… See page For information on… See page Opening the Cover Fuses and Circuit Breakers 1-8 Mounting Considerations Power Wiring 1-10 AC Supply Source Considerations 1-5 I/O Wiring...
  • Page 12 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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.) –...
  • Page 14 Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 15: Ac Supply Source Considerations

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 16 Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 17: General Grounding Requirements

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 20: Power Wiring

    Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 21 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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).
  • Page 23 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 25 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 26 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 27 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 28 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 29 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 30 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 31 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 32 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 34 Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 35: Emc Instructions

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 37 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 1-28 Installation/Wiring Notes: HongKong|UK|China [email protected] +86-755-8660-6182 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

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 42: Integral Keypad

    Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 43: Viewing And Editing Parameters

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 45 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 46 Aotewell Ltd www.aotewell.com Industry Automation Start Up Notes: HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 47: About Parameters

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 49: Display Group

    Aotewell Ltd www.aotewell.com Industry Automation 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 [Maximum Freq] Min/Max: 0.0/P035 Display: 0.1 Hz d002 [Commanded Freq]...
  • Page 50 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 51 Aotewell Ltd www.aotewell.com Industry Automation 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 1-24...
  • Page 52 Status of the communications ports. 1 = Condition True, 0 = Condition False Receiving Data Bit 0 Transmitting Data Bit 1 RS485 (DSI) Based Option Connected Bit 2 (Allen-Bradley devices only.) Communication Error Occurred Bit 3 Values Default: Read Only Min/Max: Display: d016 [Control SW Ver] Main Control Board software version.
  • Page 53 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 54 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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:...
  • Page 56 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 58 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 59 Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 60: Advanced Program Group

    Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 61 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 62 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 63 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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”...
  • Page 65 Aotewell Ltd www.aotewell.com Industry Automation 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”...
  • Page 66 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 67 Aotewell Ltd www.aotewell.com Industry Automation 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”...
  • Page 68 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 69 Aotewell Ltd www.aotewell.com Industry Automation 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]...
  • Page 70 Aotewell Ltd www.aotewell.com Industry Automation 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,...
  • Page 71 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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”.
  • Page 73 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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,...
  • Page 75 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 77 Aotewell Ltd www.aotewell.com Industry Automation Programming and Parameters 3-31 Advanced Program Group (continued) A100 [Fault Clear] Stop drive before changing this parameter. Resets a fault and clears the fault queue. Used primarily to clear a fault over network communications. Options 0 “Ready/Idle” (Default) 1 “Reset Fault”...
  • Page 78 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 79 Aotewell Ltd www.aotewell.com Industry Automation 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%...
  • Page 80 Aotewell Ltd www.aotewell.com Industry Automation 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].
  • Page 81 Aotewell Ltd www.aotewell.com Industry Automation 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:...
  • Page 82 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 83 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 84 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 85 Aotewell Ltd www.aotewell.com Industry Automation 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:...
  • Page 86 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 87 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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]...
  • Page 89 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 90 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 92 Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 93: Fault Descriptions

    Aotewell Ltd www.aotewell.com Industry Automation 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…...
  • Page 94 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 97 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 98 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 100 Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 101: Drive, Fuse & Circuit Breaker Ratings

    Aotewell Ltd www.aotewell.com Industry Automation 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: Specifications

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 104 Aotewell Ltd www.aotewell.com Industry Automation 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°...
  • Page 105 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 106 Aotewell Ltd www.aotewell.com Industry Automation Supplemental Drive Information Notes: HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 107: Product Selection

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 108 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 109 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 110 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 111 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 112 Windows based software package that provides 9306-4EXP01ENE (CD-ROM) Version 3.01 an intuitive means for monitoring or configuring or later Allen-Bradley drives and communication adapters online. Compatibility: Windows 95, 98, ME, NT 4.0 (Service Pack 3 or later), 2000, XP and CE...

  • Page 113: Product Dimensions

    Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 114 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 115 Aotewell Ltd www.aotewell.com Industry Automation 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 HongKong|UK|China [email protected] +86-755-8660-6182...
  • Page 116 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 117 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 118 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 119 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 120 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 121 Aotewell Ltd www.aotewell.com Industry Automation 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)
  • Page 122 Aotewell Ltd www.aotewell.com Industry Automation 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) HongKong|UK|China [email protected]...
  • Page 123 Aotewell Ltd www.aotewell.com Industry Automation 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) HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 124 Aotewell Ltd www.aotewell.com Industry Automation 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) HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual...

  • Page 125: Network Wiring

    Aotewell Ltd www.aotewell.com Industry Automation Appendix 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 Aotewell Ltd www.aotewell.com Industry Automation RS485 (DSI) Protocol 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

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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.

  • Page 131: Parameters

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation RS485 (DSI) Protocol Notes: HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...

  • Page 133: Connectivity Guidelines

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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"...

  • Page 136: Connecting Two Permanent Peripherals

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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. •...

  • Page 139: Steplogic Using Basic Logic Functions

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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”...

  • Page 142: Counter Function

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 144 Aotewell Ltd www.aotewell.com Industry Automation 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...

  • Page 145: Pid Loop

    Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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

    Aotewell Ltd www.aotewell.com Industry Automation 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.
  • Page 150 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 155 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 156 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 157 Aotewell Ltd www.aotewell.com Industry Automation 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...
  • Page 158 Aotewell Ltd www.aotewell.com Industry Automation Index-4 Notes: HongKong|UK|China [email protected] +86-755-8660-6182 PowerFlex 40 Adjustable Frequency AC Drive FRN 1.xx - 7.xx User Manual Publication 22B-UM001I-EN-E...
  • Page 159 Aotewell Ltd www.aotewell.com Industry Automation HongKong|UK|China [email protected] +86-755-8660-6182...
  • Page 160 Aotewell Ltd www.aotewell.com Industry Automation U.S. Allen-Bradley Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], 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. HongKong|UK|China [email protected]...

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