This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 4 Adjustable Frequency AC Drive.
The information provided Does Not
intended for qualified drive service personnel only.
For detailed PowerFlex 4 information including EMC instructions,
application considerations and related precautions refer to the
PowerFlex 4
supplied with the drive or at
User Manual
, Publication 22A-UM001x on the CD
www.ab.com/manuals/dr.
General Precautions
replace the User Manual and is
ATTENTION:
time to discharge after removal of mains supply. Before working on
!
drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.
Darkened display LEDs is not an indication that capacitors have
discharged to safe voltage levels.
ATTENTION:
if this parameter (A092 [Auto Rstrt Tries], A094 [Start At PowerUp]) is
!
used in an inappropriate application. Do not use this function without
considering applicable local, national and international codes,
standards, regulations or industry guidelines.
ATTENTION:
frequency AC drives and associated machinery should plan or
!
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
ATTENTION:
sensitive parts and assemblies. Static control precautions are required
!
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
The drive contains high voltage capacitors which take
Equipment damage and/or personal injury may result
Only qualified personnel familiar with adjustable
This drive contains ESD (Electrostatic Discharge)
ATTENTION:
component damage or a reduction in product life. Wiring or application
!
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
An incorrectly applied or installed drive can result in
Page 2
English-2
Mounting Considerations
•
Mount the drive upright on a flat, vertical and level surface.
–
Install on 35 mm DIN Rail.
or
–
Install with screws.
Minimum Panel ThicknessScrew SizeMounting Torque
1.9 mm (0.0747 in.)m4 x 0.7 (#8-32)1.56-1.96 Nm (14-17 lb.-in.)
•
Protect the cooling fan by avoiding dust or metallic particles.
UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
HMCP circuit breakers or equivalent.
Protective Features
Motor Protection:
Overcurrent:
Over Voltage:
I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)
200% hardware limit, 300% instantaneous fault
100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)
200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)
380-460V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)
Under Voltage:
100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)
200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line)
380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)
Control Ride Through:
Faultless Power Ride Through:
Minimum ride through is 0.5 Secs - typical value 2 Secs
100 milliseconds
Dynamic Braking
Internal brake IGBT included with all ratings 0.75 kW (1 HP) and larger. Refer to Appendix B of the PowerFlex 4
on CD for ordering information.
(1)
200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N104 to N114.
Switch any two motor leads to
change forward direction.
Power Terminal Block Specifications
FrameMaximum Wire Size
A3.3 mm2 (12 AWG)0.8 mm2 (18 AWG)
2
B5.3 mm
(1)
Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
(10 AWG)
(1)
Minimum Wire Size
2
1.3 mm
(16 AWG)
(1)
V/T2T/L3S/L2R/L1U/T1W/T3
Torque
1.7-2.2 N-m (16-19 lb.-in.)
Input Power Conditions
Input Power ConditionCorrective Action
Low Line Impedance (less than 1% line reactance)
Greater than 120 kVA supply transformer
Line has power factor correction capacitors
Line has frequent power interruptions
Line has intermittent noise spikes in excess of 6000V (lightning)
Phase to ground voltage exceeds 125% of normal line to line voltage
Ungrounded Distribution System
(2)
Refer to Appendix B of the PowerFlex 4
User Manual
on CD for accessory ordering information.
I/O Wiring Recommendations
(3)
•
Install Line Reactor
•
or Isolation Transformer
•
Remove MOV jumper to ground.
•
and Install Isolation Transformer with
grounded secondary if necessary.
(2)
Wire Type(s)DescriptionMinimum Insulation Rating
Belden 8760/9460
(or equiv.)
Belden 8770
(or equiv.)
(3)
If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be
necessary, but is always recommended.
0.8 mm2(18AWG), twisted pair, 100% shield with
drain.
Maximum / minimum that the terminal block will accept - these are not recommendations.
(4)
Minimum Wire Size
(4)
Torque
Refer to the PowerFlex 4
control cable length recommendations
User Manual
on CD for maximum power and
Page 5
Control Terminal Block
English-5
(1)
Important: I/O Terminal 01 is
always a coast to stop input except
when P036 [Start Source] is set to
“3-Wire” control. In three wire
control, I/O Terminal 01 is controlled
by P037 [Stop Mode]. All other stop
sources are controlled by P037
[Stop Mode].
Important: The drive is shipped with
a jumper installed between I/O
Terminals 01 and 11. Remove this
jumper when using I/O Terminal 01
as a stop input.
(2)
Two wire control shown. For three
wire control use a momentary input
on I/O Terminal 02 to
command a start. Use a maintained
input for I/O Terminal 03 to
change direction.
Relay N.O.
Relay Common
Relay N.C.
P036
[Start Source]
KeypadPer P037Coast
3-WirePer P037Per P037
2-WirePer P037Coast
RS485 PortPer P037Coast
R1
R2
R3
Stop
I/O Terminal 01
+24V
+10V
01 02 03 04 05 06
Stop
01
02
03
04
05
06
11
12
13
14
15
16
Refer to the PowerFlex 4
User Manual on CD for
detailed I/O wiring examples.
(1)
Stop
Start/Run FWD
Direction/Run REV
Digital Common
Digital Input 1
Digital Input 2
+24V DC
+10V DC
0-10V In
Analog Common
4-20mA In
RS485 Shield
(2)
Typical
SRC Wiring
Potentiometer
must be
1-10k ohm
2 Watt Min.
Typical
SNK Wiring
30V DC 125V AC 240V AC
R1 R2
Resistive 3.0A3.0A3.0A
Inductive 0.5A0.5A0.5A
R3
SNK
SRC
11 12 13 14 15
(1)
16
RS485
(DSI)
81
No. SignalDefaultDescriptionParam.
R1Relay N.O.FaultNormally open contact for output relay.A055
R2Relay Common–Common for output relay.
R3Relay N.C.FaultNormally closed contact for output relay.A055
Sink/Source DIP SwitchSource (SRC)
01Stop
(1)
Coast
02Star t/Run FWDNot Active
03Direction/Run REVNot Active
04Digital Common–
Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch
setting.
The factory installed jumper or a normally closed input
must be present for the drive to start.
Command comes from the integral keypad by default. To
disable reverse operation, see A095 [Reverse Disable].
(1)
P036
P036, P037
P036, P037,
A095
For digital inputs. Electronically isolated with digital inputs
from analog I/O.
05Digital Input 1Preset Frequencies Program with A051 [Digital In1 Sel].A051
06Digital Input 2Preset Frequencies Program with A052 [Digital In2 Sel].A052
11+24V DC–
12+10V DC–
130-10V In
(3)
Not Active
14Analog Common–
154-20mA In
(3)
Not Active
16RS485 (DSI) Shield–
(3)
Only one analog frequency source may be connected at a time. If more than one reference is connected at the same
Drive supplied power for digital inputs.
Maximum output current is 100mA.
Drive supplied power for 0-10V external potentiometer.
Maximum output current is 15mA.
For external 0-10V input supply
(input impedance = 100k ohm) or potentiometer wiper.
For 0-10V In or 4-20mA In. Electronically isolated with
analog inputs from digital I/O.
For external 4-20mA input supply
(input impedance = 250 ohm).
Ter minal should be connected to safety ground - PE when
using the RS485 (DSI) communications port.
P038
P038
P038
time, an undetermined frequency reference will result.
Page 6
English-6
Prepare For Drive Start-Up
ATTENTION:
following start-up procedures. Some of the voltages present are at
!
incoming line potential. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the procedure
before beginning. If an event does not occur while performing this
procedure,
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.
Power must be applied to the drive to perform the
Do Not Proceed. Remove All Power
including user
Before Applying Power to the Drive
1.
❏
❏
❏
❏
Confirm that all inputs are connected to the correct terminals and are
secure.
2.
Verify that AC line power at the disconnect device is within the rated
value of the drive.
3.
Verify that any digital control power is 24 volts.
4.
Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See page 5 for location.
Important:
❏
5.
Important:
Verify that the Stop input is present or the drive will not start.
The default control scheme is Source (SRC). The Stop
terminal is jumpered (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.
If I/O Terminal 01 is used as a stop input, the jumper
between I/O Terminals 01 and 11 must be removed.
Applying Power to the Drive
6.
❏
❏
Apply AC power and control voltages to the drive.
7.
Familiarize yourself with the integral keypad features (see next page)
before setting any Program Group parameters.
Start, Stop, Direction and Speed Control
Factory default parameter values allow the drive to be controlled from
the integral keypad. No programming is required to start, stop, change
direction and control speed directly from the integral keypad.
Important:
If a fault appears on power up, refer to page 11 for an explanation of the
fault code. For complete troubleshooting information, refer to the
PowerFlex 4
To disable reverse operation, see A095 [Reverse Disable].
User Manual
on the CD supplied with the drive.
Page 7
Integral Keypad
English-7
➋
FAULT
➌
VOLTS
AMPS
HERTZ
➑
➏
➊
RUN
FWD
REV
➍
➐
PROGRAM
➎
➒
No. LEDLED StateDescription
Run/Direction
➊
Status
Alphanumeric
➋
Display
Displayed UnitsSteady RedIndicates the units of the parameter value being displayed.
➌
Program StatusSteady RedIndicates parameter value can be changed.
➍
Fault StatusFlashing RedIndicates drive is faulted.
➎
Pot StatusSteady GreenIndicates potentiometer on Integral Keypad is active.
➏
Start Key Status Steady GreenIndicates Start key on Integral Keypad is active.
➐
Steady RedIndicates drive is running and commanded motor direction.
Flashing RedDrive has been commanded to change direction. Indicates
Steady RedIndicates parameter number, parameter value, or fault code.
Flashing RedSingle digit flashing indicates that digit can be edited.
MenuDescription
Display Group (View Only)
Consists of commonly viewed drive operating
conditions.
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.
actual motor direction while decelerating to zero.
All digits flashing indicates a fault condition.
The Reverse key is also active unless disabled by A095
[Reverse Disable].
No. KeyNameDescription
➑
➒
EscapeBack one step in programming menu.
Cancel a change to a parameter value and exit Program
Mode.
SelectAdvance one step in programming menu.
Select a digit when viewing parameter value.
Up Arrow
Down Arrow
EnterAdvance one step in programming menu.
PotentiometerUsed to control speed of drive. Default is active.
StartUsed to start the drive. Default is active.
ReverseUsed to reverse direction of the drive. Default is active.
StopUsed to stop the drive or clear a fault.
Scroll through groups and parameters.
Increase/decrease the value of a flashing digit.
Save a change to a parameter value.
Controlled by parameter P038.
Controlled by parameter P036.
Controlled by parameters P036 and A095.
This key is always active.
Controlled by parameter P037.
Page 8
English-8
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.
StepKey(s)Example Displays
1. When power is applied, the last user-selected
Display Group parameter number is briefly
displayed with flashing characters. The display
then defaults to that parameter’s current value.
(Example shows the value of d001 [Output
Freq] with the drive stopped.)
FAULTPROGRAM
VOLTS
AMPS
HERTZ
2. Press Esc once to display the Display Group
parameter number shown on power-up. The
parameter number will flash.
3. Press Esc again to enter the group menu. The
group menu letter will flash.
4. Press the Up Arrow or Down Arrow to scroll
through the group menu (d, P and A).
5. Press Enter or Sel to enter a group. The right
digit of the last viewed parameter in that group
will flash.
6. Press the Up Arrow or Down Arrow to scroll
through the parameters that are in the group.
7. Press Enter or Sel to view the value of a
parameter. If you do not want to edit the value,
press Esc to return to the parameter number.
8. Press Enter or Sel to enter program mode to
edit the parameter value. The right digit will
flash and the Program LED will illuminate if the
parameter can be edited.
or
or
or
or
or
VOLTS
AMPS
HERTZ
FAULTPROGRAM
VOLTS
AMPS
HERTZ
FAULTPROGRAM
VOLTS
AMPS
HERTZ
FAULTPROGRAM
VOLTS
AMPS
HERTZ
FAULTPROGRAM
VOLTS
AMPS
HERTZ
FAULTPROGRAM
9. Press the Up Arrow or Down Arrow to change
the parameter value. If desired, press Sel to
move from digit to digit or bit to bit. The digit or
bit that you can change will flash.
10. Press Esc to cancel a change. The digit will
stop flashing, the previous value is restored and
the Program LED will turn off.
Or
Press Enter to save a change. The digit will stop
flashing and the Program LED will turn off.
11. Press Esc to return to the parameter list.
Continue to press Esc to back out of the
programming menu.
If pressing Esc does not change the display,
then d001 [Output Frequency] is displayed.
Press Enter or Sel to enter the group menu.
or
VOLTS
AMPS
HERTZ
FAULTPROGRAM
VOLTS
AMPS
HERTZ
FAULTPROGRAM
Page 9
See the PowerFlex 4 User Manual on CD for more information on parameters.
English-9
Smart Start-Up with Basic Program Group Parameters
The PowerFlex 4 is designed so that start up is simple and efficient. The Program Group
contains the most commonly used parameters.
= Stop drive before changing this parameter.
No.ParameterMin/MaxDisplay/OptionsDefault
P031 [Motor NP Volts]20/Drive Rated Volts1 VACBased on Drive Rating
Set to the motor nameplate rated volts.
P032 [Motor NP Hertz]10/240 Hz1 Hz60 Hz
Set to the motor nameplate rated frequency.
P033 [Motor OL Current]0.0/(Drive Rated Amps×2) 0.1 AmpsBased on Drive Rating
Set to the maximum allowable motor current.
P034 [Minimum Freq]0.0/240.0 Hz0.1 Hz0.0 Hz
Sets the lowest frequency the drive will output
continuously.
P035 [Maximum Freq]0/240 Hz1 Hz60 Hz
Sets the highest frequency the drive will output.
P036 [Start Source]0/50 = “Keypad”
Sets the control scheme used to start the drive.
(1)
When active, the Reverse key is also active
unless disabled by A095 [Reverse Disable].
P037 [Stop Mode]0/70 = “Ramp, Clear Fault”
Active stop mode for all stop sources [e.g. keypad,
run forward (I/O Terminal 02), run reverse (I/O
Ter minal 03), RS485 port] except as noted below.
Important: I/O Terminal 01 is always a coast to
stop input except when P036 [Start Source] is set
for “3-Wire” control. When in three wire control, I/O
Ter minal 01 is controlled by P037 [Stop Mode].
Sets the source of the speed reference to the
drive.
Important: When A051 or A052 [Digital Inx Sel] is
set to option 2, 4, 5 or 6, and the digital input is
active, A051 or A052 will override the speed
reference commanded by this parameter. Refer to
Chapter 1 of the PowerFlex 4 User Manual on CD
for details.
P039 [Accel Time 1]0.0/600.0 Secs0.1 Secs10.0 Secs
Sets the rate of accel for all speed increases.
P040 [Decel Time 1]0.1/600.0 Secs0.1 Secs10.0 Secs
To clear a fault, press the Stop key, cycle power or set A100 [Fault Clear] to 1 or 2.
No.FaultDescription
F2Auxiliary Input
F3Power LossMonitor the incoming AC line for low voltage or line power interruption.
F4UnderVoltage
F5OverVoltage
F6Motor Stalled
F7Motor Overload
F8Heatsink OvrTmp
F12HW OverCurrent
F13Ground FaultCheck the motor and external wiring to the drive output terminals for a grounded condition.
F33Auto Rstrt TriesCorrect the cause of the fault and manually clear.
F38Phase U to GndCheck the wiring between the drive and motor. Check motor for grounded phase.
F39Phase V to Gnd
F40Phase W to Gnd
F41Phase UV ShortCheck the motor and drive output terminal wiring for a shorted condition.
F42Phase UW Short
F43Phase VW Short
F48Params DefaultedThe drive was commanded to write default values to EEPROM. Clear the fault or cycle power to
F63SW OverCurrent
F64Drive OverloadReduce load or extend Accel Time.
F70Power UnitCycle power. Replace drive if fault cannot be cleared.
F81Comm LossIf adapter was not intentionally disconnected, check wiring to the por t. Replace wiring, port
F100 Parameter Checksum Restore factory defaults.
F122 I/O Board FailCycle power. Replace drive if fault cannot be cleared.
(1)
Auto-Reset/Run type fault. Configure with parameters A092 and A093.
(1)
Check remote wiring.
(1)
(1)
Monitor the incoming AC line for low voltage or line power interruption.
Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be
caused by motor regeneration. Extend the decel time or install dynamic brake option.
(1)
Increase [Accel Time x] or reduce load so drive output current does not exceed the current set
by parameter A089 [Current Limit].
(1)
An excessive motor load exists. Reduce load so drive output current does not exceed the
current set by parameter P033 [Motor OL Current].
(1)
Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded
40°C (104°F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for Open type installations.
Check fan.
(1)
Check programming. Check for excess load, improper DC boost setting, DC brake volts set too
high or other causes of excess current.
Replace drive if fault cannot be cleared.
Replace drive if fault cannot be cleared.
the drive. Program the drive parameters as needed.
(1)
Check load requirements and A098 [SW Current Trip] setting.
expander, adapters or complete drive as required. Check connection. An adapter was
intentionally disconnected. Turn off using A105 [Comm Loss Action].
Page 12
English-12
T
Drive Dimensions
Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).