Allen-Bradley PowerFlex 4 User guide

Adjustable
Frequency AC
Drive

FRN 7.xx

www.abpowerflex.com

User Manual

Important User Information

Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety
considerations.

WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and

understanding of the product.

ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:

 identify a hazard
 avoid the hazard
 recognize the consequences

Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.

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.

PowerFlex is a registered trademark of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.

PLC is a registered trademark of Rockwell Automation, Inc.

Summary of Changes

The information below summarizes changes made for the July 2017
PowerFlex 4 User Manual, Publication 22A-UM001K-EN-E.

Description of New or Updated Information See Page(s)

Line fuse footnote added to Fuse Rating column.

Low Voltage Directive updated. 1-20

Attention statement on Option 3 “2-W Lvl Sens” and Important statement
about Option 4 “2-W Hi Speed” added to parameter P036 [Start Source].

Specifications table Approvals column updated. A-2

Sound Pressure Level specification added. A-3

Product Environmental Information added. A-4

Dynamic Brake Fuse Rating column and new footnote added. B-2

Network Wiring topic updated. C-1

The information below summarizes changes made for the June 2013
PowerFlex 4 User Manual, Publication 22A-UM001J-EN-E.

1-7

3-9

Description of New or Updated Information See Page(s)

Minimum Enclosure Volume column and new footnotes added.

Drive, Fuse & Circuit Breaker Ratings topic updated. A-1

Electronic Motor Overload Protection description updated. A-3

1-7, A-2

The information below summarizes changes made for the September
2010 PowerFlex 4 User Manual, Publication 22A-UM001I-EN-E.

Description of New or Updated Information See Page(s)

Parameters A117 [Bus Reg Mode] and A118 [Comm Write Mode] added.

3-13

The information below summarizes changes made for the July 2010
PowerFlex 4 User Manual, Publication 22A-UM001H-EN-E.

Description of New or Updated Information See Page(s)

Start and Speed Reference Control 1-18

The information below summarizes changes made for the March 2007
PowerFlex 4 User Manual, Publication 22A-UM001G-EN-E.

Description of New or Updated Information See Page(s)

Minimum Mounting Clearances clarified.

Footnote (2) on Bulletin 140M catalog edited. 1-7

Graphic for Analog Input, PTC wiring example corrected. 1-14

1-2

soc-2

Description of New or Updated Information See Page(s)

Stop Drive icon and related warning text removed for parameter
A110 [Anlg In 0-10V Lo].

New information on reading register address 8192 added. C-4

New information on reading register address 8193 added. C-5

3-25

The information below summarizes changes made for the September
2005 PowerFlex 4 User Manual, Publication 22A-UM001F-EN-E.

Description of New or Updated Information See Page(s)

Attention statement clarified.

240V AC – 3-Phase 3.7 kW (5.0 Hp) drive fuse rating revised to 30 amps. 1-7, A-2

Analog Input, PTC wiring example added. 1-14

Attention statement added to Multiple Digital Input Connections wiring
example.

Parameter P043 [Motor OL Ret] added. 3-12

Attention statement added to parameter A082 [DB Resistor Sel]. 3-18

External Comm Options, Compact I/O added to Ta b le B. G . B-4

Modbus function code 16 added. C-3

1-3

1-17

Preface Overview

Chapter 1 Installation/Wiring

Chapter 2 Start Up

Table of Contents

Who Should Use this Manual? . . . . . . . . . P-1

Reference Materials . . . . . . . . . . . . . . . . . P-1

Manual Conventions . . . . . . . . . . . . . . . . . P-2

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2

General Precautions . . . . . . . . . . . . . . . . . P-3

Catalog Number Explanation . . . . . . . . . . P-4

Opening the Cover . . . . . . . . . . . . . . . . . . 1-1

Mounting Considerations . . . . . . . . . . . . . 1-2

AC Supply Source Considerations . . . . . . 1-3

General Grounding Requirements . . . . . . 1-4

Fuses and Circuit Breakers . . . . . . . . . . . . 1-6

Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-8

I/O Wiring Recommendations . . . . . . . . 1-11

Start and Speed Reference Control . . . . . 1-18

EMC Instructions . . . . . . . . . . . . . . . . . . 1-20

Prepare For Drive Start-Up . . . . . . . . . . . . 2-1

Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3

Viewing and Editing Parameters. . . . . . . . 2-4

Chapter 3 Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . 3-1

Parameter Organization. . . . . . . . . . . . . . . 3-2

Display Group . . . . . . . . . . . . . . . . . . . . . . 3-3

Basic Program Group . . . . . . . . . . . . . . . . 3-8

Advanced Program Group. . . . . . . . . . . . 3-13

Parameter Cross Reference – by Name. . 3-27

Chapter 4 Troubleshooting

Drive Status. . . . . . . . . . . . . . . . . . . . . . . . 4-1

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3

Common Symptoms and Corrective Actions . .

4-5

Appendix A Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings . . . A-1

Specifications . . . . . . . . . . . . . . . . . . . . . . A-2

Product Environmental Information . . . . . A-4

Appendix B Accessories and Dimensions

Product Selection . . . . . . . . . . . . . . . . . . . B-1

Product Dimensions . . . . . . . . . . . . . . . . . B-5

ii

Appendix C RS485 (DSI) Protocol

Network Wiring . . . . . . . . . . . . . . . . . . . . . C-1

Parameter Configuration . . . . . . . . . . . . . . C-3

Supported Modbus Function Codes . . . . . C-3

Writing (06) Logic Command Data. . . . . . C-4

Writing (06) Reference . . . . . . . . . . . . . . . C-5

Reading (03) Logic Status Data. . . . . . . . . C-5

Reading (03) Feedback . . . . . . . . . . . . . . . C-5

Reading (03) Drive Error Codes . . . . . . . . C-6

Reading (03) and Writing (06) Drive

Additional Information . . . . . . . . . . . . . . . C-6

Appendix D RJ45 DSI Splitter Cable

Connectivity Guidelines . . . . . . . . . . . . . . D-1

DSI Cable Accessories . . . . . . . . . . . . . . . D-2

Connecting an RS-485 Network . . . . . . . . D-3

Index

Parameters . . . . . . . . . . . . . . . . . . . . . . C-6

Preface

Overview

The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 4 Adjustable
Frequency AC Drive.

For information on… See page…

Who Should Use this Manual? P-1

Reference Materials P-1

Manual Conventions P-2

Drive Frame Sizes P-2

General Precautions P-3

Catalog Number Explanation P-4

Who Should Use this Manual?

This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.

Reference Materials

The following manuals are recommended for general drive information:

Title Publication Available Online at …

Wiring and Grounding
Guidelines for Pulse Width
Modulated (PWM) AC Drives

Preventive Maintenance of
Industrial Control and Drive
System Equipment

Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control

A Global Reference Guide for
Reading Schematic Diagrams

Guarding Against Electrostatic
Damage

DRIVES-IN001…

DRIVES-SB001…

SGI-1.1

0100-2.10

8000-4.5.2

www.rockwellautomation.com/
literature

P-P-2 Overview

Manual Conventions

 In this manual we refer to the PowerFlex 4 Adjustable Frequency AC

Drive as: drive, PowerFlex 4 or PowerFlex 4 Drive.

 Parameter numbers and names are shown in this format:

P031 [Motor NP Volts]

 The following words are used throughout the manual to describe an

action:

Name

Number

Group

d = Display Group
P = Basic Program Group
A = Advanced Program Group

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not Recommended

Drive Frame Sizes

Similar PowerFlex 4 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in

Appendix B.

Overview P-3

!

!

!

!

!

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)]. 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: Only qualified personnel familiar with adjustable
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: This drive contains ESD (Electrostatic Discharge)
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.

ATTENTION: An incorrectly applied or installed drive can result in
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.

ATTENTION: The bus regulator function is extremely useful for
preventing nuisance overvoltage faults resulting from aggressive
decelerations, overhauling loads, and eccentric loads. However, it can
also cause either of the following two conditions to occur.

1. Fast positive changes in input voltage or imbalanced input voltages
can cause uncommanded positive speed changes;

2. Actual deceleration times can be longer than commanded
deceleration times
However, a “Stall Fault” is generated if the drive remains in this state
for 1 minute. If this condition is unacceptable, the bus regulator must be
disabled (see parameter
dynamic brake resistor will provide equal or better performance in most
cases.

). In addition, installing a properly sized

A117

P-P-4 Overview

Code Volt age Ph.

V 120V AC 1
A 240V AC 1
B 240V AC 3
D 480V AC 3

Code

Version

3 No Brake IGBT
4 Standard

Code

Interface Module

1 Fixed Keypad

Code

Enclosure

N Panel Mount - IP 20 (NEMA Type Open)
F Flange Mount - IP 20 (NEMA Type Open)
H Replacement Plate Drive - IP 20 (NEMA Type Open)

- Contact factory for ordering information.

1-3 4 5 6-8 9 10 11 12

(1)

13-14

22A - A 1P5 N 1 1 4 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional

Output Current @ 100-120V Input

Code Amps kW (HP)

1P5 1.5 0.2 (0.25)
2P3 2.3 0.4 (0.5)
4P5 4.5 0.75 (1.0)
6P0 6.0 1.1 (1.5)

Code Rating

0 Not Filtered
1Filtered

Code

22A PowerFlex 4

Code Purpose

AA Reserved for
thru custom firmware
ZZ

Output Current @ 200-240V Input, NO BRAKE

Code Amps kW (HP)

1P4 1.4 0.2 (0.25)
2P1 2.1 0.4 (0.5)
3P6 3.6 0.75 (1.0)
6P8 6.8 1.5 (2.0)
9P6 9.6 2.2 (3.0)

Output Current @ 380-480V Input

Code Amps kW (HP)

1P4 1.4 0.4 (0.5)
2P3 2.3 0.75 (1.0)
4P0 4.0 1.5 (2.0)
6P0 6.0 2.2 (3.0)
8P7 8.7 3.7 (5.0)

Output Current @ 200-240V Input

Code Amps kW (HP)

1P5 1.5 0.2 (0.25)
2P3 2.3 0.4 (0.5)
4P5 4.5 0.75 (1.0)
8P0 8.0 1.5 (2.0)
012 12.0 2.2 (3.0)
017 17.5 3.7 (5.0)

(1)

Position 12 of the Catalog Number now indicates drive type. All PowerFlex 4 drives
are equipped with RS485 communication.

Catalog Number Explanation

Chapter 1

!

Installation/Wiring

This chapter provides information on mounting and wiring the
PowerFlex 4 Drive.

For information on… See page For information on… See page

Opening the Cover 1-1 Fuses and Circuit Breakers 1-6

Mounting Considerations 1-2 Power Wiring 1-8

AC Supply Source Considerations 1-3 I/O Wiring

Recommendations

General Grounding Requirements 1-4 EMC Instructions 1-20

Most start-up difficulties are the result of incorrect wiring. Every
precaution must be taken to assure that the wiring is done as instructed.
All items must be read and understood before the actual installation
begins.

1-11

ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation, Inc. cannot assume responsibility
for the compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated
equipment. A hazard of personal injury and/or equipment damage
exists if codes are ignored during installation.

Opening the Cover

1. Press and hold in the tabs on each side of the cover.

2. Pull the cover out and up to release.

1-2 Installation/Wiring

Mounting Option A

No clearance required between drives.

Mounting Option B

Closest object that

may restrict air flow

through the drive heat

sink and chassis

Mounting Considerations

 Mount the drive upright on a flat, vertical and level surface.

– Install on 35 mm DIN Rail.

or

– Install with screws.

Table 1.A Screw Mounting Recommendations

Minimum Panel Thickness Screw Size Mounting Torque

1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.)

 Protect the cooling fan by avoiding dust or metallic particles.
 Do not expose to a corrosive atmosphere.
 Protect from moisture and direct sunlight.

Minimum Mounting Clearances

Refer to

Appendix B for mounting dimensions.

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

25 mm

(1.0 in.)

Ambient Operating Temperatures

Table 1.B Enclosure and Clearance Requirements

Ambient Temperature Enclosure Rating Minimum Mounting

Minimum Maximum

-10°C (14°F)

(1)

Rating requires installation of the PowerFlex 4 IP 30/NEMA 1/UL Type 1 option kit.

40°C (104°F)

50°C (122°F) IP 20/Open Type Use Mounting Option B

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 IP 20/Open Type applications.

Clearances

IP 20/Open Type Use Mounting Option A

(1)

IP 30/NEMA 1/UL Type 1

Use Mounting Option B

Installation/Wiring 1-3

!

Important:

Tighten screw after
jumper removal.

Storage

 Store within an ambient temperature range of -40° to +85°C.
 Store within a relative humidity range of 0% to 95%,

non-condensing.

 Do not expose to a corrosive atmosphere.

AC Supply Source Considerations

Ungrounded Distribution Systems

ATTENTION: PowerFlex 4 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
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the Figures

1.1 and 1.2.

1. Turn the screw counterclockwise to loosen.

2. Pull the jumper completely out of the drive chassis.

3. Tighten the screw to keep it in place.

Figure 1.1 Jumper Location (A Frame Shown)

Figure 1.2 Phase to Ground MOV Removal

Three-Phase

AC Input

R/L1

S/L2

T/L3

Jumper

1234

1-4 Installation/Wiring

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated
voltage of the drive (see
input power conditions which may cause component damage or
reduction in product life. If any of the conditions exist, as described in

Table 1.C, install one of the devices listed under the heading Corrective

Action on the line side of the drive.

Important: Only one device per branch circuit is required. It should be

mounted closest to the branch and sized to handle the total
current of the branch circuit.

Table 1.C Input Power Conditions

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance)  Install Line Reactor

Greater than 120 kVA supply transformer

Appendix A). Listed in Table 1.C are certain

(1)

 or Isolation 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

(1)

Refer to

Appendix B for accessory ordering information.

 Remove MOV jumper to ground.
 or Install Isolation Transformer

with grounded secondary if
necessary.

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

S/L2

T/L3

U/T1
V/T2

W/T3

SHLD

Installation/Wiring 1-5

Ground Fault Monitoring

If a system ground fault monitor (RCD) is to be used, only Type B
(adjustable) devices should be used to avoid nuisance tripping.

Safety Ground - (PE)

This is the safety ground for the drive that is required by code. One of
these points must be connected to adjacent building steel (girder, joist), a
floor ground rod or bus bar. Grounding points must comply with
national and local industrial safety regulations and/or electrical codes.

Motor Ground

The motor ground must be connected to one of the ground terminals on
the drive.

Shield Termination - SHLD

Either of the safety ground terminals located on the power terminal
block provides a grounding point for the motor cable shield. The motor
cable shield connected to one of these terminals (drive end) should also
be connected to the motor frame (motor end). Use a shield terminating or
EMI clamp to connect the shield to the safety ground terminal. The
conduit box option may be used with a cable clamp for a grounding point
for the cable shield.

When shielded cable is used for control and signal wiring, the shield
should be grounded at the source end only, not at the drive end.

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. Ensure

that the incoming supply neutral is solidly connected (bonded) to the
same building power distribution ground. Grounding must not rely on
flexible cables and should not include any form of plug or socket that
would permit inadvertent disconnection. Some local codes may require
redundant ground connections. The integrity of all connections should
be periodically checked.

1-6 Installation/Wiring

!

Fuses and Circuit Breakers

The PowerFlex 4 does not provide branch short circuit protection. This
product should be installed with either input fuses or an input circuit
breaker. National and local industrial safety regulations and/or electrical
codes may determine additional requirements for these installations.

ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in this section.

Fusing

The PowerFlex 4 has been UL tested and approved for use with input
fuses. The ratings in the table that follows are the minimum
recommended values for use with each drive rating. The devices listed in
this table are provided to serve as a guide.

Bulletin 140M (Self-Protected Combination Controller)/UL489
Circuit Breakers

When using Bulletin 140M or UL489 rated circuit breakers, the
guidelines listed below must be followed in order to meet the NEC
requirements for branch circuit protection.

 Bulletin 140M can be used in single and group motor applications.
 Bulletin 140M can be used up stream from the drive without the

need for fuses.

Installation/Wiring 1-7

Table 1.D Minimum Recommended Branch Circuit Protective Devices

Voltage
Rating

120V AC –
1-Phase

240V AC –
1-Phase
NO BRAKE

240V AC –
1-Phase

240V AC –
3-Phase

Drive Rating

kW (HP)

0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

Fuse Rating

Amps
(Line Fuse)

10
15
30
40

6
10
15
25
30

10
10
15
30

3
6
10
15
25
30

(1)

140M

Catalog No.

(2)

140M-C2E-C10
140M-C2E-C16
140M-D8E-C20
140M-F8E-C32

140M-C2E-B40
140M-C2E-B63
140M-C2E-C16
140M-C2E-C16
140M-D8E-C25

140M-C2E-B63
140M-C2E-B63
140M-C2E-C16
140M-D8E-C20

140M-C2E-B25
140M-C2E-B40
140M-C2E-C10
140M-C2E-C16
140M-C2E-C16
140M-F8E-C25

(3) (4)

Recommended
MCS Contactors

Catalog No.

100-C09
100-C12
100-C23
100-C37

100-C09
100-C09
100-C12
100-C16
100-C23

100-C09
100-C09
100-C12
100-C23

100-C09
100-C09
100-C09
100-C12
100-C16
100-C23

Min. Enclosure
Volum e

Inches

(5)

3

1655
1655
1655
1655

1655
1655
1655
1655
1655

1655
1655
1655
1655

1655
1655
1655
1655
1655
1655

480V AC –
3-Phase

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

(1)

Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.

(2)

EN61800-5-1 compliance

3
6
10
15
15

140M-C2E-B25
140M-C2E-B40
140M-C2E-B63
140M-C2E-C10
140M-C2E-C16

100-C09
100-C09
100-C09
100-C09
100-C16

1655
1655
1655
1655
1655

When using a dynamic brake resistor, the guidelines listed below must be followed.
– Only use input fuse UL Class T 600V or equivalent for branch circuit protection.
– Connect a series fuse, type PV 1000V fast-acting or equivalent, with the dynamic brake resistor.
– Recommended fuse rating is listed in

(3)

The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See

Tab l e B .C .

Bulletin 140M

Motor Protection Circuit Breakers Application Ratings.

(4)

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.

(5)

When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be
installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this
column. Application specific thermal considerations may require a larger enclosure.

1-8 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. Failure to do so may result in personal injury and/or equipment
damage.

ATTENTION: To avoid a possible shock hazard caused by induced
voltages, unused wires in the conduit must be grounded at both ends.
For the same reason, if a drive sharing a conduit is being serviced or
installed, all drives using this conduit should be disabled. This will help
minimize the possible shock hazard from “cross coupled” power leads.

Motor Cable Types Acceptable for 200-600 Volt Installations

General

A variety of cable types are acceptable for drive installations. For many
installations, unshielded cable is adequate, provided it can be separated
from sensitive circuits. As an approximate guide, allow a spacing of 0.3
meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases,
long parallel runs must be avoided. Do not use cable with an insulation
thickness less than 15 mils (0.4 mm/0.015 in.). Do not route more than
three sets of motor leads in a single conduit to minimize “cross talk”. If
more than three drive/motor connections per conduit are required,
shielded cable must be used.
UL installations in 50°C ambient must use 600V, 75°C or 90°C wire.
UL installations in 40°C ambient should use 600V, 75°C or 90°C wire.
Use copper wire only. Wire gauge requirements and recommendations
are based on 75 degree C. Do not reduce wire gauge when using higher
temperature wire.

Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry
environments provided adequate free air space and/or conduit fill rates
limits are provided. Do not use THHN or similarly coated wire in wet
areas. Any wire chosen must have a minimum insulation thickness of
15 mils and should not have large variations in insulation concentricity.

Shielded

Location Rating/Type Description

Standard
(Option 1)

Standard
(Option 2)

Class I & II;
Division I & II

600V, 75°C or 90°C (167°F
or 194°F) RHH/RHW-2

Belden 29501-29507 or
equivalent

Tray rated 600V, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2

Shawflex 2ACD/3ACD or
equivalent

Tray rated 600V, 75°C or
90°C (167°F or 194°F)
RHH/RHW-2

 Four tinned copper conductors with XLPE insulation
 Foil shield and tinned copper drain wire with 85% braid

coverage

 PVC jacket
 Three tinned copper conductors with XLPE insulation
 5 mil single helical copper tape (25% overlap min.)

with three bare copper grounds in contact with shield

 PVC jacket

 Three tinned copper conductors with XLPE insulation
 5 mil single helical copper tape (25% overlap min.)

with three bare copper grounds in contact with shield

 PVC copper grounds on #10 AWG and smaller

Installation/Wiring 1-9

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). See

The reflected wave data applies to all frequencies 2 to 16 kHz.

For 240V ratings, reflected wave effects do not need to be considered.

Table 1.E Maximum Cable Length Recommendations

Reflected Wave

380-480V Ratings Motor Insulation Rating Motor Cable Only

Table 1.E for recommendations.

(1)

1000 Vp-p 15 meters (49 feet)

1200 Vp-p 40 meters (131 feet)

1600 Vp-p 170 meters (558 feet)

(1)

Longer cable lengths can be achieved by installing devices on the output of the drive.
Consult factory for recommendations.

Output Disconnect

The drive is intended to be commanded by control input signals that will
start and stop the motor. A device that routinely disconnects then
reapplies output power to the motor for the purpose of starting and
stopping the motor should not be used. If it is necessary to disconnect
power to the motor with the drive outputting power, an auxiliary contact
should be used to simultaneously disable drive control run commands.

1-10 Installation/Wiring

V/T2T/L3S/L2R/L1 U/T1 W/T3

BR+ BR-

Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. 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 (A Frame Shown)

Terminal Description

R/L1, S/L2 1-Phase Input

R/L1, S/L2, T/L3 3-Phase Input

U/T1 To Motor U/T1

V/T2 To Motor V/T2

W/T3 To Motor W/T3

=

Switch any two motor
leads to change
forward direction.

BR+, BR- Dynamic Brake Resistor Connection

Safety Ground - PE

Table 1.F Power Terminal Block Specifications

Frame Maximum Wire Size

(1)

Minimum Wire Size

(1)

Torq ue

A 3.3 mm2 (12 AWG) 0.8 mm2 (18 AWG)

B 5.3 mm

(1)

Maximum/minimum sizes that the terminal block will accept - these are not

2

(10 AWG) 1.3 mm2 (16 AWG)

1.7-2.2 N-m (16-19 lb.-in.)

recommendations.

Installation/Wiring 1-11

!

!

!

I/O Wiring Recommendations

Motor Start/Stop Precautions

ATTENTION: A contactor or other device that routinely disconnects
and reapplies the AC line to the drive to start and stop the motor can
cause drive hardware damage. The drive is designed to use control input
signals that will start and stop the motor. If used, the input device must
not exceed one operation per minute or drive damage can occur.

ATTENTION: The drive start/stop control circuitry includes
solid-state components. If hazards due to accidental contact with
moving machinery or unintentional flow of liquid, gas or solids exist,
an additional hardwired stop circuit may be required to remove the AC
line to the drive. When the AC line is removed, there will be a loss of
any inherent regenerative braking effect that might be present - the
motor will coast to a stop. An auxiliary braking method may be
required.

Important points to remember about I/O wiring:

 Always use copper wire.
 Wire with an insulation rating of 600V or greater is recommended.
 Control and signal wires should be separated from power wires by at

least 0.3 meters (1 foot).

Important: I/O terminals labeled “Common” are

safety ground (PE) terminal and are designed to greatly
reduce common mode interference.

ATTENTION: Driving the 4-20mA analog input from a voltage
source could cause component damage. Verify proper configuration
prior to applying input signals.

not referenced to the

1-12 Installation/Wiring

Control Wire Types

Table 1.G Recommended Control and Signal Wire

Wire Type(s) Description Minimum

Belden 8760/9460
(or equiv.)

Belden 8770
(or equiv.)

(1)

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.

0.8 mm2(18AWG), 3 conductor, shielded for
remote pot only.

(1)

(1)

Insulation Rating

300V
60 degrees C
(140 degrees F)

I/O Terminal Block

Table 1.H I/O Terminal Block Specifications

Maximum Wire Size

1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

(1)

Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.

(1)

Minimum Wire Size

(1)

Torque

Maximum Control Wire Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control
signal cable length is highly dependent on electrical environment and
installation practices. To improve noise immunity, the I/O terminal
block Common must be connected to ground terminal/protective earth.
If using the RS485 (DSI) port, I/O Terminal 16 should also be connected
to ground terminal/protective earth.

Figure 1.5 Control Wiring Block Diagram

01

02

03

04

05

06

11

12

13

14

15

16

Stop

(1)

Start/Run FWD

(2)

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

R1

R2

R3

Relay N.O.

Relay Common

Relay N.C.

+24V DC

+10V DC

0-10V In

Analog Common

4-20mA In

RS485 Shield

+24V

+10V

SRCSNK

Typical

SNK Wiring

Typical

SRC Wiring

18

RS485

(DSI)

R1 R2 R3

01 02 03 04 05 06

11 12 13 14 15 16

SNK

SRC

(1)

Potentiometer
must be
1-10k ohm
2 Watt Min.

30V DC 125V AC 240V AC

Resistive 3.0A 3.0A 3.0A

Inductive 0.5A 0.5A 0.5A

(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 or enable 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.

P036

[Start Source]

Stop

I/O Terminal 01

Stop

Keypad Per P037 Coast

3-Wire Per P037 Per P037

2-Wire Per P037 Coast

RS485 Port Per P037 Coast

Installation/Wiring 1-13

No. Signal Default Description Param.

R1 Relay N.O. Fault Normally open contact for output relay.

R2 Relay Common – Common for output relay.

R3 Relay N.C. Fault Normally closed contact for output relay. A055

Sink/Source DIP Switch Source (SRC)

01 Stop

02 Start/Run FWD Not Active

03 Direction/Run REV Not Active

04 Digital Common –

05 Digital Input 1 Preset Freq Program with A051 [Digital In1 Sel].

06 Digital Input 2 Preset Freq Program with A052 [Digital In2 Sel]. A052

11 +24V DC –

12 +10V DC –

13 0-10V In

14 Analog Common –

15 4-20mA In

16 RS485 (DSI) Shield –

(3)

(1)

(3)

(3)

Only one analog frequency source may be connected at a time. If more than one reference is connected at the same
time, an undetermined frequency reference will result.

Coast

Not Active

Not Active

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].

For digital inputs. Electronically isolated with digital inputs
from analog I/O.

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).

Terminal should be connected to safety ground - PE
when using the RS485 (DSI) communications por t.

A055

P036

P036, P037

P036, P037,
A095

A051

P038

P038

P038

(1)

1-14 Installation/Wiring

13

14

+

Common

I/O Wiring Examples

Input Connection Example

Potentiometer

1-10k Ohm Pot.
Recommended
(2 Watt minimum)

P038 [Speed Reference] = 2 “0-10V Input”

12

13

14

Analog Input

0 to +10V, 100k ohm
impedance

4-20 mA, 100 ohm
impedance

Analog Input, PTC

For Drive Fault

Voltage

P038 [Speed Reference] = 2 “0-10V

Input”

Current

P038 [Speed Reference] = 3

“4-20mA Input”

Common

14

15

+

Wire the PTC and External Resistor (typically matched to the PTC Hot
Resistance) to I/O Terminals 12, 13, 14.

Wire R2/R3 Relay Output (SRC) to I/O Terminals 5 & 11.

A051

[Digital In1 Sel] = 3 “Aux Fault”

A055 [Relay Out Sel] = 10 “Above Anlg V”

A056 [Relay Out Level] = % Voltage Trip

R2
R3

11

R

e

R

PTC

12
13
14

05

R

=

PTC (hot)

R

PTC (hot)

+ R

×

100

e

V

Tr ip

Input Connection Example

11

01

02

Stop-Run

Each digital input draws 6 mA.

01
02

04

Stop-Run

11

01
02
03

Stop-Run

Forward

Stop-Run

Reverse

Common

01
02
03
04

Stop-Run

Forward

Stop-Run

Reverse

+24V

Each digital input draws 6 mA.

Stop-Run

Forward

Stop-Run

Reverse

01
02
03
04

2 Wire SRC Control -

Internal Supply (SRC) External Supply (SRC)

Non-Reversing

P036

[Start Source] = 2, 3

or 4

Input must be active for
the drive to run. When
input is opened, the drive
will stop as specified by

P037 [Stop Mode].

If desired, a User Supplied
24V DC power source can
be used. Refer to the
“External Supply (SRC)”
example.

2 Wire SNK Control -

Internal Supply (SNK)

Non-Reversing

Installation/Wiring 1-15

01

02

Stop-Run

04

+24V Common

2 Wire SRC Control ­Run FWD/Run REV

P036 [Start Source] = 2, 3

or 4

Input must be active for
the drive to run. When
input is opened, the drive
will stop as specified by

P037 [Stop Mode].

If both Run Forward and
Run Reverse inputs are
closed at the same time,
an undetermined state
could occur.

2 Wire SNK Control ­Run FWD/Run REV

Internal Supply (SRC) External Supply (SRC)

Internal Supply (SNK)

1-16 Installation/Wiring

Each digital input draws 6 mA.

Stop

Start

01
02
03
04

11

01
02
03

Stop

Start

Direction

+24V Common

Stop

Start

Direction

01
02
03
04

Each digital input draws 6 mA.

Stop

Start

Direction

01
02
03
04

Input Connection Example

3 Wire SRC Control ­Non-Reversing

P036

[Start Source] = 1

A momentary input will
start the drive. A stop
input to I/O Terminal 01
will stop the drive as
specified by

P037

[Stop

Mode].

Internal Supply (SRC) External Supply (SRC)

Stop

11

Start

+24V

Stop

Start

Common

01

02

04

01

02

3 Wire SNK Control ­Non-Reversing

3 Wire SRC Control ­Reversing

P036 [Start Source] = 1

A momentary input will
start the drive. A stop
input to I/O Terminal 01
will stop the drive as
specified by

P037 [Stop

Mode]. I/O Terminal 03
determines direction.

Internal Supply (SNK)

Internal Supply (SRC) External Supply (SRC)

3 Wire SNK Control ­Reversing

Internal Supply (SNK)

Typical Multiple Drive Connection Examples

!

ATTENTION: I/O Common terminals should not be tied

together when using SNK (Internal Supply) mode. In SNK

mode, if power is removed from one drive, inadvertent operation

of other drives that share the same I/O Common connection

may occur.

Input Connection Example

Multiple Digital
Input Connections

Customer Inputs can
be wired per
External Supply
(SRC) or Internal
Supply (SNK)
examples on

page 1-15.

Customer Inputs

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. If they are to be tied into another common (such as earth ground
or separate apparatus ground) only one point of the daisy chain of I/O Terminal
04 should be connected.

04

02 0402 0402 0402

Installation/Wiring 1-17

Optional Ground Connection

Multiple Analog
Connections

12 13 14 13 14 13 14 13 14

Remote Potentiometer Optional Ground Connection

When connecting a single potentiometer to multiple drives it is important to
connect I/O Terminal 14 common together for all drives. I/O Terminal 14
common and I/O Terminal 13 (potentiometer wiper) should be daisy-chained to
each drive. All drives must be powered up for the analog signal to be read
correctly.

1-18 Installation/Wiring

Jog Input

Enabled and Active:

A051 or A052 = 2

Ye s

Drive will Start and Run at

Jog Speed.

Direction comes from

Terminal 03 Dir/Run REV

Local/Remote Input

Enabled and Active:

A051 or A052 = 5

Ye s

Start, Speed and Direction commands

come from Integral Keypad.

Comm Select Input

Enabled and Active:

A051 or A052 = 6

Ye s

Start, Speed and Direction commands

come from RS485 (DSI) port.

P038 [Speed Reference]

= 4 or 5

Ye s

Run as specified by

P038 [Speed Reference].

Start and Direction commands come

from P036 [Start Source].

A051 / A052

Preset Inputs Active

Ye s

Run as specified by

A071-A073 [Preset Freq 1-3].

Start and Direction commands come

from P036 [Start Source].

Run as specified by

P038 [Speed Reference].

Start and Direction commands

come from P036 [Start Source].

No

No

No

No

No

Drive stopped
(not Running)

Ye s

No

Start and Speed Reference Control

The drive speed command can be obtained from a number of different
sources. The source is normally determined by
However, when A051 or A052
6, and the digital input is active, A051 or A052 will override the speed
reference commanded by
for the override priority.

P038 [Speed Reference].

[Digital Inx Sel] is set to option 2, 4, 5 or

P038 [Speed Reference]. See the chart below

Installation/Wiring 1-19

Jog Input

Enabled and Active:

A051 or A052 = 2

Ye s

A079 [Jog Accel/Decel] used.

P039 [Accel Time 1]/P040 [Decel Time 1]

are used.

RS485 (DSI) Port

Controls Speed

Active when

A067 [Accel Time 2]/A068 [Decel Time 2]

is selected by RS485 (DSI) port.

Input is programmed

as “Accel 2 & Decel 2”

A051 or A052 = 1

A067 [Accel Time 2]/A068 [Decel Time 2]

is active when input is active.

Speed is controlled

by [Preset Freq x]
A051 or A052 = 4

P039 [Accel Time 1]/P040 [Decel Time 1];

A067 [Accel Time 2]/A068 [Decel Time 2]

determined by the active Preset Frequency.

See A070-A073 [Preset Freq 0-3]

on page 3-16.

No

No

Ye s

Ye s

Ye s

No

No

Accel/Decel Selection

The selection of Accel/Decel rates can be made through digital inputs,
RS485 (DSI) communications and/or parameters.

t

1-20 Installation/Wiring

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.

CE Declarations of Conformity are available online at:

http://www.ab.com/certification/ce/docs.

Low Voltage Directive (2014/35/EU)

 EN 61800-5-1 Adjustable speed electrical power drive systems –

Part 5-1: Safety requirements – Electrical, thermal and energy.

Pollution Degree Ratings According to EN 61800-5-1

Pollution Degree Description

1 No pollution or only dry, non-conductive pollution occurs. The

pollution has no influence.

2 Normally, only non-conductive pollution occurs. Occasionally,

however, a temporary conductivity caused by condensation is to
be expected, when the drive is out of operation.

EMC Directive (2014/30/EU)

 EN61800-3 Adjustable speed electrical power drive systems Part 3:

EMC product standard including specific test methods.

General Notes

 If the plastic top panel is removed or the optional conduit box is not

installed, the drive must be installed in an enclosure with side
openings less than 12.5 mm (0.5 in.) and top openings less than 1.0
mm (0.04 in.) to maintain compliance with the LV Directive.

 The motor cable should be kept as short as possible in order to avoid

electromagnetic emission as well as capacitive currents.

 Use of line filters in ungrounded systems is not recommended.
 Conformity of the drive with CE EMC requirements does not

guarantee an entire machine installation complies with CE EMC
requirements. Many factors can influence total machine/installation
compliance.

Installation/Wiring 1-21

R/L1

S/L2
T/L3

U/T1
V/T2

W/T3

EMI Fittings and Metal Conduit

IP 30/NEMA 1/UL Type 1
Option Kit

Shielded Enclosure

(1)

Building Structure Steel

Enclosure Ground Connection

(2)

EMI Filter

L1'
L2'
L3'

L1
L2
L3

Shielded Motor Cable

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 1-5 for

additional grounding recommendations.

2. Output power, control (I/O) and signal wiring must be braided,

shielded cable with a coverage of 75% or better, metal conduit or
equivalent attenuation.

3. Allowable cable length in

Table 1.I

Table 1.I Allowable Cable Length

Filter Type EN61800-3 First Environment

Restricted Distribution or
Second Environment

Integral 10 meters (33 feet) 1 meter (3 feet)

(1)

External - S Type

External - L Type

(1)

Refer to

(2)

Equivalent to EN55011 Class A.

(3)

Equivalent to EN55011 Class B.

Appendix B for details on optional external filters.

10 meters (33 feet) 1 meter (3 feet)

(1)

100 meters (328 feet) 5 meters (16 feet)

is not exceeded.

EN61800-3 First Environment
Unrestricted Distribution

(2)

(3)

Figure 1.6 Connections and Grounding

(1)

First Environment Unrestricted Distribution installations require a shielded enclosure.
Keep wire length as short as possible between the enclosure entry point and the EMI
filter.

(2)

Integral EMI filters are available on 240V, 1-Phase drives.

1-22 Installation/Wiring

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.

 Other drive ratings meet the current harmonic requirements of

EN61000-3-2 without additional external mitigation.

Chapter 2

!

Start Up

This chapter describes how to start up the PowerFlex 4 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. 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, Do Not Proceed. Remove All Power including user
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.

Prepare For Drive Start-Up

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
location.

Important: 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.

Figure 1.5 on page 1-13 for

❏ 5. Verify that the Stop input is present or the drive will not start.

Important: If I/O Terminal 01 is used as a stop input, the jumper

between I/O Terminals 01 and 11 must be removed.

2-2 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

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: To disable reverse operation, see

If a fault appears on power up, refer to
for an explanation of the fault code.

Fault Descriptions on page 4-3

Variable Torque Fan/Pump Applications

For improved motor tuning performance when using a premium efficient
motor on a variable torque load, set
“35.0, VT”.

A084 [Boost Select] to option 2

A095 [Reverse Disable].

page 2-3)

Start Up 2-3

FAULT

VOLTS
AMPS
HERTZ

RUN
FWD
REV

PROGRAM

➊

➋

➍

➏

➒

➎

Menu Description

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.

➌

➑

➐

Integral Keypad

No. LED LED State Description

Run/Direction

➊

Status

Alphanumeric

➋

Display

Displayed Units Steady Red Indicates the units of the parameter value being displayed.

➌

Program Status Steady Red Indicates parameter value can be changed.

➍

Fault Status Flashing Red Indicates drive is faulted.

➎

Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.

➏

Start Key Status Steady Green Indicates Start key on Integral Keypad is active.

➐

Steady Red Indicates drive is running and commanded motor direction.

Flashing Red Drive has been commanded to change direction. Indicates

actual motor direction while decelerating to zero.

Steady Red Indicates parameter number, parameter value, or fault code.

Flashing Red Single digit flashing indicates that digit can be edited.

All digits flashing indicates a fault condition.

The Reverse key is also active unless disabled by
[Reverse Disable].

A095

No. Key Name Description

Escape Back one step in programming menu.

Cancel a change to a parameter value and exit Program
Mode.

Select Advance one step in programming menu.

Select a digit when viewing parameter value.

Up Arrow
Down Arrow

Enter Advance one step in programming menu.

Potentiometer Used to control speed of drive. Default is active.

Start Used to start the drive. Default is active.

Scroll through groups and parameters.
Increase/decrease the value of a flashing digit.

Save a change to a parameter value.

Controlled by parameter

Controlled by parameter

Reverse Used to reverse direction of the drive. Default is active.

Controlled by parameters
[Reverse Disable].

Stop Used to stop the drive or clear a fault.

This key is always active.
Controlled by parameter P037 [Stop Mode].

➑

➒

P038 [Speed Reference].

P036 [Start Source].

P036 [Start Source] and A095

2-4 Start Up

or

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

VOLTS
AMPS
HERTZ

FAULTPROGRAM

VOLTS
AMPS
HERTZ

FAULTPROGRAM

VOLTS
AMPS
HERTZ

FAULTPROGRAM

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.

Step Key(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.)

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.

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.

The Basic Program Group (

page 3-8) contains the most commonly changed parameters.

Chapter 3

32

Programming and Parameters

Chapter 3 provides a complete listing and description of the PowerFlex 4
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. Refer to
numbers.

For information on… See page…

About Parameters 3-1

Parameter Organization 3-2

Basic Program Group 3-8

Advanced Program Group 3-13

Parameter Cross Reference – by Name 3-27

Appendix B for catalog

About Parameters

To configure a drive to operate in a specific way, drive parameters may
have to be set. Three types of parameters exist:

 ENUM

ENUM parameters allow a selection from 2 or more items. Each item
is represented by a number.

 Numeric Parameters

These parameters have a single numerical value (i.e. 0.1 Volts).

 Bit Parameters

Bit parameters have four individual bits associated with features or
conditions. If the bit is 0, the feature is off or the condition is false. If
the bit is 1, the feature is on or the condition is true.

Some parameters are marked as follows.

= Stop drive before changing this parameter.

= 32 bit parameter. Parameters marked 32 bit will have two

parameter numbers when using RS485 communications and
programming software.

3-2 Programming and Parameters

See page 3-8

Motor NP Volts P031

Motor NP Hertz P032

Motor OL Current P033

Minimum Freq P034

Maximum Freq P035

Start Source P036

Stop Mode P037

Speed Reference P038

Accel Time 1 P039

Decel Time 1 P040

Reset To Defalts P041

Motor OL Ret P043

See page 3-3

Output Freq d001

Commanded Freq d002

Output Current d003

Output Voltage d004

DC Bus Voltage d005

Drive Status d006

Fault 1 Code d007

Fault 2 Code d008

Fault 3 Code d009

Process Display d010

Control Source d012

Contrl In Status d013

Dig In Status d014

Comm Status d015

Control SW Ver d016

Drive Type d017

Elapsed Run Time d018

Testpoint Data d019

Analog In 0-10V d020

Analog In 4-20mA d021

Drive Temp d024

See page 3-13

Digital In1 Sel A051

Digital In2 Sel A052

Relay Out Sel A055

Relay Out Level A056

Accel Time 2 A067

Decel Time 2 A068

Internal Freq A069

Preset Freq 0 A070

Preset Freq 1 A071

Preset Freq 2 A072

Preset Freq 3 A073

Jog Frequency A078

Jog Accel/Decel A079

DC Brake Time A080

DC Brake Level A081

DB Resistor Sel A082

S Curve % A083

Boost Select A084

Maximum Voltage A088

Current Limit A089

Motor OL Select A090

PWM Frequency A091

Auto Rstrt Tries A092

Auto Rstrt Delay A093

Start At PowerUp A094

Reverse Disable A095

Flying Start En A096

Compensation A097

SW Current Trip A098

Process Factor A099

Fault Clear A100

Program Lock A101

Testpoint Sel A102

Comm Data Rate A103

Comm Node Addr A104

Comm Loss Action A105

Comm Loss Time A106

Comm Format A107

Anlg In 0-10V Lo A110

Anlg In 0-10V Hi A111

Anlg In 4-20mA Lo A112

Anlg In 4-20mA Hi A113

Slip Hertz @ FLA A114

Process Time Lo A115

Process Time Hi A116

Bus Reg Mode A117

Comm Write Mode A118

Parameter Organization

Display Group

Basic

Program Group

Advanced

Program Group

Programming and Parameters 3-3

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

Min/Max: 0.0/

Display: 0.1 Hz

P035 [Maximum Freq]

d002 [Commanded Freq] Related Parameter(s): d001, d013, P034, P035, P038

Value of the active frequency command. Displays the commanded frequency even if the drive is not
running.

Important: The frequency command can come from a number of sources. Refer to

Reference Control on page 1-18 for details.

Values Default Read Only

Min/Max: 0.0/

Display: 0.1 Hz

[Maximum Freq]

P035

Start and Speed

d003 [Output Current]

The output current present at T1, T2 & T3 (U, V & W).

Values Default Read Only

Min/Max: 0.00/(Drive Rated Amps  2)

Display: 0.01 Amps

d004 [Output Voltage] Related Parameter(s): P031, A084, A088

Output voltage present at terminals T1, T2 & T3 (U, V & W).

Values Default Read Only

Min/Max: 0/Drive Rated Volts

Display: 1 VAC

d005 [DC Bus Voltage]

Present DC bus voltage level.

Values Default Read Only

Min/Max: Based on Drive Rating

Display: 1 VDC

3-4 Programming and Parameters

1 = Condition True, 0 = Condition False

Running Bit 0

Forward Bit 1

Accelerating Bit 2

Decelerating Bit 3

32

Output

Freq

Process

Factor

Process

Display

=

x

Display Group (continued)

d006 [Drive Status] Related Parameter(s): A095

Present operating condition of the drive.

Values Default Read Only

Min/Max: 0/1

Display: 1

d007 [Fault 1 Code]
d008 [Fault 2 Code]
d009 [Fault 3 Code]

A code that represents a drive fault. The codes will appear in these parameters in the order they occur
(d007 [Fault 1 Code] = the most recent fault). Repetitive faults will only be recorded once.

Refer to

Values Default Read Only

Chapter 4 for fault code descriptions.

Min/Max: F2/F122

Display: F1

d010 [Process Display] Related Parameter(s): d001, A099, A115, A116

32 bit parameter.

The output frequency scaled by
[Process Time Hi].

Values Default Read Only

A099 [Process Factor] or by A115 [Process Time Lo] and A116

Min/Max: 0.00/9999

Display: 0.01 – 1

Programming and Parameters 3-5

Start Command Digit 0
0 = Keypad
1 = 3-Wire
2 = 2-Wire
3 = 2-Wire Level Sensitive
4 = 2-Wire High Speed
5 = RS485 (DSI) Port
9 = Jog

Speed Command Digit 1
0 = Drive Potentiometer
1 =

A069

[Internal Freq]
2 = 0-10V Input/Remote Potentiometer
3 = 4-20mA Input
4 =

A070 - A073 [Preset Freq x]

(

A051 - A052 [Digital Inx Sel] must be set to 4)

5 = RS485 (DSI) Port
9 = Jog Freq

Reserved Digit 2

Reserved Digit 3

1 = Input Present, 0 = Input Not Present

Start / Run FWD Input (I/O Terminal 02) Bit 0

Direction / Run REV Input (I/O Terminal 03) Bit 1

Stop Input

(1)

(I/O Terminal 01) Bit 2

(1)

The stop input must be present in order to start the drive.
When this bit is a 1 the drive can be started.
When this bit is a 0 the drive will stop.

Reserved Bit 3

Display Group (continued)

d012 [Control Source] Related Parameter(s): P036, P038, A051, A052

Displays the active source of the Start Command and Speed Command which are normally defined
by the settings of
inputs. Refer to the flowcharts on pages

P036 [Start Source] and P038 [Speed Reference] but may be overridden by digital

1-18 and 1-19 for details.

Values Default Read Only

Min/Max: 0/9

Display: 1

d013 [Contrl In Status] Related Parameter(s): d002, P034, P035

Status of the control terminal block control inputs.

Important: Actual control commands may come from a source other than the control terminal block.

Values Default Read Only

Min/Max: 0/1

Display: 1

3-6 Programming and Parameters

1 = Input Present, 0 = Input Not Present

Digital In1 Sel (I/O Terminal 05) Bit 0

Digital In2 Sel (I/O Terminal 06) Bit 1

Reserved Bit 2

Reserved Bit 3

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

Display Group (continued)

d014 [Dig In Status] Related Parameter(s): A051, A052

Status of the control terminal block digital inputs.

Values Default Read Only

Min/Max: 0/1

Display: 1

d015 [Comm Status] Related Parameter(s): A103 - A107

Status of the communications ports.

Values Default Read Only

Min/Max: 0/1

Display: 1

d016 [Control SW Ver]

Main Control Board software version.

Values Default Read Only

Min/Max: 1.00/99.99

Display: 0.01

d017 [Drive Type]

Used by Rockwell Automation field service personnel.

Values Default Read Only

Min/Max: 1001/9999

Display: 1

Programming and Parameters 3-7

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

The present value of the function selected in A102 [Testpoint Sel].

Values Default Read Only

Min/Max: 0/FFFF

Display: 1 Hex

d020 [Analog In 0-10V] Related Parameter(s): A110, A111

The present value of the voltage at I/O Terminal 13 (100.0% = 10 volts).

Values Default Read Only

Min/Max: 0.0/100.0%

Display: 0.1%

d021 [Analog In 4-20mA] Related Parameter(s): A112, A113

The present value of the current at I/O Terminal 15 (0.0% = 4mA, 100.0% = 20mA).

Values Default Read Only

Min/Max: 0.0/100.0%

Display: 0.1%

d024 [Drive Temp]

Present operating temperature of the drive power section.

Values Default Read Only

Min/Max: 0/120 degC

Display: 1 degC

3-8 Programming and Parameters

Basic Program Group

P031 [Motor NP Volts] Related Parameter(s): d004, A084

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: 1 VAC

P032 [Motor NP Hertz] Related Parameter(s): A084, A090

Stop drive before changing this parameter.

Set to the motor nameplate rated frequency.

Values Default 60 Hz

Min/Max: 10/240 Hz

Display: 1 Hz

P033 [Motor OL Current] Related Parameter(s): P043, A055, A089, A090, A098, A114

Set to the maximum allowable motor current.

The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150% for 60
seconds.

Values Default Based on Drive Rating

Min/Max: 0.0/(Drive Rated Amps  2)

Display: 0.1 Amps

P034 [Minimum Freq] Related Parameter(s): d001, d002, d013, P035, A110, A112, A115

Sets the lowest frequency the drive will output continuously.

Values Default 0.0 Hz

Min/Max: 0.0/240.0 Hz

Display: 0.1 Hz

P035 [Maximum Freq]

Stop drive before changing this parameter.

Sets the highest frequency the drive will output.

Values Default 60 Hz

Min/Max: 0/240 Hz

Display: 1 Hz

Related Parameter(s):

d001, d002, d013, P034, A078,

A111, A113, A115

Programming and Parameters 3-9

!

ATTENTION: Hazard of injury exists due to unintended operation. When
P036 [Start Source] is set to option 3, and the Run input is maintained, the
Run inputs do not need to be toggled after a Stop input for the drive to run
again. A Stop function is provided only when the Stop input is active (open).

ATTENTION: The drive must only be controlled from the Digital Input
Terminal Blocks and must NOT be used with any other DSI or
Network device.

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
can override the setting of this parameter.

Important: For all settings except option 3, the drive must receive a leading edge from the start input
for the drive to start after a stop input, loss of power or fault condition.

Options 0 “Keypad” (Default)  Integral keypad controls drive operation.

Start and Speed Reference Control on page 1-18 for details about how other drive settings

 I/O Terminal 1 “Stop” = coast to stop.
 When active, the Reverse key is also active unless

disabled by

1 “3-Wire” I/O Terminal 1 “Stop” = stop according to the value set in

P037 [Stop Mode].

2 “2-Wire” I/O Terminal 1 “Stop” = coast to stop.

A095 [Reverse Disable].

3 “2-W Lvl Sens” Drive will restart after a “Stop” command when:

 Stop is removed

and

 Start is held active

4 “2-W Hi Speed” Important: There is greater potential voltage on the output

terminals when using this option.

Important: The drive may fault on an F5 OverVoltage if
[Start Source] is set to “2-W Hi Speed” and a Coast to Stop
command is given while the drive is running.
For example, a Coast to Stop command is given while the

P037

drive is running when
“Coast” and

 Outputs are kept in a ready-to-run state. The drive will

respond to a “Start” command within 10 ms.

 I/O Terminal 1 “Stop” = coast to stop.

P036 [Start Source] = 4.

[Stop Mode] = 1 “Coast, CF” or 5

P036

5 “Comm Port”  Remote communications. Refer to

 I/O Terminal 1 “Stop” = coast to stop.

Important: When commanding Jog via the RS485 communications port on drives with firmware
version 1.02 or earlier, the Jog command will follow the commanded direction from I/O Terminal 03.
On firmware versions 1.03 and later, the commanded direction will be provided via the RS485
communications port.

Important: When sending a continuous start command via the RS485 communications port on drives
with firmware version 1.02 or earlier, a maintained stop input is required to stop the drive. Once the
stop input is inactive, the drive will restart. On firmware versions 1.03 and later, once a stop input is
received, the start command must transition from high to low to high for the drive to start.

Appendix C for details.

3-10 Programming and Parameters

Basic Program Group (continued)

P037 [Stop Mode] Related Parameter(s): P036, A080, A081, A082, A105

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.

P036

Important: I/O Terminal 01 is always a coast to stop input except when
“3-Wire” control. When in three wire control, I/O Terminal 01 is controlled by

Hardware Enable Circuitry

By default, I/O Terminal 01 is a coast to stop input. The status of the input is interpreted by drive
software. If the application requires the drive to be disabled without software interpretation, a “dedicat­ed” hardware enable configuration can be utilized. This is accomplished by removing the ENBL
enable jumper on the control board. In this case, the drive will always coast to a stop regardless of the
settings of

P036 [Start Source] and P037 [Stop Mode].

[Start Source] is set for

P037 [Stop Mode].

Options 0 “Ramp, CF”

1 “Coast, CF”

2 “DC Brake, CF”

3 “DCBrkAuto,CF”

4 “Ramp” Ramp to Stop.

5 “Coast” Coast to Stop.

6 “DC Brake” DC Injection Braking Stop.

7 “DC BrakeAuto” DC Injection Braking Stop with Auto Shutoff.

(1)

(Default) Ramp to Stop. “Stop” command clears active fault.

(1)

(1)

Coast to Stop. “Stop” command clears active fault.

DC Injection Braking Stop. “Stop” command clears active
fault.

(1)

DC Injection Braking Stop with Auto Shutoff.

 Standard DC Injection Braking for value set in

Brake Time].

OR

 Drive shuts off if the drive detects that the motor is

stopped.

“Stop” command clears active fault.

 Standard DC Injection Braking for value set in A080

Brake Time].

OR

 Drive shuts off if current limit is exceeded.

A080 [DC

[DC

(1)

Stop input also clears active fault.

Programming and Parameters 3-11

Maximum Freq

Accel Time

Accel Rate=

Speed

0

Time

P035 [Maximum Freq]

P039 or A067

[Accel Time x]

P040 or A068

[Decel Time x]

0

Acceleration

D

eceleration

Basic Program Group (continued)

P038 [Speed Reference] Related Parameter(s): d001, d002, d012, P039, P040, A051, A052,

A069, A070-A073, A110, A111, A112, A113

Sets the source of the speed reference to the drive.

The drive speed command can be obtained from a number of different sources. The source is
normally determined by
to option 2, 4, 5, 6, 11, 12, 13, 14, 15 and the digital input is active, the speed reference commanded
by

P038 [Speed Reference] will be overridden. Refer to the flowchart on page 1-18 for more

information on speed reference control priority.

Options 0 “Drive Pot” (Default) Internal frequency command from the potentiometer on the

P038 [Speed Reference]. However, when A051 - A052 [Digital Inx Sel] is set

integral keypad.

1 “InternalFreq” Internal frequency command from

A069 [Internal Freq].

2 “0-10V Input” External frequency command from the 0-10V analog input or

remote potentiometer.

3 “4-20mA Input” External frequency command from the 4-20mA analog input.

4 “Preset Freq” External frequency command as defined by

[Preset Freq x] when

A051 and A052 [Digital Inx Sel] are

A070

- A073

programmed as “Preset Frequencies” and the digital inputs
are active.

5 “Comm Port” External frequency command from the communications port.

P039 [Accel Time 1] Related Parameter(s): P038, P040, A051, A052, A067, A070-A073

Sets the rate of acceleration for all speed increases.

Values Default 10.0 Secs

Min/Max: 0.0/600.0 Secs

Display: 0.1 Secs

3-12 Programming and Parameters

Maximum Freq

Decel Time

Decel Rate

=

Speed

0

Time

P035 [Maximum Freq]

P039 or A067
[Accel Time x]

P040 or A068

[Decel Time x]

0

Acceleration

D

eceleration

Basic Program Group (continued)

P040 [Decel Time 1] Related Parameter(s): P038, P039, A051, A052, A068, A070-A073

Sets the rate of deceleration for all speed decreases.

Values Default 10.0 Secs

Min/Max: 0.1/600.0 Secs

Display: 0.1 Secs

P041 [Reset To Defalts]

Stop drive before changing this parameter.

Resets all parameter values to factory defaults.

Options 0 “Idle State” (Default)

1 “Reset Defaults”  After the reset function is complete, this parameter will set

itself back to “0”.

 Causes an F48

Params Defaulted fault.

P043 [Motor OL Ret] Related Parameter(s): P033

Enables/disables the Motor Overload Retention function. When Enabled, the value held in the motor
overload counter is saved at power-down and restored at power-up. A change to this parameter
setting resets the counter.

Options 0 “Disabled” (Default)

1 “Enabled”

Advanced Program Group

Stop drive before changing this parameter.

Programming and Parameters 3-13

A051 [Digital In1 Sel]

(I/O Terminal 5)

Related Parameter(s):

d012, d014, P038, P039, P040,

A067, A068, A070-A073, A078, A079

A052 [Digital In2 Sel]

(I/O Terminal 6)

Selects the function for the digital inputs. Refer to the flowchart on page 1-18 for more information on
speed reference control priority.

Options 0 “Not Used” Terminal has no function but can be read over network

communications via

1 “Acc 2 & Dec 2”  When active,

2] are used for all ramp rates except Jog.

 Can only be tied to one input.

Refer to the flowchart on
Accel/Decel selection.

2 “Jog”  When input is present, drive accelerates according to the

value set in A079 [Jog Accel/Decel] and ramps to the
value set in

 When input is removed, drive ramps to a stop according to

the value set in

 A valid “Start” command will override this input.

3 “Aux Fault” When enabled, an F2

input is removed.

d014 [Dig In Status]

A067 [Accel Time 2] and A068 [Decel Time

page 1-19

A078 [Jog Frequency].

A079 [Jog Accel/Decel].

Auxiliary Input fault will occur when the

for more information on

4 “Preset Freq” (Default) Refer to

Important: Digital Inputs have priority for frequency control

when programmed as a Preset Speed and are active. Refer
to the flowchart on
reference control priority.

5 “Local” When active, sets integral keypad as start source and

potentiometer on the integral keypad as speed source.

6 “Comm Port”  When active, sets communications device as default start/

 Can only be tied to one input.

7 “Clear Fault” When active, clears an active fault.

8 “RampStop,CF” Causes drive to immediately ramp to a stop regardless of how

P037 [Stop Mode] is set.

9 “CoastStop,CF” Causes drive to immediately coast to a stop regardless of

how

10 “DCInjStop,CF” Causes drive to immediately begin a DC Injection stop

regardless of how

11 “Jog Forward” Drive accelerates to

[Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.

A070 - A073 [Preset Freq x].

1-18 for more information on speed

speed command source.

P037 [Stop Mode] is set.

P037 [Stop Mode] is set.

A078 [Jog Frequency] according to A079

12 “Jog Reverse” Drive accelerates to A078 [Jog Frequency] according to A079

[Jog Accel/Decel] and ramps to stop when input becomes
inactive. A valid start will override this command.

3-14 Programming and Parameters

A051 &
A052
Options

(Cont.)

A055 [Relay Out Sel]

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

Options 0 “Ready/Fault”

13 “10V In Ctrl” Selects 0-10V or ±10V control as the frequency reference.

Start source is not changed.

14 “20mA In Ctrl” Selects 4-20mA control as the frequency reference. Start

source is not changed.

15 - 25 Reserved

26 “Anlg Invert” Inverts the scaling of the analog input levels set in

A110 [Anlg In 0-10V Lo] and A111 [Anlg In 0-10V Hi] or
A112 [Anlg In4-20mA Lo] and A113 [Anlg In4-20mA Hi].

Related Parameter(s):

Relay changes state when power is applied. This indicates

(Default)

1 “At Frequency” Drive reaches commanded frequency.

2 “MotorRunning” Motor is receiving power from the drive.

3 “Reverse” Drive is commanded to run in reverse direction.

4 “Motor Overld” Motor overload condition exists.

that the drive is ready for operation. Relay returns drive to
shelf state when power is removed or a fault occurs.

P033, A056, A092

5 “Ramp Reg” Ramp regulator is modifying the programmed accel/decel

times to avoid an overcurrent or overvoltage fault from
occurring.

6 “Above Freq” Drive exceeds the frequency (Hz) value set in

Out Level].

7 “Above Cur” Drive exceeds the current (% Amps) value set in

Out Level].

Important: Value for
in percent of drive rated output current.

8 “Above DCVolt” Drive exceeds the DC bus voltage value set in

Out Level].

9 “Retries Exst” Value set in

10 “Above Anlg V”  Analog input voltage (I/O Terminal 13) exceeds the value

set in

 This parameter setting can also be used to indicate a PTC

trip point when the input (I/O Terminal 13) is wired to a
PTC and external resistor.

 Use A056 to set threshold.

11-19 Reserved

20 “ParamControl” Enables the output to be controlled over network

communications by writing to
(0 = Off, 1 = On.)

A092 [Auto Rstrt Tries] is exceeded.

A056 [Relay Out Level].

A056 [Relay Out Level] must be entered

A056 [Relay Out Level].

A056 [Relay

A056 [Relay

A056 [Relay

21 “NonRec Fault”” Value set in

A092 [Auto Rstrt Tries] is exceeded.

Programming and Parameters 3-15

32

A055 Setting A056 Min/Max

6
7
8
10
20

0/240 Hz
0/180%
0/815 Volts
0/100%
0/1

Maximum Freq

Accel Time

Accel Rate=

Speed

0

Time

P035 [Maximum Freq]

P039 or A067
[Accel Time x]

P040 or A068

[Decel Time x]

0

Acceleration

Deceleration

Maximum Freq

Decel Time

Decel Rate

=

Speed

0

Time

P035 [Maximum Freq]

P039 or A067
[Accel Time x]

P040 or A068

[Decel Time x]

0

Acceleration

Deceleration

Advanced Program Group

(continued)

A056 [Relay Out Level] Related Parameter(s): A055

32 bit parameter.

Sets the trip point for the digital output relay if the value of

A055 [Relay Out Sel] is 6, 7, 8, 10 or 20.

Values Default 0.0

Min/Max: 0.0/9999

Display: 0.1

A067 [Accel Time 2] Related Parameter(s): P039

When active, sets the rate of acceleration for all speed increases except jog. Refer to the flowchart on

page 1-19 for details.

Values Default 20.0 Secs

Min/Max: 0.0/600.0 Secs

Display: 0.1 Secs

A068 [Decel Time 2] Related Parameter(s): P040

When active, sets the rate of deceleration for all speed decreases except jog. Refer to the flowchart

page 1-19 for details.

on

Values Default 20.0 Secs

Min/Max: 0.1/600.0 Secs

Display: 0.1 Secs

3-16 Programming and Parameters

Input State of Digital In 1

(I/O Terminal 05)

Input State of Digital In 2

(I/O Terminal 06) Frequency Source Accel / Decel Parameter Used

(2)

0 0 A070 [Preset Freq 0] [Accel Time 1] / [Decel Time 1]

1 0 A071 [Preset Freq 1] [Accel Time 1] / [Decel Time 1]

0 1 A072 [Preset Freq 2] [Accel Time 2] / [Decel Time 2]

1 1 A073 [Preset Freq 3] [Accel Time 2] / [Decel Time 2]

(2)

When a Digital Input is set to “Accel 2 & Decel 2”, and the input is active, that input overrides the settings in
this table.

Advanced Program Group (continued)

A069 [Internal Freq] Related Parameter(s): P038

Provides the frequency command to the drive when P038 [Speed Reference] is set to 1 “Internal
Freq”. When enabled, this parameter will change the frequency command in “real time” using the
integral keypad Up Arrow or Down Arrow when in program mode.

Important: Once the desired command frequency is reached, the Enter key must be pressed to store
this value to EEPROM memory. If the ESC key is used before the Enter key, the frequency will return
to the original value following the normal accel/decel curve.

Values Default 60.0 Hz

Min/Max: 0.0/240.0 Hz

Display: 0.1 Hz

A070 [Preset Freq 0]

(1)

Related Parameter(s):

P038, P039, P040, A051, A052,

A071 [Preset Freq 1]
A072 [Preset Freq 2]
A073 [Preset Freq 3]

Values A070 Default

A071 Default
A072 Default
A073 Default

Min/Max: 0.0/240.0 Hz

Display: 0.1 Hz

Provides a fixed frequency command value when
Frequencies”.

An active preset input will override speed command as shown in the flowchart on

(1)

To activate A070 [Preset Freq 0] set

0.0 Hz

5.0 Hz

10.0 Hz

20.0 Hz

A051 - A052 [Digital Inx Sel] is set to 4 “Preset

P038 [Speed Reference] to option 4 “Preset Freq 0-3”.

A067, A068

page 1-19.

A078 [Jog Frequency] Related Parameter(s): P035, A051, A052, A079

Sets the output frequency when a jog command is issued.

Values Default 10.0 Hz

Min/Max: 0.0/

Display: 0.1 Hz

P035 [Maximum Freq]

Programming and Parameters 3-17

e

p

e

d

d

[

]

[

]

p

e

e

d

[

]

[

]

Voltage

Speed

!

ATT E NT ION : If a hazard of injury due to movement of equipment or material exists,

an auxiliary mechanical braking device must be used.

!

ATTENTION: This feature should not be used with synchronous or permanent

magnet motors. Motors may be demagnetized during braking.

Advanced Program Group (continued)

A079 [Jog Accel/Decel] Related Parameter(s): A051, A052, A078

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

Values Default 10.0 Secs

Min/Max: 0.1/600.0 Secs

Display: 0.1 Secs

A080 [DC Brake Time] Related Parameter(s): P037, A081

Sets the length of time that DC brake current is “injected” into the motor. Refer to parameter A081 [DC
Brake Level].

Values Default 0.0 Secs

Min/Max: 0.0/90.0 Secs

Display: 0.1 Secs

A081 [DC Brake Level] Related Parameter(s): P037, A080

Defines the maximum DC brake current, in amps, applied to the motor when P037 [Stop Mode] is set
to either “Ramp” or “DC Brake”.

Values Default Drive Rated Amps  0.05

Min/Max: 0.0/(Drive Rated Amps  1.8)

Display: 0.1 Amps

Ramp-to-Stop Mod

eed

olts/S

Stop Comman

DC Brake Time

DC Brake Level

Tim

DC Injection Braking Mod

Voltage

eed

Spee

olts/S

Stop Comman

DC Brake Time

DC Brake Level

Tim

3-18 Programming and Parameters

Setting Min/Max

0
1
2
3-99

“Disabled”
“Normal RA Res” (5% Duty Cycle) - Refer to

Table B.C on page B-2

“No Protection” (100% Duty Cycle)
“x%Duty Cycle” Limited (3% – 99% of Duty Cycle)

!

ATTENTION: A risk of fire exists if external braking resistors are not protected. The

external resistor package must be self-protected from over temperature or the protective

circuit shown in

Figure B.7 on page B-9, or equivalent, must be supplied.

1/2 S Curve Time

2.5 Seconds

Total Time to Accelerate = Accel Time + S Curve Time

50% S Curve

Target

Target/2

Accel Time

10 Seconds

1/2 S Curve Time

2.5 Seconds

Advanced Program Group (continued)

A082 [DB Resistor Sel]

Stop drive before changing this parameter.

Enables/disables external dynamic braking.

The drive is able to provide full braking indefinitely. Braking power is limited by the external DB
resistor. When this parameter is set to 1 “Normal RA Res” and an appropriate RA resistor is used (see
selection
cannot protect against a brake IGBT failure.

Tab l e B . C ), the drive provides calculated resistor overload protection. However, the drive

Values Default 0

Min/Max: 0/99

Display: 1

A083 [S Curve %]

Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve. Time
is added, 1/2 at the beginning and 1/2 at the end of the ramp.

Values Default 0% (Disabled)

Min/Max: 0/100%

Display: 1%

Example:

Accel Time = 10 Seconds
S Curve Setting = 50%
S Curve Time = 10  0.5 = 5 Seconds
Total Time = 10 + 5 = 15 Seconds

Programming and Parameters 3-19

Advanced Program Group (continued)

A084 [Boost Select] Related Parameter(s): d004, P031, P032

Sets the boost voltage (% of P031 [Motor NP Volts]) and redefines the Volts per Hz curve.

(1)

Drive may add additional voltage unless option 5 is selected.

Options 1 “30.0, VT”

(1)

100

2 “35.0, VT”

3 “40.0, VT”

4 “45.0, VT”

5 “0.0 no IR”

6 “0.0”

7 “2.5, CT”

[Default for 3.7kW
(5HP) Drives]

8 “5.0, CT” (Default)

9 “7.5, CT”

10 “10.0, CT”

11 “12.5, CT”

12 “15.0, CT”

13 “17.5, CT”

14 “20.0, CT”

Variable Torque

Constant Torque

1/2 [Motor NP Volts]

50

% P031 [Motor NP Volts]

Settings

5-14

0 50 100

% P032 [Motor NP Hertz]

4
3
2
1

1/2

[Motor NP Hertz]

A088 [Maximum Voltage]

Sets the highest voltage the drive will output.

Values Default Drive Rated Volts

Min/Max: 20/Drive Rated Volts

Display: 1 VAC

3-20 Programming and Parameters

e

0

80

00

60

0

0

e

0

80

00

60

0

0

[

]

e

0

80

00

60

0

0

020017515012510075

5025

0200

5

5012510075

5025

0

00175150

5

5025

68

84

88

80

6

96

00

92

64

60

56

52

8765315

14

61310

9

Advanced Program Group (continued)

A089 [Current Limit]

Maximum output current allowed before current limiting occurs.

Values Default Drive Rated Amps  1.5

Min/Max: 0.1/(Drive Rated Amps  1.8)

Display: 0.1 Amps

A090 [Motor OL Select] Related Parameter(s): P032

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I2t
overload function.

Options 0 “No Derate” (Default)

1 “Min Derate”

2 “Max Derate”

1

4

2

No Derat

1

4

2

17

1

Min Derat

1

Motor OL Curent

4

2

of P033

1251007

2

Max Derat

A091 [PWM Frequency]

Sets the carrier frequency for the PWM output waveform. The chart below provides derating
guidelines based on the PWM frequency setting.

Important: Ignoring derating guidelines can cause reduced drive performance.

Values Default 4.0 kHz

Min/Max: 2.0/16.0 kHz

Display: 0.1 kHz

1

7

1

Programming and Parameters 3-21

!

ATT E NT ION : Equipment damage and/or personal injury may result if this parameter

is used in an inappropriate application. Do not use this function without considering

applicable local, national and international codes, standards, regulations or industry

guidelines.

!

ATT E NT ION : Equipment damage and/or personal injury may result if this parameter

is used in an inappropriate application. Do not use this function without considering

applicable local, national and international codes, standards, regulations or industry

guidelines.

Advanced Program Group (continued)

A092 [Auto Rstrt Tries]

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. Set A092 [Auto Rstrt Tries] to a value other than “0”.

2. Set

Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting the drive.

1. Set A092 [Auto Rstrt Tries] to a value other than “0”.

2. Set

A093 [Auto Rstrt Delay] to a value other than “0”.

A093 [Auto Rstrt Delay] to “0”.

Values Default 0

Min/Max: 0/9

Display: 1

A093 [Auto Rstrt Delay] Related Parameter(s): A092

Sets the time between restart attempts when A092 [Auto Rstrt Tries] is set to a value other than zero.

Values Default 1.0 Secs

Min/Max: 0.0/300.0 Secs

Display: 0.1 Secs

A094 [Start At PowerUp]

Stop drive before changing this parameter.

Enables/disables a feature that allows a Start or Run command to automatically cause the drive to
resume running at commanded speed after drive input power is restored. Requires a digital input
configured for Run or Start and a valid start contact.

This parameter will not function if parameter

[Start Source] is set to 4 “2-W High Speed”.

P036

Options 0 “Disabled” (Default)

1 “Enabled”

3-22 Programming and Parameters

Output

Freq

Process

Factor

Process

Display

=

x

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. All reverse inputs
including two-wire Run Reverse will be ignored with reverse disabled.

Options 0 “Rev Enabled” (Default)

1 “Rev Disabled”

A096 [Flying Start En]

Sets the condition that allows the drive to reconnect to a spinning motor at actual RPM.

Options 0 “Disabled” (Default)

1 “Enabled”

A097 [Compensation]

Enables/disables correction options that may improve problems with motor instability.

Options 0 “Disabled”

1 “Electrical” (Default) Some drive/motor combinations have inherent instabilities

which are exhibited as non-sinusodial motor currents. This
setting attempts to correct this condition.

2 “Mechanical” Some motor/load combinations have mechanical resonances

which can be excited by the drive current regulator. This
setting slows down the current regulator response and
attempts to correct this condition.

3 “Both”

A098 [SW Current Trip] Related Parameter(s): P033

Enables/disables a software instantaneous (within 100 ms) current trip.

Values Default 0.0 (Disabled)

Min/Max: 0.0/(Drive Rated Amps 2)

Display: 0.1 Amps

A099 [Process Factor] Related Parameter(s): d010

Scales the value displayed by d010 [Process Display].

Values Default 30.0

Min/Max: 0.1/999.9

Display: 0.1

Programming and Parameters 3-23

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”

-d009 [Fault x Code])

2 “Clear Buffer” (Parameters

A101 [Program Lock]

Protects parameters against change by unauthorized personnel.

Options 0 “Unlocked” (Default)

1 “Locked”

d007

A102 [Testpoint Sel]

Used by Rockwell Automation field service personnel.

Values Default 400

Min/Max: 0/FFFF

Display: 1 Hex

A103 [Comm Data Rate] Related Parameter(s): d015

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

Important: Power to drive must be cycled before any changes will affect drive operation.

Options 0 “1200”

1 “2400”

2 “4800”

3 “9600” (Default)

4 “19.2K”

5 “38.4K”

A104 [Comm Node Addr] Related Parameter(s): d015

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

Important: Power to drive must be cycled before any changes will affect drive operation.

Values Default 100

Min/Max: 1/247

Display: 1

3-24 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.

1 “Coast to Stop” Stops drive via coast to stop.

2 “Stop” Stops drive via

3 “Continu Last” Drive continues operating at communication commanded

speed saved in RAM.

P037 [Stop Mode] setting.

A106 [Comm Loss Time] Related Parameter(s): d015, A105

Sets the time that the drive will remain in communication loss before implementing the option selected
in

A105 [Comm Loss Action].

Values Default 5.0 Secs

Min/Max: 0.1/60.0 Secs

Display: 0.1 Secs

A107 [Comm Format]

Selects the protocol (RTU only), data bits (8 data bits only), parity (N
stop bit only) used by the RS485 port on the drive.

Refer to

Important: Power to drive must be cycled before any changes will affect drive operation.

Options 0 “RTU 8-N-1” (Default)

Appendix C for details on using the drive communication features.

one, Even, Odd), and stop bits (1

1 “RTU 8-E-1”

2 “RTU 8-O-1”

3 “RTU 8-N-2”

4 “RTU 8-E-2”

5 “RTU 8-O-2”

Programming and Parameters 3-25

0

P035 [Maximum Freq]

P034 [Minimum Freq]

A110 [Anlg In 0-10V Lo] A111 [Anlg In 0-10V Hi]

0

Speed Reference

A110 [Anlg In 0-10V Lo] Related Parameter(s):

d020, P034, P038, A051, A052

Sets the analog input level that corresponds to P034 [Minimum Freq] if a 0-10V input is used by P038
[Speed Reference].

Analog inversion can be accomplished by setting this value larger than
setting

A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”

A111 [Anlg In 0-10V Hi] or by

Values Default 0.0%

Min/Max: 0.0/100.0%

Display: 0.1%

A111 [Anlg In 0-10V Hi] Related Parameter(s): d020, P035, P038, A051, A052

Sets the analog input level that corresponds to P035 [Maximum Freq] if a 0-10V input is used by P038
[Speed Reference].

Analog inversion can be accomplished by setting this value smaller than
setting

A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.

A110 [Anlg 0-10V In Lo] or by

Values Default 100.0%

Min/Max: 0.0/100.0%

Display: 0.1%

A112 [Anlg In4-20mA Lo] Related Parameter(s): d021, P034, P038, A051, A052

Sets the analog input level that corresponds to P034 [Minimum Freq] if a 4-20mA input is used by
P038 [Speed Reference].

Analog inversion can be accomplished by setting this value larger than
setting

A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.

A113

[Anlg In4-20mA Hi] or by

Values Default 0.0%

Min/Max: 0.0/100.0%

Display: 0.1%

A113 [Anlg In4-20mA Hi] Related Parameter(s): d021, P035, P038, A051, A052

Sets the analog input level that corresponds to P035 [Maximum Freq] if a 4-20mA input is used by
P038 [Speed Reference].

Analog inversion can be accomplished by setting this value smaller than
by setting

Values Default 100.0%

A051 - A052 [Digital Inx Sel] to option 26 “Anlg Invert”.

A112 [Anlg In4-20mA Lo] or

Min/Max: 0.0/100.0%

Display: 0.1%

3-26 Programming and Parameters

!

ATTENTION: Risk of equipment damage exists. If a controller is

programmed to write parameter data to Non-Volatile Storage (NVS)
frequently, the NVS will quickly exceed its life cycle and cause the
drive to malfunction. Do not create a program that frequently uses
configurable outputs to write parameter data to NVS unless A164
[Comm Write Mode] is set to option 1.

A114 [Slip Hertz @ FLA] Related Parameter(s):

Compensates for the inherent slip in an induction motor. This frequency is added to the commanded
output frequency based on motor current.

Values Default 2.0 Hz

Min/Max: 0.0/10.0 Hz

Display: 0.1 Hz

P033

A115 [Process Time Lo] Related Parameter(s): d010, P034

Scales the time value when the drive is running at P034 [Minimum Freq]. When set to a value other
than zero,

Values Default 0.00

d010 [Process Display] indicates the duration of the process.

Min/Max: 0.00/99.99

Display: 0.01

A116 [Process Time Hi] Related Parameter(s): d010, P035

Scales the time value when the drive is running at P035 [Maximum Freq]. When set to a value other
than zero,

d010 [Process Display] indicates the duration of the process.

Values Default 0.00

Min/Max: 0.00/99.99

Display: 0.01

A117 [Bus Reg Mode]

Controls the operation of the drive voltage regulation, which is normally operational at decel or when

the bus voltage rises.

Refer to the Attention statement on page

Options 0 “Disabled”

1 “Enabled” (Default)

P-3 for important information on bus regulation.

A118 [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.

Options 0 “Save” (Default)

1“RAM Only”

Programming and Parameters 3-27

Parameter Cross Reference – by Name

Parameter Name No. Group

Accel Time 1 P039 Basic Program

Accel Time 2 A067 Advanced Program

Analog In 0-10V d020 Display

Analog In 4-20mA d021 Display

Anlg In 0-10V Hi A111 Advanced Program

Anlg In 0-10V Lo A110 Advanced Program

Anlg In4-20mA Hi A113 Advanced Program

Anlg In4-20mA Lo A112 Advanced Program

Auto Rstrt Delay A093 Advanced Program

Auto Rstrt Tries A092 Advanced Program

Boost Select A084 Advanced Program

Bus Reg Mode A117 Advanced Program

Comm Data Rate A103 Advanced Program

Comm Format A107 Advanced Program

Comm Loss Action A105 Advanced Program

Comm Loss Time A106 Advanced Program

Comm Node Addr A104 Advanced Program

Comm Status d015 Display

Comm Write Mode A118 Advanced Program

Commanded Freq d002 Display

Compensation A097 Advanced Program

Contrl In Status d013 Display

Control Source d012 Display

Control SW Ver d016 Display

Current Limit A089 Advanced Program

DB Resistor Sel A082 Advanced Program

DC Brake Level A081 Advanced Program

DC Brake Time A080 Advanced Program

DC Bus Voltage d005 Display

Decel Time 1 P040 Basic Program

Decel Time 2 A068 Advanced Program

Dig In Status d014 Display

Digital Inx Sel A051, A052 Advanced Program

Drive Status d006 Display

Drive Temp d024 Display

Drive Type d017 Display

Elapsed Run Time d018 Display

Parameter Name

Fault x Code d007-d009 Display

Fault Clear A100 Advanced Program

Flying Start En A096 Advanced Program

Internal Freq A069 Advanced Program

Jog Accel/Decel A079 Advanced Program

Jog Frequency A078 Advanced Program

Maximum Freq P035 Basic Program

Maximum Voltage A088 Advanced Program

Minimum Freq P034 Basic Program

Motor NP Hertz P032 Basic Program

Motor NP Volts P031 Basic Program

Motor OL Current P033 Basic Program

Motor OL Ret P043 Basic Program

Motor OL Select A090 Advanced Program

Output Current d003 Display

Output Freq d001 Display

Output Voltage d004 Display

Preset Freq x A070-A073 Advanced Program

Process Display d010 Display

Process Factor A099 Advanced Program

Process Time Hi A116 Advanced Program

Process Time Lo A115 Advanced Program

Program Lock A101 Advanced Program

PWM Frequency A091 Advanced Program

Relay Out Level A056 Advanced Program

Relay Out Sel A055 Advanced Program

Reset To Defalts P041 Basic Program

Reverse Disable A095 Advanced Program

S Curve % A083 Advanced Program

Slip Compensation A114 Advanced Program

Speed Reference P038 Basic Program

Start At PowerUp A094 Advanced Program

Start Source P036 Basic Program

Stop Mode P037 Basic Program

SW Current Trip A098 Advanced Program

Testpoint Data d019 Display

Testpoint Sel A102 Advanced Program

No. Group

3-28 Programming and Parameters

Notes:

Chapter 4

Troubleshooting

Chapter 4 provides information to guide you in troubleshooting the
PowerFlex 4 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…

Drive Status 4-1 Fault Descriptions 4-3

Faults 4-1 Common Symptoms and

Corrective Actions

Drive Status

4-5

The condition or state of your drive is constantly monitored. Any
changes will be indicated through the integral keypad.

LED Indications

page 2-3 for information on drive status indicators and controls.

See

Faults

A fault is a condition that stops the drive. There are two fault types.

Type Fault Description

Auto-Reset/Run When this type of fault occurs, and

➀

set to a value greater than “0,” a user-configurable timer,
[Auto Rstrt Delay], begins. When the timer reaches zero, the
drive attempts to automatically reset the fault. If the condition
that caused the fault is no longer present, the fault will be reset
and the drive will be restarted.

Non-Resetable This type of fault may require drive or motor repair, or is

➁

caused by wiring or programing errors. The cause of the fault
must be corrected before the fault can be cleared.

A092 [Auto Rstrt Tries] is

A093

4-2 Troubleshooting

FAULT

VOLTS
AMPS
HERTZ

RUN
FWD
REV

PRGOGRAM

Fault Indication

Condition Display

Drive is indicating a fault.

The integral keypad provides visual notification of a
fault condition by displaying the following.

 Flashing fault number

 Flashing fault indicator

Press the Escape key to regain control of the
integral keypad.

Manually Clearing Faults

Step Key(s)

1. Press Esc to acknowledge the fault. The fault information will be
removed so that you can use the integral keypad.

Access d007

2. Address the condition that caused the fault.
The cause must be corrected before the fault can be cleared.
See Tab l e 4 .A .

3. After corrective action has been taken, clear the fault by one of these
methods.

 Press Stop if

 Cycle drive power.

 Set

 Cycle digital input if

A100 [Fault Clear] to “1” or “2”.

“Clear Fault”.

[Fault 1 Code] to view the most recent fault information.

P037 [Stop Mode] is set to a value between “0” and “3”.

A051 - A052 [Digital Inx Select] is set to option 7

Automatically Clearing Faults

Option / Step

Clear a Type 1 fault and restart the drive.

1. Set

2. Set

A092 [Auto Rstrt Tries] to a value other than “0”.

A093 [Auto Rstrt Delay] to a value other than “0”.

Clear an OverVoltage, UnderVoltage or Heatsink OvrTmp fault
without restarting the drive.

1. Set

2. Set

A092 [Auto Rstrt Tries] to a value other than “0”.

A093 [Auto Rstrt Delay] to “0”.

Auto Restart (Reset/Run)

The Auto Restart feature provides the ability for the drive to
automatically perform a fault reset followed by a start attempt without
user or application intervention. This allows remote or “unattended”
operation. Only certain faults are allowed to be reset. Certain faults
(Type 2) that indicate possible drive component malfunction are not
resettable.

Caution should be used when enabling this feature, since the drive will
attempt to issue its own start command based on user selected
programming.

Fault Descriptions

Table 4.A Fault Types, Descriptions and Actions

(1)

Troubleshooting 4-3

No. Fault

F2 Auxiliary Input

F3 Power Loss

F4 UnderVoltage

F5 OverVoltage

F6 Motor Stalled

F7 Motor Overload

F8 Heatsink

OvrTmp

F12 HW OverCurrent

F13 Ground Fault

Description Action

Type

Auxiliary input interlock is open. 1. Check remote wiring.

➀

2. Verify communications
programming for intentional fault.

DC bus voltage remained below

➁

85% of nominal.

DC bus voltage fell below the

➀

minimum value.

DC bus voltage exceeded

➀

maximum value.

Drive is unable to accelerate

➀

motor.

Internal electronic overload trip. 1. An excessive motor load exists.

➀

Heatsink temperature exceeds a

➀

predefined value.

The drive output current has

➁

exceeded the hardware current
limit.

A current path to earth ground

➁

has been detected at one or
more of the drive output
terminals.

1. Monitor the incoming AC line for
low voltage or line power
interruption.

2. Check input fuses.

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.

Increase
or reduce load so drive output
current does not exceed the current
set by parameter A089 [Current
Limit].

2. Verify

1. Check for blocked or dirty heat

2. Check fan.

Check programming. Check for
excess load, improper
Select] setting, DC brake volts set
too high or other causes of excess
current.

Check the motor and external wiring
to the drive output terminals for a
grounded condition.

P039 - A067 [Accel Time x]

Reduce load so drive output
current does not exceed the
current set by parameter
[Motor OL Current].

A084 [Boost Select]

setting

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 IP20/Open type installations.

A084 [Boost

P033

(1)

page 4-1 for a description of fault types.

See

4-4 Troubleshooting

(1)

No. Fault

F33 Auto Rstrt Tries

F38 Phase U to Gnd

F39 Phase V to Gnd

F40 Phase W to Gnd

F41 Phase UV Short

F42 Phase UW Short

F43 Phase VW Short

F48 Params

Defaulted

F63 SW OverCurrent

F64 Drive Overload

F70 Power Unit

F71 Net Loss The communication network has

F81 Comm Loss

F100 Parameter

Checksum

F122 I/O Board Fail

Description Action

Typ e

Drive unsuccessfully attempted

➁

to reset a fault and resume
running for the programmed
number of
Tr ie s] .

A phase to ground fault has been

➁

detected between the drive and
motor in this phase.

Excessive current has been

➁

detected between these two
output terminals.

The drive was commanded to
write default values to EEPROM.

Programmed

➀

Trip] has been exceeded.

Drive rating of 150% for 1 minute

➁

or 200% for 3 seconds has been
exceeded.

Failure has been detected in the

➁

drive power section.

faulted.

RS485 (DSI) port stopped

➁

communicating.

The checksum read from the

➁

board does not match the
checksum calculated.

Failure has been detected in the

➁

drive control and I/O section.

A092 [Auto Rstrt

A098 [SW Current

Correct the cause of the fault and
manually clear.

1. Check the wiring between the
drive and motor.

2. Check motor for grounded
phase.

3. Replace drive if fault cannot be
cleared.

1. Check the motor and drive output
terminal wiring for a shorted
condition.

2. Replace drive if fault cannot be
cleared.

1. Clear the fault or cycle power to
the drive.

2. Program the drive parameters as
needed.

Check load requirements and A098
[SW Current Trip] setting.

Reduce load or extend Accel Time.

1. Cycle power.

2. Replace drive if fault cannot be
cleared.

1. Cycle power.

2. Check communications cabling.

3. Check network adapter setting.

4. Check external network status.

1. If adapter was not intentionally
disconnected, check wiring to the
port. Replace wiring, port
expander, adapters or complete
drive as required.

2. Check connection.

3. An adapter was intentionally
disconnected.

4. Turn off using
Action].

P041 [Reset To Defalts] to

Set
option 1 “Reset Defaults”.

1. Cycle power.

2. Replace drive if fault cannot be
cleared.

A105 [Comm Loss

(1)

See

page 4-1 for a description of fault types.

Troubleshooting 4-5

Common Symptoms and Corrective Actions

Motor does not Start.

Cause(s) Indication Corrective Action

No output voltage to the motor. None Check the power circuit.

 Check the supply voltage.

 Check all fuses and disconnects.

Check the motor.

 Verify that the motor is

connected properly.

Check the control input signals.

 Verify that a Start signal is

present. If 2-Wire control is used,
verify that either the Run
Forward or Run Reverse signal is
active, but not both.

 Verify that I/O Terminal 01 is

active.

 Verify that P036 [Start Source]

matches your configuration.

Improper boost setting at initial
start-up.

 Verify that

Disable] is not prohibiting
movement.

None Set A084 [Boost Select] to option 2

“35.0, VT”.

A095 [Reverse

Drive does not Start from Integral Keypad.

Cause(s) Indication Corrective Action

Integral keypad is not enabled. Green LED above Start key is

not illuminated.

I/O Terminal 01 “Stop” input is
not present.

None Wire inputs correctly and/or install

 Set parameter

Source] to option 0 “Keypad”.

 Set parameter

[Digital Inx Select] to option 5
“Local” and activate the input.

jumper.

P036 [Start

A051 - A052

4-6 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

[Fault Clear] to option 1

Incorrect programming.

P036



 A051 - A052 [Digital Inx Select]

Incorrect input wiring.
See

 2 wire control requires Run

 3 wire control requires Start and

 Stop input is always required.

Incorrect Sink/Source DIP switch
setting.

[Start Source] is set to
option 0 “Keypad” or option 5
“RS485 (DSI) Port”.

is set to option 5 “Local” and the
input is active.

1-14 for wiring examples.

Forward, Run Reverse or Jog
input.

Stop inputs

 Set A100

“Clear Faults”.

 Cycle digital input if

[Digital Inx Select] is set to option
7 “Clear Fault”.

None Check parameter settings.

None Wire inputs correctly and/or install

jumper.

None Set switch to match wiring scheme.

A051 - A052

Drive does not respond to changes in speed command.

Cause(s) Indication Corrective Action

No value is coming from the
source of the command.

Incorrect reference source is
being selected via remote
device or digital inputs.

The drive “Run” indicator is lit
and output is 0 Hz.

None  Check

 Check d012

Source] for correct source.

 If the source is an analog input,

check wiring and use a meter to
check for presence of signal.

 Check

to verify correct command.

correct source.

 Check

see if inputs are selecting an
alternate source. Verify settings

A051

for
Select].

 Check

for the source of the speed
reference. Reprogram as
necessary.

 Review the Speed Reference

Control chart on

d002 [Commanded Freq]

d012 [Control Source] for

d014 [Dig In Status] to

- A052 [Digital Inx

P038 [Speed Reference]

d012 [Control

page 1-18.

Troubleshooting 4-7

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

Cause(s) Indication Corrective Action

Acceleration time is excessive. None Reprogram

A067 [Accel Time 2].

Excess load or short
acceleration times force the
drive into current limit, slowing
or stopping acceleration.

Speed command source or
value is not as expected.

Programming is preventing the
drive output from exceeding
limiting values.

None Compare

A089 [Current Limit].

Remove excess load or reprogram

P039 [Accel Time 1] or A067 [Accel

Time 2].

Check for improper
Select] setting.

None Verify

Check
proper Speed Command.

None Check

insure that speed is not limited by
programming.

P039 [Accel Time 1] or

d003

[Output Current] with

d002 [Commanded Freq].

d012 [Control Source] for the

P035

[Maximum Freq] to

A084

[Boost

Motor operation is unstable.

Cause(s) Indication Corrective Action

Motor data was incorrectly
entered.

None 1. Correctly enter motor nameplate

data into

2. Enable

3. Use
reduce boost level.

P031, P032 and P033.

A097 [Compensation].

A084

[Boost Select] to

Drive will not reverse motor direction.

Cause(s) Indication Corrective Action

Digital input is not selected for
reversing control.

Digital input is incorrectly
wired.

Motor wiring is improperly
phased for reverse.

Reverse is disabled. None Check

None Check [Digital Inx Sel]

page 3-13). Choose correct input

and program for reversing mode.

None Check input wiring.

None Switch two motor leads.

A095 [Reverse Disable].

(See

(See page 1-13)

4-8 Troubleshooting

Notes:

Appendix A

Supplemental Drive Information

For information on… See page…

Drive, Fuse & Circuit Breaker Ratings A-1

Specifications A-2

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. Sizes listed are the recommended
sizes based on 40 °C (104 °F) and the U.S. N.E.C. Other country, state or
local codes may require different ratings.

Fusing

The recommended fuse types are listed below. If available current ratings
do not match those listed in the tables provided, choose the next higher
fuse rating.

(1)

 IEC – BS88 (British Standard) Parts 1 & 2

2, type gG or equivalent should be used.

 UL – UL Class CC, T or J must be used.

, EN60269-1, Parts 1 &

(2)

Circuit Breakers

The “non-fuse” listing in the following tables include inverse time circuit
breakers, instantaneous trip circuit breakers (motor circuit protectors)
and 140M self-protected combination motor controllers. If one of these
is chosen as the desired protection method, the following requirements
apply:

 IEC – Both types of circuit breakers and 140M self-protected

combination motor controllers are acceptable for IEC installations.

 UL – Only inverse time circuit breakers and the specified 140M

self-protected combination motor controllers are acceptable for UL
installations.

(1)

Typical designations include, but may not be limited to the following; Parts 1 & 2: AC,

AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

(2)

Typical designations include; Type CC - KTK-R, FNQ-R

Type J - JKS, LPJ

Type T - JJS, JJN

A-2 Supplemental Drive Information

U

L

®

L

I

S

T

E

D

9

6

6

X

UL508C

U

L

®

L

I

S

T

E

D

9

6

6

X

I

N

D

C

O

N

T

E

Q

C

CSA 22.2

EMC Directive: 2014/30/EU: EN 61800-3
LV Directive: 2014/35/EU: EN 61800-5-1

Low Voltage TR CU 004/2011
EMC TR CU 020/2011

KCC-REM-RAA-22B

Specifications

Drive Ratings

Catalog
Number

100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output

22A-V1P5N104 0.2 (0.25) 1.5 90-126 0.75 6.0 10 140M-C2E-C10 100-C09 1655

22A-V2P3N104 0.4 (0.5) 2.3 90-126 1.15 9.0 15 140M-C2E-C16 100-C12 1655

22A-V4P5N104 0.75 (1.0) 4.5 90-126 2.25 18.0 30 140M-D8E-C20 100-C23 1655

22A-V6P0N104 1.1 (1.5) 6.0 90-126 3.0 24.0 40 140M-F8E-C32 100-C37 1655

200 - 240V AC (±10%) – 1-Phase

22A-A1P4N103 0.2 (0.25) 1.4 180-265 0.7 3.2 6 140M-C2E-B40 100-C09 1655

22A-A2P1N103 0.4 (0.5) 2.1 180-265 1.05 5.3 10 140M-C2E-B63 100-C09 1655

22A-A3P6N103 0.75 (1.0) 3.6 180-265 1.8 9.2 15 140M-C2E-C16 100-C12 1655

22A-A6P8N103 1.5 (2.0) 6.8 180-265 3.4 14.2 25 140M-C2E-C16 100-C16 1655

22A-A9P6N103 2.2 (3.0) 9.6 180-265 4.8 19.6 30 140M-D8E-C25 100-C23 1655

200 - 240V AC (±10%) – 1-Phase

22A-A1P5N104 0.2 (0.25) 1.5 180-265 0.75 5.0 10 140M-C2E-B63 100-C09 1655

22A-A2P3N104 0.4 (0.5) 2.3 180-265 1.15 6.0 10 140M-C2E-B63 100-C09 1655

22A-A4P5N104 0.75 (1.0) 4.5 180-265 2.25 10.0 15 140M-C2E-C16 100-C12 1655

22A-A8P0N104 1.5 (2.0) 8.0 180-265 4.0 18.0 30 140M-D8E-C20 100-C23 1655

200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output

22A-B1P5N104 0.2 (0.25) 1.5 180-265 0.75 1.8 3 140M-C2E-B25 100-C09 1655

22A-B2P3N104 0.4 (0.5) 2.3 180-265 1.15 2.5 6 140M-C2E-B40 100-C09 1655

22A-B4P5N104 0.75 (1.0) 4.5 180-265 2.25 5.2 10 140M-C2E-C10 100-C09 1655

22A-B8P0N104 1.5 (2.0) 8.0 180-265 4.0 9.5 15 140M-C2E-C16 100-C12 1655

22A-B012N104 2.2 (3.0) 12.0 180-265 5.5 15.5 25 140M-C2E-C16 100-C16 1655

22A-B017N104 3.7 (5.0) 17.5 180-265 8.6 21.0 30 140M-F8E-C25 100-C23 1655

380 - 480V AC (±10%) – 3-Phase

22A-D1P4N104 0.4 (0.5) 1.4 340-528 1.4 1.8 3 140M-C2E-B25 100-C09 1655

22A-D2P3N104 0.75 (1.0) 2.3 340-528 2.3 3.2 6 140M-C2E-B40 100-C09 1655

22A-D4P0N104 1.5 (2.0) 4.0 340-528 4.0 5.7 10 140M-C2E-B63 100-C09 1655

22A-D6P0N104 2.2 (3.0) 6.0 340-528 5.9 7.5 15 140M-C2E-C10 100-C09 1655

22A-D8P7N104 3.7 (5.0) 8.7 340-528 8.6 9.0 15 140M-C2E-C16 100-C16 1655

Input/Output Ratings

Output Frequency: 0-240 Hz (Programmable)

Efficiency: 97.5% (Typical)

Output Ratings Input Ratings Branch Circuit Protection

kW (HP) Amps

Voltage
Range kVA Amps Fuses

(1)

Input, 0 - 230V 3-Phase Output, NO BRAKE

(1)

Input, 0 - 230V 3-Phase Output

Input, 0 - 460V 3-Phase Output

140M Motor
Protectors

(2) (3)

Approvals

Contactors

Min. Enclosure
Vol um e

(4)

(in.3)

Digital Control Inputs (Input Current = 6mA) Analog Control Inputs

SRC (Source) Mode:

18-24V = ON
0-6V = OFF

SNK (Sink) Mode:

0-6V = ON
18-24V = OFF

4-20mA Analog: 250 ohm input impedance
0-10V DC Analog: 100k ohm input impedance
External Pot: 1-10k ohms, 2 Watt minimum

Control Output (Programmable Output, form C relay)

Resistive Rating: 3.0A at 30V DC, 125V AC and 240V AC Inductive Rating: 0.5A at 30V DC, 125V AC, and 240V AC

Recommended Fuses and Circuit Breakers

Fuse: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent. Circuit Breakers: HMCP or Bulletin 140U or equivalent.

Protective Features

Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)

Overcurrent: 200% hardware limit, 300% instantaneous fault

Over Voltage: 100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)

Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)

Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs

Faultless Power Ride Through: 100 milliseconds

Dynamic Braking

Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 4 User Manual
on CD for ordering information.

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)

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)

Supplemental Drive Information A-3

(1)

200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix changes from N103 to N113
and N104 to N114.

(2)

The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M Motor Protection

Circuit Breakers Application Ratings.

(3)

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.

(4)

When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be installed in a ventilated or
non-ventilated enclosure with the minimum volume specified in this column. Application specific thermal considerations
may require a larger enclosure.

Category Specification

Environment Altitude: 1000 m (3300 ft) max. without derating

Maximum Surrounding Air

Temperature without derating:

IP20:

NEMA 1:

Flange Mount:

Cooling Method

Convection:

Fan:

Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)

Atmosphere: Important: Drive must

Relative Humidity: 0 to 95% non-condensing

Shock (operating): 15G peak for 11ms duration (±1.0ms)

Vibration (operating): 1G peak, 5 to 2000 Hz

Sound Pressure Level

(A-weighted)

Frame A:

Frame B:

Control Carrier Frequency 2-16 kHz. Drive rating based on 4 kHz.

Frequency Accuracy

Digital Input:

Analog Input:

Speed Regulation - Open Loop
with Slip Compensation:

Stop Modes: Multiple programmable stop modes including -

Accel/Decel: Two independently programmable accel and

Intermittent Overload: 150% Overload capability for up to 1 minute

Electronic Motor Overload
Protection

–10 to 50° C (14 to 122° F)

–10 to 40° C (14 to 104° F)

Heatsink: –10 to 40° C (14 to 104° F)

Drive: –10 to 50° C (14 to 122° F)

0.2 kW (0.25 HP) drives

Flange Mount drives, all ratings

All other drive ratings.

not be installed in an
area where the ambient atmosphere contains
volatile or corrosive gas, vapors or dust. If the
drive is not going to be installed for a period of
time, it must be stored in an area where it will not
be exposed to a corrosive atmosphere.

Measurements are taken 1 m from the drive.

Maximum 50 dBA

Maximum 51 dBA

Within ±0.05% of set output frequency.

Within 0.5% of maximum output frequency.

±2% of base speed across a 40:1 speed range.

Ramp, Coast, DC-Brake, Ramp-to-Hold and
S Curve.

decel times. Each time may be programmed from
0 - 600 seconds in 0.1 second increments.

200% Overload capability for up to 3 seconds

Provides class 10 motor overload protection
according to NEC article 430 and motor
over-temperature protection according to NEC
article 430.126 (A) (2). UL 508C File 29572.

A-4 Supplemental Drive Information

PowerFlex 4 Estimated Watts Loss (Rated Load, Speed & PWM)

Voltage kW (HP) External Watts Internal Watts Total Watts Loss

100–120V 0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.1 (1.5)

200–240V 0.2 (0.25)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

380–480V 0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

Product Environmental Information

16
22
35
58

16
22
35
63
100
150

17
30
48
75
125

16
18
20
22

16
18
20
22
25
30

18
20
22
25
25

32
40
55
80

32
40
55
85
125
180

35
50
70
100
150

Rockwell Automation maintains current product environmental
information on its website at:

http://www.rockwellautomation.com/rockwellautomation/about-us/
sustainability-ethics/product-environmental-compliance.page.

At the end of its life, this equipment should be collected separately from any
unsorted municipal waste.

Appendix B

Accessories and Dimensions

For information on… See page

Product Selection B-1

Product Dimensions B-5

Product Selection

Table B.A Catalog Number Description

22A - A 1P5 N 1 1 4

Drive Voltage Rating Rating Enclosure HIM Emission Class Type

Table B.B PowerFlex 4 Drives

Drive Ratings Catalog Number

Output
Current Panel Mount Flange Mount

120V 50/60 Hz
1-Phase

No Filter

240V 50/60 Hz
1-Phase

NO BRAKE
With Integral “S Type”

EMC Filter

240V 50/60 Hz
1-Phase

NO BRAKE
No Filter

240V 50/60 Hz
1-Phase

With Integral “S Type”
EMC Filter

240V 50/60 Hz
1-Phase

No Filter

240V 50/60 Hz
3-Phase

No Filter

480V 50/60 Hz
3-Phase

No Filter

(1)

Replacement Plate drives are also available. Contact factory for ordering information.

0.2 0.25 1.5A 22A-V1P5N104 22A-V1P5F104 A

0.4 0.5 2.3A 22A-V2P3N104 22A-V2P3F104 A

0.75 1.0 4.5A 22A-V4P5N104 22A-V4P5F104 B

1.1 1.5 6.0A 22A-V6P0N104 22A-V6P0F104 B

0.2 0.25 1.4A 22A-A1P4N113 – A

0.4 0.5 2.1A 22A-A2P1N113 – A

0.75 1.0 3.6A 22A-A3P6N113 – A

1.5 2.0 6.8A 22A-A6P8N113 – B

2.2 3.0 9.6A 22A-A9P6N113 – B

0.2 0.25 1.4A 22A-A1P4N103 22A-A1P4F103 A

0.4 0.5 2.1A 22A-A2P1N103 22A-A2P1F103 A

0.75 1.0 3.6A 22A-A3P6N103 22A-A3P6F103 A

1.5 2.0 6.8A 22A-A6P8N103 22A-A6P8F103 B

2.2 3.0 9.6A 22A-A9P6N103 22A-A9P6F103 B

0.2 0.25 1.5A 22A-A1P5N114 – A

0.4 0.5 2.3A 22A-A2P3N114 – A

0.75 1.0 4.5A 22A-A4P5N114 – A

1.5 2.0 8.0A 22A-A8P0N114 – B

0.2 0.25 1.5A 22A-A1P5N104 22A-A1P5F104 A

0.4 0.5 2.3A 22A-A2P3N104 22A-A2P3F104 A

0.75 1.0 4.5A 22A-A4P5N104 22A-A4P5F104 A

1.5 2.0 8.0A 22A-A8P0N104 22A-A8P0F104 B

0.2 0.25 1.5A 22A-B1P5N104 22A-B1P5F104 A

0.4 0.5 2.3A 22A-B2P3N104 22A-B2P3F104 A

0.75 1.0 4.5A 22A-B4P5N104 22A-B4P5F104 A

1.5 2.0 8.0A 22A-B8P0N104 22A-B8P0F104 A

2.2 3.0 12.0A 22A-B012N104 22A-B012F104 B

3.7 5.0 17.5 22A-B017N104 22A-B017F104 B

0.4 0.5 1.4A 22A-D1P4N104 22A-D1P4F104 A

0.75 1.0 2.3A 22A-D2P3N104 22A-D2P3F104 A

1.5 2.0 4.0A 22A-D4P0N104 22A-D4P0F104 A

2.2 3.0 6.0A 22A-D6P0N104 22A-D6P0F104 B

3.7 5.0 8.7A 22A-D8P7N104 22A-D8P7F104 B

(1)

Frame
SizeInput Voltage kW HP

B-2 Accessories and Dimensions

Table B.C Dynamic Brake Modules

Drive Ratings

Input Voltage kW HP

120V 50/60 Hz
1-Phase

240V 50/60 Hz
1-Phase

240V 50/60 Hz
3-Phase

480V 50/60 Hz
3-Phase

0.2 0.25 60 10 AK-R2-091P500

0.4 0.5 60 10 AK-R2-091P500

0.75 1.0 60 10 AK-R2-091P500

1.1 1.5 60 10 AK-R2-091P500

0.2 0.25 60 10 AK-R2-091P500

0.4 0.5 60 10 AK-R2-091P500

0.75 1.0 60 10 AK-R2-091P500

1.5 2.0 60 10 AK-R2-091P500

0.2 0.25 60 10 AK-R2-091P500

0.4 0.5 60 10 AK-R2-091P500

0.75 1.0 60 10 AK-R2-091P500

1.5 2.0 60 10 AK-R2-091P500

2.2 3.0 48 12 AK-R2-047P500

3.7 5.0 32 20 AK-R2-047P500

0.4 0.5 121 10 AK-R2-091P500

0.75 1.0 121 10 AK-R2-360P500

1.5 2.0 121 10 AK-R2-360P500

2.2 3.0 97 12 AK-R2-120P1K2

3.7 5.0 97 12 AK-R2-120P1K2

Minimum
Resistance 

Dynamic
Brake Fuse

(1)

Rating

Catalog Number

(2) (3)

(1)

Refer to

(2)

The resistors listed in this table are rated for 5% duty cycle.

(3)

Use of Rockwell resistors is always recommended. The resistors listed have been carefully

EN61800-5-1 compliance in Table 1.D for more information.

selected for optimizing performance in a varity of applications. Alternative resistors may be used,
however care must be taken when making a selection. Refer to the

Resistor Calculator

, publication PFLEX-AT001….

PowerFlex Dynamic Braking

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

Maximum

Input Voltage kW HP

240V 50/60 Hz
3-Phase

0.2 0.25 2 3 12.0 mh 7.5 W 1321-3R2-A

0.4 0.5 4 6 12.0 mh 21 W 1321-3R4-D

0.75 1.0 8 12 3.0 mh 29 W 1321-3R8-B

1.5 2.0 8 12 1.5 mh 19.5 W 1321-3R8-A

2.2 3.0 12 18 1.25 mh 26 W 1321-3R12-A

3.7 5.0 18 27 0.8 mh 36 W 1321-3R18-A

480V 50/60 Hz
3-Phase

0.4 0.5 2 3 20.0 mh 11.3 W 1321-3R2-B

0.75 1.0 4 6 9.0 mh 20 W 1321-3R4-C

1.5 2.0 4 6 6.5 mh 20 W 1321-3R4-B

2.2 3.0 8 12 5.0 mh 25.3 W 1321-3R8-C

3.7 5.0 18 27 3.0 mh 29 W 1321-3R-12-B

Fundamental
Amps

Continuous
Amps Inductance

Watts
Loss

Catalog
Number

(1)

(1)

Catalog numbers listed are for 3% impedance open style units. NEMA Type 1 and 5% impedance
reactor types are also available. Refer to publication 1321-TD001….

Table B.E EMC Line Filters

Accessories and Dimensions B-3

Drive Ratings

Input Voltage kW HP

120V 50/60 Hz
1-Phase

0.2 0.25 – 22-RF010-AL

0.4 0.5 – 22-RF010-AL

S Type Filter
Catalog Number

L Type Filter

(1)

Catalog Number

0.75 1.0 – 22-RF018-BL

1.1 1.5 – 22-RF025-CL

240V 50/60 Hz
1-Phase

240V 50/60 Hz
1-Phase
NO BRAKE

240V 50/60 Hz
3-Phase

0.2 0.25

0.4 0.5

0.75 1.0

1.5 2.0

0.2 0.25

0.4 0.5

0.75 1.0

1.5 2.0

2.2 3.0

0.2 0.25 22-RF9P5-AS 22-RF9P5-AL

0.4 0.5 22-RF9P5-AS 22-RF9P5-AL

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

22-RF010-AL

22-RF010-AL

22-RF010-AL

22-RF018-BL

22-RF010-AL

22-RF010-AL

22-RF010-AL

22-RF018-BL

22-RF025-CL

0.75 1.0 22-RF9P5-AS 22-RF9P5-AL

1.5 2.0 22-RF9P5-AS 22-RF9P5-AL

2.2 3.0 22-RF021-BS 22-RF021-BL

3.7 5.0 22-RF021-BS 22-RF021-BL

480V 50/60 Hz
3-Phase

0.4 0.5 22-RF5P7-AS 22-RF5P7-AL

0.75 1.0 22-RF5P7-AS 22-RF5P7-AL

1.5 2.0 22-RF5P7-AS 22-RF5P7-AL

2.2 3.0 22-RF012-BS 22-RF012-BL

3.7 5.0 22-RF012-BS 22-RF012-BL

(1)

This filter is suitable for use with a cable length up to 10 meters (33 feet) for Class A and 1 meter
for Class B environments.

(2)

These ratings can be ordered with internal “S Type” filters. Refer to the Catalog Number
explanation on

(3)

This filter is suitable for use with a cable length up to 100 meters for Class A and 5 meters for

page P-4 and Ta b l e B. B for details.

Class B environments.

(4)

The piggyback mounting option cannot be used with Frame B PowerFlex 4 drives and Frame C
EMC Line Filters.

(3)

(4)

(4)

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

Item Description Catalog Number

LCD Display, Remote Panel
Mount

LCD Display, Remote Handheld Digital speed control

Bezel Kit Panel mount for LCD Display, Remote

DSI HIM Cable
(DSI HIM to RJ45 cable)

(1)

The 22-HIM-C2S is smaller than the 22-HIM-C2 and cannot be used as a direct replacement.

Digital speed control
CopyCat capable
IP66 (NEMA Type 4X/12) indoor use only
22-HIM-C2 includes 2.9 meter cable.
22-HIM-C2S includes 2 meter cable.

Full numeric keypad
CopyCat capable
IP30 (NEMA Type 1)
Includes 1.0 meter cable
Panel mount with optional Bezel Kit

Handheld unit, IP30 (NEMA Type 1)

1.0 Meter (3.3 Feet)

2.9 Meter (9.51 Feet)

22-HIM-C2
22-HIM-C2S

22-HIM-A3

22-HIM-B1

22-HIM-H10
22-HIM-H30

(1)

B-4 Accessories and Dimensions

Table B.G Communication Option Kits

Item Description Catalog Number

External DSI™
Communications Kit

External Comms Power
Supply

Compact I/O Module Three channel. 1769-SM2

Serial Converter Module
(RS485 to RS232)

DSI Cable 2.0 meter RJ45 to RJ45 cable, male to male

Serial Cable 2.0 meter serial cable with a locking low profile

Null Cable Converter For use when connecting the serial converter to

Splitter Cable RJ45 one to two port splitter cable AK-U0-RJ45-SC1

Terminating Resistors RJ45 120 Ohm resistors (2 pieces) AK-U0-RJ45-TR1

Terminal Block RJ45 Two position terminal block (5 pieces) AK-U0-RJ45-TB2P

DriveExplorer Software
(CD-ROM) Version 3.01
or later

DriveExecutive software
(CD-ROM) Version 1.01
or later

External mounting kit for 22-COMM-C, -D, -E, -P. 22-XCOMM-DC-BASE

Optional 100-240V AC Power Supply for External
DSI Communications Kit.

Provides serial communication via DF1 protocol
for use with DriveExplorer and DriveExecutive
software. Includes:

DSI to RS232 serial converter (1)
1203-SFC serial cable (1)
22-RJ45CBL-C20 cable (1)
DriveExplorer Lite CD (1)

connectors.

connector to connect to the serial converter and a
9-pin sub-miniature D female connector to connect
to a computer.

DriveExplorer on a handheld PC.

Windows based software package that provides
an intuitive means for monitoring or configuring
Allen-Bradley drives and communication adapters
online.

Compatibility:

Windows 95, 98, ME, NT 4.0 (Service Pack 3 or
later), 2000, XP and CE

Windows based software package that provides
an intuitive means for monitoring or configuring
Allen-Bradley drives and communication adapters
online and offline.

Compatibility:

Windows 98, ME, NT 4.0 (Service Pack 3 or
later), 2000 and XP

(2)

20-XCOMM-AC-PS1

22-SCM-232

22-RJ45CBL-C20

1203-SFC

1203-SNM

9306-4EXP01ENE

(1)

9303-4DTE01ENE

(1)

See www.ab.com/drives/driveexplorer.htm for supported devices.

(2)

For pricing information, refer to the PowerFlex 4-Class

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

Item Description

IP30/NEMA 1/UL Type 1
Kit

(1)

For pricing information, refer to the PowerFlex 4-Class

Field installed kit. Converts drive to IP30/
NEMA 1/UL Type 1 enclosure. Includes
conduit box with mounting screws and
plastic top panel.

Price List, Publication 22-PL001….

Drive
Frame Catalog Number

A22-JBAA

B22-JBAB

Price List, Publication 22-PL001….

(1)

Accessories and Dimensions B-5

a

ge

d

c

b

f

5.5 (0.22)

59.2

(2.33)

40.0

(1.57)

20.7

(0.81)

75.3

(2.96)

109.3
(4.30)

74.3

(2.93)

109.9

(4.33)

64.1

(2.52)

79.1

(3.11)

40.6

(1.60)

25.6

(1.01)

∅ 22.2
(0.87)

∅ 22.2
(0.87)

Frame A - 22-JBAA Frame B - 22-JBAB

Product Dimensions

Table B.I PowerFlex 4 Panel Mount Drives – Ratings are in kW and (HP)

120V AC – 1-Phase

Frame

A 0.2 (0.25)

0.37(0.5)

B 0.75(1.0)

1.1 (1.5)

Figure B.1 PowerFlex 4 Panel Mount Drives – Dimensions are in millimeters and

(inches). Weights are in kilograms and (pounds).

240V AC – 1-Phase
No Brake

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

240V AC – 1-Phase 240V AC – 3-Phase 480V AC – 3-Phase

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0) 2.2 (3.0)

0.2 (0.25)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

3.7 (5.0)

0.37 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

Frame a b

A 80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64) 152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1)

B 100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9)

(1)

Overall height of drive with IP 30/NEMA 1/UL Type 1 option kit installed.

(2)

Overall height of standard IP 20/Open Type drive.

(1)

cde

(2)

fg

Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit – Dimensions are in millimeters and

(inches)

Shipping
Weight

B-6 Accessories and Dimensions

175

(6.89)

210

(8.27)

54.7

(2.15)

92.8

(3.65)

145

(5.71)

244

(9.61)

250

(9.84)

94.3

(3.71)

63.1

(2.48)

214

(8.43)

Frame A

Frame B

Figure B.3 PowerFlex 4 Flange Mount Drives – Dimensions are in millimeters and

(inches)

Accessories and Dimensions B-7

195

(7.68)

97.5

(3.84)

179

(7.05)

8

(0.31)

130

(5.12)

114

(4.49)

5.3

(0.21)

8

(0.31)

98

(3.86)

49

(1.93)

16

(0.63)

210

(8.27)

98

(3.86)

160

(6.30)

145

(5.71)

49

(1.93)

31

(1.22)

7.5

(0.30)

14

(0.55)

98.5

(3.88)

197

(7.76)

6.5

(0.26)

225

(8.86)

23.5

(0.93)

5.3

(0.21)

Frame A

Frame B

Figure B.4 PowerFlex 4 Cutout Dimensions – Dimensions are in millimeters and

(inches)

B-8 Accessories and Dimensions

104.8

(4.13)

175

(6.89)

152

(5.98)

163

(6.42)

81.5

(3.21)

6

(0.24)

88

(3.46)

92

(3.62)

80

(3.15)

50

(1.97)

5.3

(0.21)

Frame A

Frame B

Figure B.5 PowerFlex 4 Replacement Plate Drive Dimensions – Dimensions are in

millimeters and (inches)

112

(4.41)

80

(3.15)

100

(3.94)

125

(4.92)

96

(3.78)

(0.21)

192

(7.56)

5.3

204

(8.03)

180

(7.09)

88

(3.46)

9.5

(0.37)

Accessories and Dimensions B-9

335.0

(13.19)

60.0

(2.36)

30.0

(1.18)

17.0

(0.67)

59.0

(2.32)

13.0

(0.51)

405.0

(15.94)

386.0

(15.20)

316.0

(12.44)

61.0

(2.40)

31.0

(1.22)

ROCKWELL

AUTOMATION

CUS

SURFACES MAY BE

ROCKWELL

AUTOMATION

CUS

Frame A Frame B

Power On

R (L1)
S (L2)

T (L3)

Power Source DB Resistor Thermostat

Power Off

M

M

(Input Contactor) M

Three-Phase

AC Input

Figure B.6 Dynamic Brake Modules – Dimensions are in millimeters and (inches)

Frame Catalog Number

A AK-R2-091P500, AK-R2-047P500, AK-R2-360P500

B AK-R2-030P1K2, AK-R2-120P1K2

Figure B.7 Recommended External Brake Resistor Circuitry

B-10 Accessories and Dimensions

Figure B.8 Bulletin 1321-3R Series Line Reactors

– Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds).

a

b

e

Catalog Number a b c d e 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 112 (4.40) 104 (4.10) 70 (2.75) 50 (1.98) 37 (1.44) 1.8 (4)

1321-3R4-B 112 (4.40) 104 (4.10) 76 (3.00) 50 (1.98) 37 (1.44) 1.8 (4)

1321-3R4-C 112 (4.40) 104 (4.10) 86 (3.38) 60 (2.35) 37 (1.44) 2.3 (5)

1321-3R4-D 112 (4.40) 104 (4.10) 92 (3.62) 66 (2.60) 37 (1.44) 2.7 (6)

1321-3R8-A 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.1 (7)

1321-3R8-B 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 3.6 (8)

1321-3R8-C 152 (6.00) 127 (5.00) 85 (3.35) 63 (2.48) 51 (2.00) 4.9 (11)

1321-3R12-A 152 (6.00) 127 (5.00) 76 (3.00) 53 (2.10) 51 (2.00) 4.1 (9)

1321-3R18-A 152 (6.00) 133 (5.25) 79 (3.10) 54 (2.13) 51 (2.00) 4.1 (9)

d

c

Accessories and Dimensions B-11

5.5 (0.22)

17.8

(0.70)

24

(0.94)

60

(2.36)

80

(3.15)

50

(1.97)

29.8

(1.17)

220

(8.66)

208

(8.19)

208

(8.19)

5.5 (0.22)

17.8

(0.70)

24.0

(0.94)

78

(3.07)

100

(3.94)

50

(1.97)

29.8

(1.17)

229

(9.02)

216

(8.50)

217

(8.54)

Figure B.9 Frame A EMC Line Filters – Dimensions are in millimeters and (inches)

Catalog Numbers: 22-RF5P7-AS, -AL; 22-RF9P5-AS, -AL; 22-RF010-AL

Figure B.10 Frame B EMC Line Filters – Dimensions are in millimeters and (inches)

Catalog Numbers: 22-RF012-BS, -BL (Series B); 22-RF018-BS; 22-RF021-BS, -BL

B-12 Accessories and Dimensions

5.5 (0.22)

17

(0.67)

30

(1.18)

90

(3.54)

130

(5.12)

60

(2.36)

32

(1.26)

309

(12.17)

297

(11.69)

297

(11.69)

Figure B.11 Frame C EMC Line Filters – Dimensions are in millimeters and (inches)

Catalog Number: 22-RF025-CL

Important: The piggyback mounting option cannot be used with

Frame B PowerFlex 4 drives and Frame C EMC Line
Filters.

Accessories and Dimensions B-13

04

(

)

6

(

)

9m

0

(

)

5

(4.92)

60.5

(2.38)

38

(1.50)

8

(

)

66

(

)

1

(

)

8

(

)

Figure B.12 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches)

Catalog Number: 22-HIM-C2

17.

0.69

2.

1

4.09

22

8.66

7

3.07

2.60

19.

0.75

194

(7.64)

12

4.

0.19

B-14 Accessories and Dimensions

93

(

)

5

(

)

80

(

)

54

(6.06)

(3.03)

5

(

)

67

(

)

60

(

)

1

(

)

8

(

)

Figure B.13 Remote (Panel Mount) Small HIM – Dimensions are in millimeters and

(inches) Catalog Number: 22-HIM-C2S

2

0.98

3.66

1

7.09

2.64

2.36

1

19.

0.75

4.

0.19

23.

0.93

Important: The 22-HIM-C2S is smaller than the 22-HIM-C2 and

cannot be used as a direct replacement.

Accessories and Dimensions B-15

93

(3.66)

25.2

(0.99)

180

(7.09)

11. 1

(0.44)

154

(6.06)

77

(

)

5

(

)

67

(

)

60

(

)

1

(

)

8

(

)

Figure B.14 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches)

Catalog Number: 22-HIM-B1

2.64

2.36

19.

0.75

4.

0.19

3.03

23.

0.93

B-16 Accessories and Dimensions

Notes:

Appendix C

Controller

RS485 (DSI) Protocol

PowerFlex 4 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
4 drives can be multi-dropped on an RS485 network using Modbus
protocol in RTU mode.

For information regarding DeviceNet or other communication protocols,
refer to the appropriate usr manual.

Network Wiring

Network wiring consists of a shielded 2-conductor cable that is
daisy-chained from node to node.

Figure C.1 Network Wiring Diagram

PowerFlex 4

Master

TxRxD-

120 ohm resistor

TxRxD+

Shield Shield Shield

Node 1

5

4

X X X

TxRxD-

TxRxD+

NOTE: The shield is connected at ONLY ONE end of each cable segment.

01 02 03 04 05

11 12 13 14 15

06 07 08 09

16 17 18 19

W/T3

V/T2T/L3S/L2R/L1 U/T1

RS485

(DPI)

PowerFlex 4

Node 2

5

4

AK-00-RJ45-TB2P
TxRxD­TxRxD+

PowerFlex 4

Node "n"

TxRxD-

TxRxD+

01 02 03 04 05

11 12 13 14 15

V/T2T/L3S/L2R/L1 U/T1 W/T3

120 ohm resistor

5

4

06 07 08 09

16 17 18 19

PIN 8

FRONT

RS485

(DPI)

PIN 1

TxRxD­TxRxD+

BR+ BR-DC- DC+

BR+ BR-DC- DC+

C-2 RS485 (DSI) Protocol

Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on
the PowerFlex 4 RJ45 socket must not be connected because they
contain power, etc. for other Rockwell Automation peripheral devices.

Wiring terminations on the master controller will vary depending on the
master controller used and “TxRxD+” and “TxRxD-” are shown for
illustration purposes only. Refer to the master controller’s user manual
for network terminations. Note that there is no standard for the “+” and
“-” wires, and consequently Modbus device manufacturers interpret
them differently. If you have problems with initially establishing
communications, try swapping the two network wires at the master
controller.

Standard RS485 wiring practices apply.

 Termination resistors need to be applied at each end of the network

cable.

 RS485 repeaters may need to be used for long cable runs, or if

greater than 32 nodes are needed on the network.

 Network wiring should be separated from power wires by at least 0.3

meters (1 foot).

 Network wiring should only cross power wires at a right angle.

I/O Terminal 16 (RS485 Shield) on the PowerFlex 4 must also be
connected to PE ground (there are two PE terminals on the drive). See

Figure 1.5

Network Common is internally tied to I/O Terminal 04 (Digital
Common). Tying I/O Terminal 04 to PE ground may improve noise
immunity in some applications.

for more information.

RS485 (DSI) Protocol C-3

Parameter Configuration

The following PowerFlex 4 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

the network.

P038 [Speed Reference] Set to 5 “RS485 (DSI) Port” if the Speed Reference is

controlled from the network.

A103 [Comm Data Rate] Sets the data rate for the RS485 (DSI) Port. All nodes

on the network must be set to the same data rate.

A104 [Comm Node Addr] Sets the node address for the drive on the network.

Each device on the network requires a unique node
address.

A105 [Comm Loss Action] Selects the drive’s response to communication

problems.

A106 [Comm Loss Time] Sets the time that the drive will remain in

communication loss before the drive implements A105
[Comm Loss Action].

A107 [Comm Format] Sets the transmission mode, data bits, parity and stop

bits for the RS485 (DSI) Port. All nodes on the network
must be set to the same setting.

Page 3-9

Page 3-11

Page 3-23

Page 3-23

Page 3-24

Page 3-24

Page 3-24

Supported Modbus Function Codes

The peripheral interface (DSI) used on PowerFlex 4 drives supports
some of the Modbus function codes.

Modbus Function Code (Decimal) Command

03 Read Holding Registers

06 Preset (Write) Single Register

16 (10 Hexadecimal) Preset (Write) Multiple Registers

Important: Modbus devices can be 0-based (registers are numbered

starting at 0) or 1-based (registers are numbered starting at

1). Depending on the Modbus Master used, the register
addresses listed on the following pages may need to be
offset by +1. For example, Logic Command may be register
address 8192 for some master devices (e.g. ProSoft
3150-MCM SLC Modbus scanner) and 8193 for others
(e.g. PanelViews).

C-4 RS485 (DSI) Protocol

Writing (06) Logic Command Data

The PowerFlex 4 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. In addition to being written, register address 8192
can be read using Function Code 03.

Address (Decimal) Bit(s) Description

0 1 = Stop, 0 = Not Stop

1 1 = Start, 0 = Not Start

2 1 = Jog, 0 = No Jog

3 1 = Clear Faults, 0 = Not Clear Faults

5,4

6 Not Used

7 Not Used

9,8

8192

11,10

14,13,12

15 Not Used

Logic Command

00 = No Command

01 = Forward Command

10 = Reverse Command

11 = No Command

00 = No Command

01 = Accel Rate 1 Enable

10 = Accel Rate 2 Enable

11 = Hold Accel Rate Selected

00 = No Command

01 = Decel Rate 1 Enable

10 = Decel Rate 2 Enable

11 = Hold Decel Rate Selected

000 = No Command

001 = Freq. Source = P036 [Start Source]

010 = Freq. Source = A069 [Internal Freq]

011 = Freq. Source = Comms (Addr 8193)

100 = A070 [Preset Freq 0]

101 = A071 [Preset Freq 1]

110 = A072 [Preset Freq 2]

111 = A073 [Preset Freq 3]

RS485 (DSI) Protocol C-5

Writing (06) Reference

The Speed Reference to a PowerFlex 4 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” in order to accept the Speed Reference. In addition to being
written, register address 8193 can be read using Function Code 03.

Reference

Address (Decimal) Description

8193

A decimal value entered as xxx.x where the decimal point is fixed. For
example, a decimal “100” equals 10.0 Hz and “543” equals 54.3 Hz.

Reading (03) Logic Status Data

The PowerFlex 4 Logic Status data can be read via the network by
sending Function Code 03 reads to register address 8448 (Logic Status).

Logic Status

Address (Decimal) Bit(s) Description

0 1 = Ready, 0 = Not Ready

1 1 = Active (Running), 0 = Not Active

2 1 = Cmd Forward, 0 = Cmd Reverse

3 1 = Rotating Forward, 0 = Rotating Reverse

4 1 = Accelerating, 0 = Not Accelerating

5 1 = Decelerating, 0 = Not Decelerating

6 1 = Alarm, 0 = No Alarm

8448

7 1 = Faulted, 0 = Not Faulted

8 1 = At Reference, 0 = Not At Reference

9 1 = Reference Controlled by Comm

10 1 = Operation Cmd Controlled by Comm

11 1 = Parameters have been locked

12 Digital Input 1 Status

13 Digital Input 2 Status

14 Not Used

15 Not Used

Reading (03) Feedback

The Feedback (Output Frequency) from the PowerFlex 4 drive can be
read via the network by sending Function Code 03 reads to register
address 8451 (Feedback).

Feedback

Address (Decimal) Description

8451

(1)

Returns the same data as Reading (03) Parameter d001 [Output Freq].

A xxx.x decimal value where the decimal point is fixed. For example, a decimal
“123” equals 12.3 Hz and “300” equals 30.0 Hz.

(1)

C-6 RS485 (DSI) Protocol

Reading (03) Drive Error Codes

The PowerFlex 4 Error Code data can be read via the network by sending
Function Code 03 reads to register address 8449 (Drive Error Codes).

Address (Decimal) Value (Decimal) Description

0 No Fault

2 Auxiliary Input

3 Power Loss

4 Undervoltage

5 Overvoltage

6 Motor Stalled

7 Motor Overload

8 Heatsink Overtemperature

12 HW Overcurrent (300%)

13 Ground Fault

29 Analog Input Loss

33 Auto Restart Tries

8449

38 Phase U to Ground Short

39 Phase V to Ground Short

40 Phase W to Ground Short

41 Phase UV Short

42 Phase UW Short

43 Phase VW Short

63 Software Overcurrent

64 Drive Overload

70 Power Unit Fail

80 AutoTune Fail

81 Communication Loss

100 Parameter Checksum Error

122 I/O Board Fail

Logic Status

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].

Additional Information

Refer to http://www.ab.com/drives/ for additional information.

Appendix D

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RJ45 DSI Splitter Cable

The PowerFlex 4 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. The
peripherals may not perform as intended if these Connectivity
Guidelines are not followed. Precautions should be taken to follow
these Connectivity Guidelines.

 Two peripherals maximum can be attached to a drive.
 If a single peripheral is used, it must be connected to the Master port

(M) on the splitter and configured for “Auto” (default) or “Master.”
Parameter 9 [Device Type] on the DSI / MDI keypads and Parameter
1 [Adapter Cfg] on the Serial Converter are used to select the type
(Auto / Master / Slave).

 If two peripherals will be powered up at the same time, one must be

configured as the “Master” and connected to the Master port (M) and
the other must be connected as the “Slave” and connected to the
Slave port (S).

D-2 RJ45 DSI Splitter Cable

Slave Port

Master Port

PIN 8

PIN 1

M

S

TB2

(PIN 5)

TB1

(PIN 4)

PIN 8

PIN 1

PIN 8

PIN 1

DSI Cable Accessories

RJ45 Splitter Cable – Catalog Number: AK-U0-RJ45-SC1

RJ45 Two-Position Terminal Block Adapter –

Catalog Number: AK-U0-RJ45-TB2P

RJ45 Adapter with Integrated Termination Resistor –

Catalog Number: AK-U0-RJ45-TR1