Rockwell Automation 22А User Manual

Adjustable Frequency AC

Drive

FRN 1.xx - 2.xx

User Manual

www.abpowerflex.com

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) 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 respo consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative pur

poses. 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, circu

its, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes 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.

describes some important

nsible or liable for indirect or

or in part, without written

to make you aware of safety

Important: Ide

ntifies 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:

• i

dentify a hazard

void the hazard

• a

• 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.

Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks of Rockwell Automation, Inc. DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc. PLC is a registered trademark of Rockwell Automation, Inc.

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

Summary of Changes

The information below summarizes the changes to the PowerFlex 4M User Manual since the July 2008 release.

Manual Updates

Description of New or Updated Information Page(s)

Minimum Enclosure Volume column and new footnotes added. 1-8 Drive, Fuse & Circuit Breaker Ratings topic updated. A-1 Electronic Motor Overload Protection description updated. A-4

The information below summarizes the changes to the PowerFlex 4M User Manual since the August 2007 release.

Manual Updates

Description of New or Updated Information Page(s)

Footnote (2) deleted from “EN61800-3 Second Environment” in Table 1.I Note to stop drive before changing parameter t211 [Anlg In 0-10V Lo]

removed. New option 13, I/O Control, for parameter t221 [Relay Out Sel] added. 3-15 Fault description for F3 corrected. 4-3 Corrected Ta bl e B .F by adding the 0.75 kW (1.0 HP) and 1.5 kW (2.0 HP)

ratings for the 22F-RF025-BL EMC line filter. Description for bits 14, 13, and 12 of register address 8192 corrected. C-4 Information on reading register address 8192 clarified. C-4 Description for bits 6, 7, and 15 of register address 8192 updated. C-4 Information on reading register address 8193 clarified. C-5

Figure C.1, Network Wiring Diagram, updated. C-1

Guidelines on standard RS485 wiring practices added. C-1

, A-2

. 1-22

3-14

B-4

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soc-2

The information below summarizes the changes to the PowerFlex 4M User Manual since the February 2007 release.

Manual Updates

Description of New or Updated Information Page(s)

Input description and attention text for Multiple Digital Input Connection example corrected.

Description for option 21 of parameter t221 [Relay Out Sel] corrected. 3-15 Invalid catalog number for L Type Filter deleted. B-4, B-10 Graphic for the “Connecting an RS-485 Network” section corrected D-3

1-18

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Preface Overview

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

Chapter 1 Installation/Wiring

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

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

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

General Grounding Requirements . . . . . . 1-5

Fuses and Circuit Breakers . . . . . . . . . . . . 1-7

Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-9

I/O Wiring Recommendations . . . . . . . . 1-13

Start and Speed Reference Control . . . . . 1-19

EMC Instructions . . . . . . . . . . . . . . . . . . 1-21

Chapter 2 Start Up

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

Terminal Block Group. . . . . . . . . . . . . . . 3-13

Communications Group . . . . . . . . . . . . . 3-17

Advanced Program Group. . . . . . . . . . . . 3-19

Parameter Cross Reference – by Name. . 3-31

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

Appendix B Accessories and Dimensions

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

Product Dimensions . . . . . . . . . . . . . . . . . B-6

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ii Table of Contents

Appendix C RS485 (DSI) Protocol

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

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

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

Writing (06) Logic Comman

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

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

Reading (03) Feedback . . . . . . . . . . . . . . . C-6

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

Reading (03) and Writing (06) Dri

Additional Information . . . . . . . . . . . . . . . C-7

Appendix D RJ45 DSI Splitter Cable

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

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

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

Index

d Data. . . . . . C-4

Parameters . . . . . . . . . . . . . . . . . . . . . . C-7

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Preface

Overview

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

For information on… See page…

Who Should Use this Manual? 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. program and operate Adjustable Frequency AC Drive devices. In addition, you must have an understanding of the parameter settings and functions.

P-1

You must be able to

Reference Materials

The following manuals are recommended f

Title Publication Available Online at …

Wiring and Grounding Guidelines Modulated (PWM) AC Drives

Preventive Maintenance of In System Equipment

Safety Guidelines for the Applica Maintenance of Solid State Control

A Global Reference Guide for Read

Guarding Against Electrostatic Damag

for Pulse Width

dustrial Control and Drive

tion, Installation and

ing Schematic Diagrams

DRIVES-IN001…

DRIVES-SB001…

SGI-1.1

0100-2.10

8000-4.5.2

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

or general drive information:

www.rockwellautomation.com/

terature

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P-2 Overview

Manual Conventions

• In this manual we refer to the PowerFlex 4M Adjustable Frequency

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

arameter numbers and names are shown in this format:

• P

P101 [Motor NP Volts]

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

action:

Wor d 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

Name Number Group d = Display Group P = Basic Program Group t = Terminal Block Group C = Communications Group A = Advanced Program Group

Drive Frame Sizes

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

Appendix B.

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grouped into frame sizes to

Overview P-3

General Precautions

ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the –DC and +DC terminals on the Power Terminal Block (refer to Terminal descriptions). The

Darkened LEDs or a darkened LCD display 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.

voltage must be zero.

Chapter 1 Power

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 o can cause uncommanded positive speed changes;

2. Actual deceleration times can 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.

A441). In addition, installing a properly sized

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

be longer than commanded

r imbalanced input voltages

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P-4 Overview

Code Vol ta ge 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)

1-3 4 5 6-8 9 10 11 12 13-14

22F - D 8P7 N 1 1 3 AA

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Type Optional

Code

22F PowerFlex 4M

Code Purpose

AA Reserved for thru custom firmware ZZ

Output Current @ 380-480V Input

Code Amps kW (HP)

1P5 1.5 0.4 (0.5) 2P5 2.5 0.75 (1.0) 4P2 4.2 1.5 (2.0) 6P0 6.0 2.2 (3.0) 8P7 8.7 3.7 (5.0) 013 13.0 5.5 (7.5) 018 18.0 7.5 (10.0) 024 24.0 10.0 (15.0)

Output Current @ 100-120V Input

Code Amps kW (HP)

1P6 1.6 0.2 (0.25) 2P5 2.5 0.4 (0.5) 4P5 4.5 0.75 (1.0) 6P0 6.0 1.1 (1.5)

Output Current @ 200-240V Input

Code Amps kW (HP)

1P6 1.6 0.2 (0.25) 2P5 2.5 0.4 (0.5) 4P2 4.2 0.75 (1.0) 8P0 8.0 1.5 (2.0) 011 11.0 2.2 (3.0) 012 12.0 2.2 (3.0) 017 17.5 3.7 (5.0) 025 25.0 5.5 (7.5) 033 33.0 7.5 (10.0)

Code Rating

0 Not Filtered 1Filtered

Additional accessories, options and adapters are available. See Appendix B

for details.

Catalog Number Explanation

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Chapter 1

Installation/Wiring

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

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

Opening the Cover Mounting Considerations 1-2 Power Wiring 1-9 AC Supply Source Considerations 1-3 I/O Wiring

General Grounding Requirements 1-5 EMC Instructions 1-21

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.

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.

1-1 Fuses and Circuit Breakers 1-7

1-13

Recommendations

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.

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1-2 Installation/Wiring

76.2 mm (3.0 in.)

Closest object that may obstruct air flow through the drive heat sink and chassis

76.2 mm (3.0 in.)

Airflow

See Table 1.B

Mounting Considerations

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

– Install on 35 mm DIN Rail (for frames A and B).

– 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.

Ambient Operating Temperatures

Table 1.B Enclosure and Clearance Requirements

Horizontal Clearance between drives

0 mm and greater -10°C (14°F) 40°C (104°F) 25 mm and greater -10°C (14°F) 50°C (122°F)

Drive enclosure is rated IP20, NEMA/UL Type Open.

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Minimum Maximum

Ambient Temperature

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 4M 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

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.

and 1.2.

Figure 1.1 Jumper Location (Frame A shown)

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1-4 Installation/Wiring

Figure 1.2 Phase to Ground MOV Removal

Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see Appendix 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

Action on the line side of the drive.

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

Table 1.C Input Power Conditions

, install one of the devices listed under the heading Corrective

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

AC Input

R/L1 S/L2 T/L3

Jumper

123

Three-Phase

A). Listed in Table 1.C are certain

Input Power Condition Corrective Action

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

Greater than 120 kVA supply transformer

• 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.

(1)

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Installation/Wiring 1-5

R/L1

S/L2 T/L3

U/T1 V/T2

W/T3

SHLD

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

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.

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1-6 Installation/Wiring

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.

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Installation/Wiring 1-7

Fuses and Circuit Breakers

The PowerFlex 4M 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 4M has been UL tested and approved for use with input fuses. The ratings in the table that follows are the maximum 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.

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1-8 Installation/Wiring

Table 1.D Minimum Recommended Branch Circuit Protective Devices

(1)

(2) (3)

Voltage Rating

120V AC – 1-Phase

240V AC – 1-Phase

240V AC – 3-Phase

480V AC – 3-Phase

(1)

(2)

(3)

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)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10.0)

0.4 (0.5)

0.75 (1.0)

1.5 (2.0)

2.2 (3.0)

3.7 (5.0)

5.5 (7.5)

7.5 (10.0)

11.0 (15.0)

Fuse Rating

Amps

10 15 30 40

10 10 15 35 40

3 6 10 15 25 35 45 60

3 6 10 10 15 25 30 50

Recommended Fuse Type: UL Class J, RK1, T or Type BS88; 600V (550V) or equivalent. The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M

Motor Protection Circuit Breakers Application Ratings.

Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240

140M

Catalog No.

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

140M-C2E-B63 140M-C2E-C10 140M-C2E-C16 140M-D8E-C25 140M-F8E-C32

140M-C2E-B25 140M-C2E-B40 140M-C2E-B63 140M-C2E-C16 140M-D8E-C20 140M-F8E-C25 140M-F8E-C32 140M-F8E-C45

140M-C2E-B25 140M-C2E-B40 140M-C2E-C10 140M-C2E-C10 140M-C2E-C16 140M-D8E-C20 140M-F8E-C25 140M-F8E-C32

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.

Recommended MCS Contactors

Catalog No.

100-C09 100-C12 100-C23 100-C30

100-C09 100-C09 100-C12 100-C23 100-C30

100-C09 100-C09 100-C09 100-C12 100-C23 100-C23 100-C37 100-C60

100-C09 100-C09 100-C09 100-C09 100-C12 100-C23 100-C23 100-C30

Min. Enclosure Vol um e

Inches

1655 1655 1655 1655

1655 1655 1655 1655 1655

1655 1655 1655 1655 1655 1655 3441 3441

1655 1655 1655 1655 1655 3441 3441 3441

(4)

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Installation/Wiring 1-9

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.

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1-10 Installation/Wiring

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

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 Table 1.E

The reflected wave data applies to all frequencies 2 to 10 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

(1)

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

for recommendations.

1000 Vp-p 15 meters (49 feet)

1200 Vp-p 40 meters (131 feet)

1600 Vp-p 170 meters (558 feet)

(1)

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.

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Installation/Wiring 1-11

Power Terminal Block

The drive utilizes a finger guard over the power wiring terminals. To remov e:

1. Press in and hold the locking tab.

2. For the finger guard on the top of the drive, slide it down and out.

For the finger guard at the bottom of the drive, slide it up and out.

Replace the finger guard when wiring is complete.

Figure 1.4 Power Terminal Block

Frame A and B

T/L3S/L2R/L1

Frame C

T/L3S/L2R/L1

Frame A and B

Terminal Description

R/L1, S/L2 1-Phase Input R/L1, S/L2, T/L3 3-Phase Input

DC Bus Inductor Connection (Frame C drives only.)

(1)

, P2

The Frame C drive is shipped with a jumper between Terminals P1

(1)

and P2. Remove this jumper only when a DC Bus Inductor will be connected. Drive will not power up without a jumper or inductor

connected. U/T1 To Motor U/T1 V/T2 To Motor V/T2 W/T3 To Motor W/T3

DC+

W/T3V/T2U/T1

DC-

Frame C

BR+ DC+

W/T3V/T2U/T1

DC-BR-

Switch any two motor

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

leads to change forward direction.

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1-12 Installation/Wiring

Terminal Description

(2)

DC+ BR+

(1)

(2)

, DC-

(1)

, BR-

For Frame C only [5.5 kW (7.5 HP) ratings and higher]. Not applicable to 120 V, 1-Phase drives.

DC Bus Connection

(1)

Dynamic Brake Resistor Connection Safety Ground - PE

Table 1.F Power Terminal Block Specifications

Frame Maximum Wire Size

A 3.3 mm

B 8.4 mm

C 13.3 mm

(1)

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

(12 AWG) 0.8 mm2 (18 AWG) 1.4-1.6 N-m (12-14 lb.-in.)

(8 AWG) 0.8 mm2 (18 AWG) 1.6-1.9 N-m (14-17 lb.-in.)

(6 AWG) 3.3 mm2 (12 AWG) 2.7-3.2 N-m (24-28 lb.-in.)

(1)

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.

Minimum Wire Size

(1)

Tor qu e

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Installation/Wiring 1-13

I/O Wiring Recommendations

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

not referenced to the 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.

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.

(18AWG), twisted pair, 100%

0.8 mm shield with drain.

0.8 mm remote pot only.

(1)

(18AWG), 3 conductor, shielded for

(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

(16 AWG) 0.2 mm2 (24 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

1.3 mm

(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.

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

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1-14 Installation/Wiring

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 P106 [Start Source] is set to “3-Wire” control. In three wire control, I/O Terminal 01 is controlled by P107 [Stop Mode]. All other stop sources are controlled by P107 [Stop Mode].

Important: The drive is shipped with a ju mper 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.

P106

[Start Source]

Stop

I/O Terminal 01

Stop

Keypad Per P107 Coast

3-Wir e Per P 107 Per P107

2-Wire Per P107 Coast

RS485 Port Per P107 Coast

Figure 1.5 Control Wiring Block Diagram

SRCSNK

Relay N.O.

Relay Common

Relay N.C.

R2 R3

R1 R2 R3

No. Signal Default Description Param.

R1 Relay N.O. Fault Normally open contact for output relay. t221 R2 Relay Common – Common for output relay. R3 Relay N.C. Fault Normally closed contact for output relay. t221

Sink/Source DIP Switch Source (SRC)

01 Stop

(1)

Coast

02 Start/Run FWD Not Active

03 Direction/Run REV Not Active

04 Digital Common –

Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting.

The factory installed jumper or a normally closed input must be present for the drive to start.

Command comes from the integral keypad by default. To disable reverse operation, see A095 [Reverse Disable].

For digital inputs. Electronically isol ated with digital inputs

from analog I/O. 05 Digital Input 1 Preset Freq Program with t201 [Digital In1 Sel]. t201 06 Digital Input 2 Preset Freq Program with t202 [Digital In2 Sel]. t202

11 +24V DC –

Drive supplied power for digital inputs.

Maximum output current is 100mA.

Stop

Start/Run FWD

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

+24V

+10V

SNK

SRC

01 02 03 04 05 06

11 12 13 14 15 16

+24V DC

+10V DC

0-10V In

Analog Common

4-20mA In

RS485 Shield

(1)

SRC Wiring

(2)

Typical

RS485

(DSI)

Typical

SNK Wiring

P106

P106, P107 P106

A434

(1)

, P107,

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

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Installation/Wiring 1-15

13 14

Common

No. Signal Default Description Param.

12 +10V DC –

13 0-10V In

14 Analog Common –

15 4-20mA In

16 RS485 (DSI) Shield –

(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.

Not Active

(3)

Not Active

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 port.

P108

I/O Wiring Examples

Input Connection Example Potentiometer

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

Analog Input

0 to +10V, 100k ohm impedance

4-20 mA, 100 ohm impedance

[Speed Reference] = 2 “0-10V Input”

P108

Voltage

P108

[Speed Reference] = 2 “0-10V

Input”

12 13 14

Current

P108 [Speed Reference] = 3

“4-20mA Input”

Common

14 15

Analog Input, PTC

For Drive Fault

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.

[Digital In1 Sel] = 3 “Aux Fault”

t201

[Relay Out Sel] = 10 “Above Anlg V”

t221 t222

[Relay Out Level] = % Voltage Trip

R2 R3

PTC

12 13 14

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

PTC (hot)

Tri p

PTC (hot)

+ R

100

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1-16 Installation/Wiring

01 02

Stop-Run

01 02

Stop-Run

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

Input Connection Example 2 Wire SRC Control -

Non-Reversing

[Start Source] = 2, 3

P106

or 4 Input must be active for

the drive to run. When input is opened, the drive will stop as specified by

[Stop Mode].

P107

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

2 Wire SNK Control Non-Reversing

Internal Supply (SRC) External Supply (SRC)

Internal Supply (SNK)

Stop-Run

+24V Common

Each digital input draws 6 mA.

2 Wire SRC Control Run FWD/Run REV

[Start Source] = 2, 3

P106

or 4 Input must be active for

the drive to run. When input is opened, the drive will stop as specified by

[Stop Mode].

P107

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

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

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Internal Supply (SRC) External Supply (SRC)

Internal Supply (SNK)

Input Connection Example

Each digital input draws 6 mA.

Stop

Start

01 02 03 04

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

3 Wire SRC Control -

Internal Supply (SRC) External Supply (SRC)

Non-Reversing

[Start Source] = 1

P106

A momentary input will

Stop

start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by P107

[Stop

Start

Mode].

Installation/Wiring 1-17

+24V

Stop

Start

Common

01 02

3 Wire SNK Control Non-Reversing

3 Wire SRC Control Reversing

[Start Source] = 1

P106

A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by P107

[Stop Mode]. I/O Terminal 03 determines direction.

3 Wire SNK Control Reversing

Internal Supply (SNK)

Internal Supply (SRC) External Supply (SRC)

Internal Supply (SNK)

PowerFlex 4M Adjustable Frequency Drive FRN 1.xx - 2.xx User Manual

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1-18 Installation/Wiring

Customer Inputs

Optional Ground Connection

02 0402 0402 0402

ATTENTION: Digital inputs on multiple drives 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.

Typical Multiple Drive Connection Examples

Input Connection Example Multiple Digital

Input Connections

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

page 1-16

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.

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.

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Installation/Wiring 1-19

Jog Input

Enabled and Active:

t201 or t202 = 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:

t201 or t202 = 5

Ye s

Start, Speed and Direction commands

come from Integral Keypad.

Comm Select Input

Enabled and Active:

t201 or t202 = 6

Ye s

Start, Speed and Direction commands

come from RS485 (DSI) port.

P108 [Speed Reference]

= 4 or 5

Ye s

Run as specified by

P108 [Speed Reference].

Start and Direction commands come

from P106 [Start Source].

t201 / t202

Preset Inputs Active

Ye s

Run as specified by

A411-A413 [Preset Freq 1-3].

Start and Direction commands come

from P106 [Start Source].

Run as specified by

P108 [Speed Reference].

Start and Direction commands

come from P106 [Start Source].

Start and Speed Reference Control

The drive speed command can be obtained from a number of different sources. The source is normally determined by P108 However, when t201 and the digital input is active, t201 reference commanded by P108

or t202 Digital Inx Sel is set to option 2, 4, 5 or 6,

or t202 will override the speed

[Speed Reference]. See the chart below

for the override priority.

[Speed Reference].

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1-20 Installation/Wiring

Jog Input

Enabled and Active:

t201 or t202 = 2

Ye s

A405 [Jog Accel/Decel] used.

P109 [Accel Time 1]/P110 [Decel Time 1]

are used.

RS485 (DSI) Port

Controls Speed

Active when

A401 [Accel Time 2]/A402 [Decel Time 2]

is selected by RS485 (DSI) port.

Input is programmed

as “Accel 2 & Decel 2”

t201 or t202 = 1

A401 [Accel Time 2]/A402 [Decel Time 2]

is active when input is active.

Speed is controlled

by [Preset Freq x]

t201 or t202 = 4

P109 [Accel Time 1]/P110 [Decel Time 1]; A401 [Accel Time 2]/A402 [Decel Time 2]

determined by the active Preset Frequency.

See A410-A413 [Preset Freq 0-3]

on page 3-21

Ye s

Accel/Decel Selection

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

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