Rockwell Automation Allen-Bradley PowerFlex 4 FKN6 Series Bedienungsanleitung

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Adjustable Frequency AC Drive

Drehzahlveränderbarer Frequenzumrichter

Variateur de vitesse c.a.

Inverter CA a frequenza variabile

Variador de Frecuencia Ajustable de CA

AC Drive

Inversor CA de Freqüência Ajustável

FRN 6.xx

Quick Start

PowerFlex 4 Adjustable

Frequency AC Drive

FRN 6.xx

This Quick Start guide summarizes the basic steps needed to install,

start-up and program the PowerFlex 4 Adjustable Frequency AC Drive.

The information provided Does Not replace the User Manual and is

intended for qualified drive service personnel only.

For detailed PowerFlex 4 information including EMC instructions,

application considerations and related precautions refer to the

PowerFlex 4 User Manual, Publication 22A-UM001… at

www.rockwellautomation.com/literature.

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: Equipment damage and/or personal injury may result

if parameter A092 [Auto Rstrt Tries] or A094 [Start At PowerUp] is

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

considering applicable local, national and international codes,

standards, regulations or industry guidelines.

ATTENTION: 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.

English-2

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

•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

Ambient Operating Temperatures

Refer to the PowerFlex 4 User Manual for details on how to comply with

the Low Voltage (LV) and Electromagnetic Compatibility (EMC)

Directives.

Mounting Considerations

Min. Panel Thickness Screw Size Screw Torque DIN Rail

1.9 mm (0.0747 in.) M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm

Ambient Temperature Enclosure Rating Minimum Mounting

Clearances

Minimum Maximum

-10°C (14°F) 40°C (104°F) IP 20/Open Type Use Mounting Option A

IP 30/NEMA 1/UL Type 1(1)

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

Use Mounting Option B

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

25 mm

(1.0 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

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

See page 12 for

mounting dimensions.

General Grounding Requirements

U/T1

V/T2

W/T3

R/L1

S/L2

T/L3

SHLD

Important: The MOV to ground jumper must be

removed if the drive is installed on an ungrounded or

resistive grounded distribution system.

Tighten screw after jumper removal.

Jumper

Location

CE Conformity

English-3

Specifications, Fuses and Circuit Breakers

Drive Ratings

Catalog

Number

Output Ratings Input Ratings Branch Circuit Protection Power

Dissipation

kW (HP) Amps

Voltage

Range kVA Amps Fuses

140M Motor

Protectors Contactors

IP20 Open

Watts

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 32

22A-V2P3N104 0.4 (0.5) 2.3 90-126 1.15 9.0 15 140M-C2E-C16 100-C12 40

22A-V4P5N104 0.75 (1.0) 4.5 90-126 2.25 18.0 30 140M-D8E-C20 100-C23 55

22A-V6P0N104 1.1 (1.5) 6.0 90-126 3.0 24.0 40 140M-D8E-C25 100-C37 80

200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output, NO BRAKE

22A-A1P4N103 0.2 (0.25) 1.4 180-265 0.7 3.2 6 140M-C2E-B40 100-C09 32

22A-A2P1N103 0.4 (0.5) 2.1 180-265 1.05 5.3 10 140M-C2E-B63 100-C09 40

22A-A3P6N103 0.75 (1.0) 3.6 180-265 1.8 9.2 15 140M-C2E-C16 100-C12 55

22A-A6P8N103 1.5 (2.0) 6.8 180-265 3.4 14.2 25 140M-C2E-C16 100-C16 85

22A-A9P6N103 2.2 (3.0) 9.6 180-265 4.8 19.6 30 140M-D8E-C25 100-C23 125

200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output

22A-A1P5N104 0.2 (0.25) 1.5 180-265 0.75 5.0 10 140M-C2E-B63 100-C09 32

22A-A2P3N104 0.4 (0.5) 2.3 180-265 1.15 6.0 10 140M-C2E-B63 100-C09 40

22A-A4P5N104 0.75 (1.0) 4.5 180-265 2.25 10.0 15 140M-C2E-C16 100-C12 55

22A-A8P0N104 1.5 (2.0) 8.0 180-265 4.0 18.0 30 140M-D8E-C20 100-C23 85

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 32

22A-B2P3N104 0.4 (0.5) 2.3 180-265 1.15 2.5 6 140M-C2E-B40 100-C09 40

22A-B4P5N104 0.75 (1.0) 4.5 180-265 2.25 5.2 10 140M-C2E-C10 100-C09 55

22A-B8P0N104 1.5 (2.0) 8.0 180-265 4.0 9.5 15 140M-C2E-C16 100-C12 85

22A-B012N104 2.2 (3.0) 12.0 180-265 5.5 15.5 25 140M-C2E-C16 100-C16 125

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

380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output

22A-D1P4N104 0.4 (0.5) 1.4 340-528 1.4 1.8 3 140M-C2E-B25 100-C09 35

22A-D2P3N104 0.75 (1.0) 2.3 340-528 2.3 3.2 6 140M-C2E-B40 100-C09 50

22A-D4P0N104 1.5 (2.0) 4.0 340-528 4.0 5.7 10 140M-C2E-B63 100-C09 70

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

22A-D8P7N104 3.7 (5.0) 8.7 340-528 8.6 9.0 15 140M-C2E-C16 100-C16 150

Input/Output Ratings Approvals

Output Frequency: 0-240 Hz (Programmable)

Efficiency: 97.5% (Typical)

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)

200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)

380-460V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)

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

200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line)

380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)

Control Ride Through: 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

for DB resistor ordering information.

(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.

UL508C

CSA 22.2

No. 14

CUS

EMC Directive 89/336/EEC, LV Dir. 73/23/EEC

LV: EN 50178

EMC: EN 61800-3

English-4

Power Terminal Block (A Frame Shown)

Power Terminal Block Specifications

Input Power Conditions

I/O Terminal Block Specifications

Refer to the PowerFlex 4 User Manual for recommendations on

maximum power and control cable length.

Power Wiring

Power Wire Rating Recommended Copper Wire

Unshielded 600V, 75°C (167°F) THHN/THWN 15 Mils insulated, dry location

Shielded 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Belden 29501-29507 or equivalent

Shielded Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Shawflex 2ACD/3ACD or equivalent

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

BR+ BR-

Terminal Description

R/L1, S/L2 1-Phase Input

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

U/T1 To Motor U/T1

=Switch any two motor leads to

change forward direction.

V/T2 To Motor V/T2

W/T3 To Motor W/T3

BR+, BR- Dynamic Brake Resistor Connection [0.75 kW (1 HP) ratings and higher]

Safety Ground - PE

Frame Maximum Wire Size (1) Minimum Wire Size (1) Torque

A 3.3 mm2 (12 AWG) 0.8 mm2 (18 AWG) 1.7-2.2 N-m (16-19 lb.-in.)

B 5.3 mm2 (10 AWG) 1.3 mm2 (16 AWG)

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

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line reactance) •Install Line Reactor(2)

•or Isolation Transformer

Greater than 120 kVA supply transformer

Line has power factor correction capacitors

Line has frequent power interruptions

Line has intermittent noise spikes in excess of 6000V (lightning)

Phase to ground voltage exceeds 125% of normal line to line voltage •Remove MOV jumper to ground.

•or Install Isolation Transformer with

grounded secondary if necessary.

Ungrounded Distribution System

(2) Refer to Appendix B of the PowerFlex 4 User Manual for accessory ordering information.

I/O Wiring Recommendations(3)

Wire Type(s) Description Minimum Insulation Rating

Belden 8760/9460

(or equiv.)

0.8 mm2(18AWG), twisted pair, 100% shield with

drain. 300V

60 degrees C

(140 degrees F)

Belden 8770

(or equiv.)

0.8 mm2(18AWG), 3 conductor, shielded for

remote pot only.

(3) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be

necessary, but is always recommended.

Maximum Wire Size (4) Minimum Wire Size (4) Torque

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

(4) Maximum / minimum that the terminal block will accept - these are not recommendations.

English-5

Control Terminal Block

No. Signal Default Description Param.

R1 Relay N.O. Fault Normally open contact for output relay. A055

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

01 Stop(1) Coast The factory installed jumper or a normally closed input

must be present for the drive to start. P036(1)

02 Start/Run FWD Not Active Command comes from the integral keypad by default. To

disable reverse operation, see A095 [Reverse Disable].

P036, P037

03 Direction/Run REV Not Active P036, P037,

A095

04 Digital Common – For digital inputs. Electronically isolated with digital inputs

from analog I/O.

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

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

11 +24V DC – Drive supplied power for digital inputs.

Maximum output current is 100mA.

12 +10V DC – Drive supplied power for 0-10V external potentiometer.

Maximum output current is 15mA. P038

13 0-10V In(3) Not Active For external 0-10V input supply

(input impedance = 100k ohm) or potentiometer wiper. P038

14 Analog Common – For 0-10V In or 4-20mA In. Electronically isolated with

analog inputs from digital I/O.

15 4-20mA In(3) Not Active For external 4-20mA input supply

(input impedance = 250 ohm). P038

16 RS485 (DSI) Shield – Terminal should be connected to safety ground - PE when

using the RS485 (DSI) communications port.

(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.

Stop

(1)

Start/Run FWD

(2)

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

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

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.

Refer to the PowerFlex 4

User Manual for more

information.

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

English-6

Before Applying Power to the Drive

❏1. Confirm that all inputs are connected to the correct terminals and are

secure.

❏2. Verify that AC line power at the disconnect device is within the rated

value of the drive.

❏3. Verify that any digital control power is 24 volts.

❏4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to

match your control wiring scheme. See page 5 for location.

Important: 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.

❏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.

Applying Power to the Drive

❏6. Apply AC power and control voltages to the drive.

❏7. Familiarize yourself with the integral keypad features (see next page)

before setting any Program Group parameters.

Start, Stop, Direction and Speed Control

Factory default parameter values allow the drive to be controlled from

the integral keypad. No programming is required to start, stop, change

direction and control speed directly from the integral keypad.

Important: To disable reverse operation, see A095 [Reverse Disable].

If a fault appears on power up, refer to page 11 for an explanation of the

fault code. For complete troubleshooting information, refer to the

PowerFlex 4 User Manual.

Prepare For Drive Start-Up

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.

English-7

Integral Keypad

No. LED LED State Description

➊Run/Direction

Status

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.

➋Alphanumeric

Display

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.

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

➍Program Status Steady Red Indicates parameter value can be changed.

➎Fault Status Flashing Red Indicates drive is faulted.

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

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

The Reverse key is also active unless disabled by A095

[Reverse Disable].

No. Key Name Description

➑Escape 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

Scroll through groups and parameters.

Increase/decrease the value of a flashing digit.

Enter Advance one step in programming menu.

Save a change to a parameter value.

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

Controlled by parameter P038.

Start Used to start the drive. Default is active.

Controlled by parameter P036.

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

Controlled by parameters P036 and A095.

Stop Used to stop the drive or clear a fault.

This key is always active.

Controlled by parameter P037.

FAULT

VOLTS

AMPS

HERTZ

RUN

FWD

REV

PROGRAM

➊➋

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

English-8

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.

Viewing and Editing Parameters

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.

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.

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

See the PowerFlex 4 User Manual for more information on parameters.

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