Manual Powerflex 700
Manual Powerflex 700
Manual Powerflex 700
Frequency AC
Drive
FRN 1.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) 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.
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
Plate Drive Installation . . . . . . . . . . . . . . . 1-3
AC Supply Source Considerations . . . . . . 1-3
General Grounding Requirements . . . . . . 1-5
Fuses and Circuit Breakers . . . . . . . . . . . . 1-6
Power Wiring . . . . . . . . . . . . . . . . . . . . . . 1-8
Common Bus/Precharge Notes . . . . . . . . 1-12
I/O Wiring Recommendations . . . . . . . . 1-12
Start and Speed Reference Control . . . . . 1-26
EMC Instructions . . . . . . . . . . . . . . . . . . 1-28
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Display/Fault Reset . . . . . . . . . . . . . . . . . . 2-3
Drive Programming Tools . . . . . . . . . . . . . 2-3
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Basic Display Group . . . . . . . . . . . . . . . . . 3-3
Basic Program Group . . . . . . . . . . . . . . . . 3-9
Advanced Program Group. . . . . . . . . . . . 3-15
Enhanced Program Group . . . . . . . . . . . . 3-48
Advanced Display Group . . . . . . . . . . . . 3-59
Parameter Cross Reference – by Name. . 3-61
Chapter 4 Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and
Corrective Actions. . . . . . . . . . . . . . . . . . 4-6
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-7
2 Table of Contents
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 40P
Adjustable Frequency AC Drive.
Reference Materials
The following manuals are recommended for general drive information:
Manual Conventions
• In this manual we refer to the PowerFlex 40P Adjustable Frequency
AC Drive as; drive, PowerFlex 40P or PowerFlex 40P Drive.
Name
Number
Group
b = Basic Display Group
P = Basic Program Group
A = Advanced Program Group
E = Enhanced Program Group
d = Advanced Display 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
General Precautions
22D - B 2P3 N 1 0 4 AA
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Version Optional
Code Purpose
AA Reserved for
thru custom firmware
ZZ
Code Enclosure
N Panel Mount - IP 20 (NEMA Type Open)
F Flange Mount - IP 20 (NEMA Type Open)
H Plate Drive - IP 20 (NEMA Type Open)
Output Current @ 200-240V Input Output Current @ 380-480V Input Output Current @ 460-600V Input
Code Amps kW (HP) Code Amps kW (HP) Code Amps kW (HP)
2P3 2.3 0.4 (0.5) 1P4 1.4 0.4 (0.5) 1P7 1.7 0.75 (1.0)
5P0 5.0 0.75 (1.0) 2P3 2.3 0.75 (1.0) 3P0 3.0 1.5 (2.0)
8P0 8.0 1.5 (2.0) 4P0 4.0 1.5 (2.0) 4P2 4.2 2.2 (3.0)
012 12 2.2 (3.0) 6P0 6.0 2.2 (3.0) 6P6 6.6 4.0 (5.0)
017 17.5 3.7 (5.0) 010 10.5 4.0 (5.0) 9P9 9.9 5.5 (7.5)
024 24 5.5 (7.5) 012 12 5.5 (7.5) 012 12 7.5 (10)
033 33 7.5 (10) 017 17 7.5 (10) 019 19 11 (15)
024 24 11 (15)
Additional accessories, options and adapters are available. See Appendix B for details.
Chapter 1
Installation/Wiring
This chapter provides information on mounting and wiring the
PowerFlex 40P 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 1-12
Recommendations
General Grounding Requirements 1-5 EMC Instructions 1-28
Mounting Considerations
• Mount the drive upright on a flat, vertical and level surface.
Frame Screw Size Screw Torque DIN Rail
B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 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.
25 mm
(1.0 in.)
120 mm 120 mm
(4.7 in.) (4.7 in.)
Mounting Option A
RUN
REV
FAULT
RUN
REV
FAULT
No clearance required RUN
REV
FAULT
RUN
REV
FAULT
between drives.
Mounting Option B
120 mm 120 mm
(4.7 in.) (4.7 in.)
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.
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.
Installation/Wiring 1-3
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.
Important:
Tighten screw after
jumper removal.
Jumper 1 2 3 4
1-4 Installation/Wiring
RUN
REV
FAULT
R/L1 U/T1
S/L2 V/T2
T/L3 W/T3
SHLD
Motor Ground
The motor ground must be connected to one of the ground terminals on
the drive.
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.
1-6 Installation/Wiring
Fusing
The ratings in the table that follows are the recommended values for use
with each drive rating. The devices listed in this table are provided to
serve as a guide.
Power Wiring
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/Armored Cable
Shielded cable contains all of the general benefits of multi-conductor
cable with the added benefit of a copper braided shield that can contain
much of the noise generated by a typical AC Drive. Strong consideration
for shielded cable should be given in installations with sensitive
equipment such as weigh scales, capacitive proximity switches and other
devices that may be affected by electrical noise in the distribution
system. Applications with large numbers of drives in a similar location,
imposed EMC regulations or a high degree of communications /
networking are also good candidates for shielded cable.
Installation/Wiring 1-9
Shielded cable may also help reduce shaft voltage and induced bearing
currents for some applications. In addition, the increased impedance of
shielded cable may help extend the distance that the motor can be
located from the drive without the addition of motor protective devices
such as terminator networks. Refer to Reflected Wave in “Wiring and
Grounding Guidelines for PWM AC Drives,” publication
DRIVES-IN001A-EN-P.
Other types of shielded cable are available, but the selection of these
types may limit the allowable cable length. Particularly, some of the
newer cables twist 4 conductors of THHN wire and wrap them tightly
with a foil shield. This construction can greatly increase the cable
charging current required and reduce the overall drive performance.
Unless specified in the individual distance tables as tested with the drive,
these cables are not recommended and their performance against the lead
length limits supplied is not known.
Reflected Wave
380-480V Ratings Motor Insulation Rating Motor Cable Only(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.
B Frame C Frame
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1
Frame Maximum Wire Size (3) Minimum Wire Size (3) Torque
B&C 1.3 mm2 (16 AWG) 0.13 mm2 (26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
(3) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
(1)
Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start
Source] is set to “3-Wire”, “2-W Lvl Sens” or “Momt FWD/REV” 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].
P036 [Start Source] Stop I/O Terminal 01 Stop
3-Wire Per P037 Per P037(5)
2-Wire Per P037 Coast
2-W Lvl Sens Per P037 Per P037(5)
2-W Hi Speed Per P037 Coast
RS485 Port Per P037 Coast
Momt FWD/REV Per P037 Per P037(5)
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.
(3)
The function of I/O Terminal 03 is fully programmable. Program with E202 [Digital
Term 3].
(4)
When using an opto output with an inductive load such as a relay, install a recovery
diode parallel to the relay as shown, to prevent damage to the output.
(5)
When the ENBL enable jumper is removed, I/O Terminal 01 will always act as a
hardware enable, causing a coast to stop without software interpretation.
1-16 Installation/Wiring
Encoder Interface
The PowerFlex 40P Encoder Interface can source 5 or12 volt power and
accept 5, 12 or 24 volt single ended or differential inputs.
12V +V Cm B- B A- A
5V
➊
Common
Internal Drive Cm Common External to
B-
+
Power B Power SHLD
to SHLD External
Internal (drive) A- Source Power
Supply
A
12V DC,
250mA
Encoder to Power Supply
Encoder
Signal – Common Signal –
+V +V to SHLD
Single-Ended, Cm Differential, Cm
B NOT
Dual Channel B- Dual B-
B NOT
B B
B
A NOT Channel B
A NOT
A- A-
A A
A A
to SHLD
N
SK-U1-CVR4-E
N
SK-U1-CVR4-E
Installation/Wiring 1-19
4
3
2
1
-/+ 10V 13 + 13
Common 14 Common 14 Common 14
+ 15
Analog Input, PTC Wire the PTC and External Resistor (typically matched to the PTC Hot
For Drive Fault 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
Re 12
RPTC (hot)
13 %VTrip = × 100
14 RPTC (hot) + Re
RPTC
05
1-22 Installation/Wiring
0-20mA/4-20mA, 16
+
525 ohm maximum
Installation/Wiring 1-25
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
No
Speed commands come from
0-10V or -10-10V.
0-10V Override
Enabled and Active: Yes Start and Direction
[Digital Inx Sel] = 13 follows P036 [Start Source]
or
Bi-Polar input when enabled.
No
No
Run as specified by
P038 [Speed Reference].
P038 [Speed Reference] Yes
= 4 or 5 Start and Direction commands come All Results
from P036 [Start Source].
No
Run as specified by
A071-A077 [Preset Freq 1-7]. Encoder Enabled
A051/A052/A053 Yes Yes No change in control.
P038 = 8
Preset Inputs Active Start and Direction commands come Run according to Priority Checklist.
or
from P036 [Start Source]. A132 = 9
No No
No No
Run as specified by
P038 [Speed Reference].
Start and Direction commands come No change in control.
from P036 [Start Source].
Installation/Wiring 1-27
Accel/Decel Selection
The Accel/Decel rate can be obtained by a variety of methods. The
default rate is determined by P039 [Accel Time 1] and P040 [Decel Time
1]. Alternative Accel/Decel rates can be made through digital inputs,
RS485 (DSI) communications and/or parameters. See the chart below
for the override priority.
No
No
No
Either
P039 [Accel Time 1]/P040 [Decel Time 1]
or
Speed is controlled Yes A067 [Accel Time 2]/A068 [Decel Time 2]
by Stp Logic or
can be selected by:
Pos Logic
Step Logic parameters A140-A147
or
Position Logic parameters E230-E245
No
EMC Instructions
CE Conformity(1)
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.
(1)
600 Volt class drives are not CE Certified.
Installation/Wiring 1-29
(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.
1-30 Installation/Wiring
EN61000-3-2
• 0.75 kW (1 HP) 240V 3-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 40P Drive. To
simplify drive setup, the most commonly programmed parameters are
organized in a single Basic Program Group.
❏ 2. Verify that AC line power at the disconnect device is within the rated
value of the drive.
❏ 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
Display/Fault Reset
Menu Description
Basic Display Group (View Only)
Commonly viewed drive operating
conditions.
Advanced Display Group (View Only)
RUN
REV
Consists of advanced drive operating
FAULT conditions.
➊ ➋
Fault Designator
Consists of list of codes for specific fault
conditions. Displayed only when fault is
present.
Notes:
Chapter 3
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.
Parameter Organization
Refer to page 3-61 for an alphabetical listing of parameters.
Basic Display Group Output Voltage b004 Contrl In Status b013 Analog In 4-20mA b021
DC Bus Voltage b005 Dig In Status b014 Output Power b022
Drive Status b006 Comm Status b015 Output Powr Fctr b023
Fault 1 Code b007 Control SW Ver b016 Drive Temp b024
Fault 2 Code b008 Drive Type b017 Counter Status b025
Output Freq b001 Fault 3 Code b009 Elapsed Run Time b018 Timer Status b026
Commanded Freq b002 Process Display b010 Testpoint Data b019 Stp Logic Status b028
Output Current b003 Control Source b012 Analog In 0-10V b020 Torque Current b029
Basic Program Group Motor NP Volts P031 Minimum Freq P034 Accel Time 1 P039
Motor NP Hertz P032 Maximum Freq P035 Decel Time 1 P040
Motor OL Current P033 Start Source P036 Reset To Defalts P041
Stop Mode P037 Voltage Class P042
Speed Reference P038 Motor OL Ret P043
Advanced Program Group Jog Frequency A078 Anlg Out Setpt A109 Stp Logic 0 A140
Jog Accel/Decel A079 Anlg In 0-10V Lo A110 Stp Logic 1 A141
DC Brake Time A080 Anlg In 0-10V Hi A111 Stp Logic 2 A142
DC Brake Level A081 Anlg In4-20mA Lo A112 Stp Logic 3 A143
DB Resistor Sel A082 Anlg In4-20mA Hi A113 Stp Logic 4 A144
Digital In1 Sel A051 S Curve % A083 Slip Hertz @ FLA A114 Stp Logic 5 A145
Digital In2 Sel A052 Boost Select A084 Process Time Lo A115 Stp Logic 6 A146
Digital In3 Sel A053 Start Boost A085 Process Time Hi A116 Stp Logic 7 A147
Digital In4 Sel A054 Break Voltage A086 Bus Reg Mode A117 Stp Logic Time 0 A150
Relay Out Sel A055 Break Frequency A087 Current Limit 2 A118 Stp Logic Time 1 A151
Relay Out Level A056 Maximum Voltage A088 Skip Frequency A119 Stp Logic Time 2 A152
Opto Out1 Sel A058 Current Limit 1 A089 Skip Freq Band A120 Stp Logic Time 3 A153
Opto Out1 Level A059 Motor OL Select A090 Stall Fault Time A121 Stp Logic Time 4 A154
Opto Out2 Sel A061 PWM Frequency A091 Analog In Loss A122 Stp Logic Time 5 A155
Opto Out2 Level A062 Auto Rstrt Tries A092 10V Bipolar Enbl A123 Stp Logic Time 6 A156
Opto Out Logic A064 Auto Rstrt Delay A093 Var PWM Disable A124 Stp Logic Time 7 A157
Analog Out Sel A065 Start At PowerUp A094 Torque Perf Mode A125 EM Brk Off Delay A160
Analog Out High A066 Reverse Disable A095 Motor NP FLA A126 EM Brk On Delay A161
Accel Time 2 A067 Flying Start En A096 Autotune A127 MOP Reset Sel A162
Decel Time 2 A068 Compensation A097 IR Voltage Drop A128 DB Threshold A163
Internal Freq A069 SW Current Trip A098 Flux Current Ref A129
Preset Freq 0 A070 Process Factor A099 PID Trim Hi A130
Preset Freq 1 A071 Fault Clear A100 PID Trim Lo A131
Preset Freq 2 A072 Program Lock A101 PID Ref Sel A132
Preset Freq 3 A073 Testpoint Sel A102 PID Feedback Sel A133
Preset Freq 4 A074 Comm Data Rate A103 PID Prop Gain A134
Preset Freq 5 A075 Comm Node Addr A104 PID Integ Time A135
Preset Freq 6 A076 Comm Loss Action A105 PID Diff Rate A136
Preset Freq 7 A077 Comm Loss Time A106 PID Setpoint A137
Comm Format A107 PID Deadband A138
Language A108 PID Preload A139
Enhanced Program Group Comm Write Mode E207 Motor Fdbk Type E216 Step Units 0 E230
Power Loss Mode E208 Motor NP Poles E217 Step Units 1 E232
Half Bus Enable E209 Encoder PPR E218 Step Units 2 E234
Max Traverse E210 Pulse In Scale E219 Step Units 3 E236
Traverse Inc E211 Ki Speed Loop E220 Step Units 4 E238
LED Display Opt E201 Traverse Dec E212 Kp Speed Loop E221 Step Units 5 E240
Digital Term 3 E202 P Jump E213 Positioning Mode E222 Step Units 6 E242
Accel Time 3 E203 Sync Time E214 Find Home Freq E223 Step Units 7 E244
Decel Time 3 E204 Speed Ratio E215 Find Home Dir E224 Pos Reg Filter E246
Accel Time 4 E205 Encoder Pos Tol E225 Pos Reg Gain E247
Decel Time 4 E206 Counts Per Unit E226 Enh Control Word E248
Advanced Display Group Drive Status 2 d301 Slip Hz Meter d303 Units Traveled H d308
Fibers Status d302 Speed Feedback d304 Units Traveled L d309
Encoder Speed d306
Programming and Parameters 3-3
b002 [Commanded Freq] Related Parameter(s): b001, b013, 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 Start and Speed
Reference Control on page 1-26 for details.
Values Default: Read Only
Min/Max: 0.0/P035 [Maximum Freq]
Display: 0.1 Hz
P032 [Motor NP Hertz] Related Parameter(s): A084, A085, A086, A087, A090
Stop drive before changing this parameter.
Set to the motor nameplate rated frequency.
Values Default: 60 Hz
Min/Max: 15/500 Hz
Display: 1 Hz
P033 [Motor OL Current] Related Parameter(s): A055, A058, A061, A089, A090,
A098, A114, A118
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): b001, b002, b013, P035, A085,
A086, A087, A110, A112
Sets the lowest frequency the drive will output continuously.
Values Default: 0.00 Hz
Min/Max: 0.00/500.0 Hz
Display: 0.01 Hz
P035 [Maximum Freq] Related Parameter(s): b001, b002, b013, P034, A065,
A078, A085, A086, A087, A111, A113
Stop drive before changing this parameter.
Sets the highest frequency the drive will output.
Values Default: 60.00 Hz
Min/Max: 0.00/500.0 Hz
Display: 0.01 Hz
3-10 Programming and Parameters
cel
er
era
Speed
cel
tion
Ac
0
P039, A067, Time P040, A068,
E203 or E205 E204 or E206
0 [Accel Time x] [Decel Time x]
cel
rat
e
era
Speed
cel
tion
Ac
0
P039, A067, Time P040, A068,
E203 or E205 E204 or E206
0 [Accel Time x] [Decel Time x]
A051 - 14 “20mA In Ctrl” Selects 4-20mA control as the frequency reference. Start
A054 source is not changed.
Options 15 “PID Disable” Disables PID function. Drive uses the next valid non-PID
(Cont.) speed reference.
16 “MOP Up” Increases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
17 “MOP Down” Decreases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
18 “Timer Start” Clears and starts the timer function. May be used to control
the relay or opto outputs.
19 “Counter In” Starts the counter function. May be used to control the relay
or opto outputs.
20 “Reset Timer” Clears the active timer.
21 “Reset Countr” Clears the active counter.
22 “Rset Tim&Cnt” Clears the active timer and counter.
23 “Logic In1” Logic function input number 1. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with StepLogic
parameters A140 - A147 [Stp Logic x]. Logically ORed with
E248 [Enh Control Word] bit 7 “Logic In 1”.
24 “Logic In2” Logic function input number 2. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with StepLogic
parameters A140 - A147 [Stp Logic x]. Logically ORed with
E248 [Enh Control Word] bit 8 “Logic In 2”.
25 “Current Lmt2” When active, A118 [Current Limit 2] determines the drive
current limit level.
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].
27 “EM Brk Rlse” If EM brake function is enabled, this input releases the brake.
Refer to A160 [EM Brk Off Delay] for additional information.
A051 - 30 “Inertia Dcel” Forces drive into Inertia Ride-Through state. The drive will
A054 attempt to regulate the DC bus at the current level.
Options 31 “Sync Enable” Must be used in order to hold the existing frequency when
(Cont.) Sync Time is set to enable speed synchronization. When this
input is released the drive will accelerate to the commanded
frequency in E214 [Sync Time].
32 “Traverse Dis” When an input is programmed the traverse function will be
disabled while this input is active. Refer to E210 [Max
Traverse].
33 “Home Limit” In Positioning mode, this indicates the drive is at the home
position. Refer to Appendix F for detailed information on
positioning.
34 “Find Home” In Positioning mode this causes the drive to return to the
Home position when a start is issued. It does this by using the
[Find Home Freq] and [Find Home Direction] until the “Home
Limit” input is activated. If it passes this point, it then runs in
the reverse direction at 1/10th the frequency of [Find Home
Freq] until the “Home Limit” is activated again. As long as this
input is active, any start command will cause the drive to
enter the homing routing. Only functions if in Positioning
mode. Once the Find Home routine has finished, the drive will
stop. Refer to Appendix F for detailed information on
positioning.
35 “Hold Step” In Positioning mode, this input over-rides other inputs and
causes the drive to remain at its current step (running at zero
speed once it reaches its position) until released. While in
“Hold”, the drive will ignore any input command which would
normally result in a move to a new step. Timers continue to
run. Therefore, when the Hold is removed, the drive must see
any required digital inputs transition (even if they already
transitioned during the hold), but it does not reset any timer.
Refer to Appendix F for detailed information on positioning.
36 “Pos Redefine” In Positioning mode, this input resets the home position to the
current position of the machine. Refer to Appendix F for
detailed information on positioning.
A055 [Relay Out Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157,
A160, A161
Sets the condition that changes the state of the output relay contacts.
Options 0 “Ready/Fault” Relay changes state when power is applied. This indicates
(Default) that the drive is ready for operation. Relay returns drive to
shelf state when power is removed or a fault occurs.
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.
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 A056 [Relay
Out Level].
• Use A056 to set threshold.
3-18 Programming and Parameters
A055 7 “Above Cur” • Drive exceeds the current (% Amps) value set in A056
Options [Relay Out Level].
(Cont.) • Use A056 to set threshold.
Important: Value for A056 [Relay Out Level] must be entered
in percent of drive rated output current.
8 “Above DCVolt” • Drive exceeds the DC bus voltage value set in A056
[Relay Out Level].
• Use A056 to set threshold.
9 “Retries Exst” Value set in A092 [Auto Rstrt Tries] is exceeded.
10 “Above Anlg V” • Analog input voltage (I/O Terminal 13) exceeds the value
set in A056 [Relay Out Level].
• Do not use if A123 [10V Bipolar Enbl] is set to 1 “Bi-Polar
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 “Logic In 1” An input is programmed as “Logic In 1” and is active.
12 “Logic In 2” An input is programmed as “Logic In 2” and is active.
13 “Logic 1 & 2” Both Logic inputs are programmed and active.
14 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is
active.
15 “StpLogic Out” Drive enters StepLogic step with Digit 3 of Command Word
(A140 - A147) set to enable StepLogic output.
16 “Timer Out” • Timer has reached value set in A056 [Relay Out Level].
• Use A056 to set threshold.
17 “Counter Out” • Counter has reached value set in A056 [Relay Out Level].
• Use A056 to set threshold.
18 “Above PF Ang” • Power Factor angle has exceeded the value set in A056
[Relay Out Level].
• Use A056 to set threshold.
19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In
Loss] for desired action when input loss occurs.
20 “ParamControl” Enables the output to be controlled over network
communications by writing to A056 [Relay Out Level].
(0 = Off, 1 = On.)
21 “NonRec Fault” • Value set in A092 [Auto Rstrt Tries] is exceeded.
• A092 [Auto Rstrt Tries] in not enabled.
• A Non-resettable fault has occurred.
22 “EM Brk Cntrl” EM brake is energized. Program A160 [EM Brk Off Delay] and
A161 [EM Brk On Delay] for desired action.
23 “At Position” The drive is in Positioning mode and has reached the
commanded position. Tolerance is adjusted with E225
[Counts Per Unit].
24 “At Home” The drive is in Positioning mode and has reached the home
position. Tolerance is adjusted with E225 [Counts Per Unit].
25 “Safe-Off” The DriveGuard Safe Off option is installed and both safe-off
inputs are active.
Programming and Parameters 3-19
A058 [Opto Out1 Sel] Related Parameter(s): P033, A056, A092, A140-A147, A150-A157
A061 [Opto Out2 Sel]
Determines the operation of the programmable opto outputs.
Options 0 “Ready/Fault” Opto outputs are active when power is applied. This indicates
that the drive is ready for operation. Opto outputs are inactive
when power is removed or a fault occurs.
1 “At Frequency” Drive reaches commanded frequency.
(A061 Default)
2 “MotorRunning” Motor is receiving power from the drive.
(A058 Default)
3 “Reverse” Drive is commanded to run in reverse direction.
4 “Motor Overld” Motor overload condition exists.
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 A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
7 “Above Cur” • Drive exceeds the current (% Amps) value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
Important: Value for A059 or A062 [Opto Outx Level] must be
entered in percent of drive rated output current.
8 “Above DCVolt” • Drive exceeds the DC bus voltage value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
9 “Retries Exst” Value set in A092 [Auto Rstrt Tries] is exceeded.
3-20 Programming and Parameters
A058, 10 “Above Anlg V” • Analog input voltage (I/O Terminal 13) exceeds the value
A061 set in A059 or A062 [Opto Outx Level].
Options • Do not use if A123 [10V Bipolar Enbl] is set to 1 “Bi-Polar
(Cont.) 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 A059 or A062 to set threshold.
11 “Logic In 1” An input is programmed as “Logic In 1” and is active.
12 “Logic In 2” An input is programmed as “Logic In 2” and is active.
13 “Logic 1 & 2” Both Logic inputs are programmed and active.
14 “Logic 1 or 2” One or both Logic inputs are programmed and one or both is
active.
15 “StpLogic Out” Drive enters StepLogic step with Digit 3 of Command Word
(A140 - A147) set to enable StepLogic output.
16 “Timer Out” • Timer has reached value set in A059 or A062 [Opto Outx
Level].
• Use A059 or A062 to set threshold.
17 “Counter Out” • Counter has reached value set in A059 or A062 [Opto
Outx Level].
• Use A059 or A062 to set threshold.
18 “Above PF Ang” • Power Factor angle has exceeded the value set in A059 or
A062 [Opto Outx Level].
• Use A059 or A062 to set threshold.
19 “Anlg In Loss” Analog input loss has occurred. Program A122 [Analog In
Loss] for desired action when input loss occurs.
20 “ParamControl” Enables the output to be controlled over network
communications by writing to A059 or A062 [Opto Outx
Level].
(0 = Off, 1 = On.)
21 “NonRec Fault” • Value set in A092 [Auto Rstrt Tries] is exceeded.
• A092 [Auto Rstrt Tries] in not enabled.
• A Non-resettable fault has occurred.
22 “EM Brk Cntrl” EM brake is energized. Program A160 [EM Brk Off Delay] and
A161 [EM Brk On Delay] for desired action.
23 “At Position” The drive is in Positioning mode and has reached the
commanded position. Tolerance is adjusted with E225
[Counts Per Unit].
24 “At Home” The drive is in Positioning mode and has reached the home
position. Tolerance is adjusted with E225 [Counts Per Unit].
25 “Safe-Off” The DriveGuard Safe Off option is installed and both safe-off
inputs are active.
Programming and Parameters 3-21
Values Default: 0
Min/Max: 0/3
Display: 1
3-22 Programming and Parameters
Values Default: 0
Min/Max: 0/20
Display: 1
cel
0 0 Acc/Dec 1
er
era
Speed
cel
tion
Ac
0 1 Acc/Dec 2
1 0 Acc/Dec 3
0
P039, A067, Time P040, A068, 1 1 Acc/Dec 4
E203 or E205 E204 or E206
0 [Accel Time x] [Decel Time x]
(1)
To activate A070 [Preset Freq 0] set P038 [Speed Reference] to option 4 “Preset Freq 0-3”.
Volts/Speed
Vo
lta Speed [DC Brake Time]
ge
Spe [DC Brake Time]
ed
[DC Brake Level] [DC Brake Level]
Time Time
Stop Command Stop Command
Setting Min/Max
0 “Disabled”
1 “Normal RA Res” (5% Duty Cycle) – Refer to Table B.C on page B-2.
2 “NoProtection” (100% Duty Cycle)
3-99 “x%Duty Cycle” Limited (3% – 99% of Duty Cycle)
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 resistor is used (see
selection Table B.C), the drive provides calculated resistor overload protection. However, the drive
cannot protect against a brake IGBT failure.
For more information on external dynamic brake kits, refer to the External Dynamic Brake Kit
Installation Instructions, publication RA-IN004.
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-12, or equivalent, must be supplied.
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: 50% S Curve
Accel Time = 10 Seconds Target
S Curve Setting = 50%
S Curve Time = 10 × 0.5 = 5 Seconds
Total Time = 10 + 5 = 15 Seconds
Target/2
100
% P031 [Motor NP Volts]
Settings
5-14
0 50 100
% P032 [Motor NP Hertz]
3-28 Programming and Parameters
100
96
92
88
84
80
76
72
68
64
60
56
52
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A092 [Auto Rstrt Tries] Related Parameter(s): A055, A058, A061, A093
Sets the maximum number of times the drive attempts to reset a fault and restart.
For information on faults and fault codes refer to Chapter 4.
ATTENTION: 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.
Values Default: 0
Min/Max: 0/9
Display: 1
ATTENTION: 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.
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”
3-32 Programming and Parameters
A108 [Language]
Selects the language displayed by the remote communications option.
Options 1 “English” (Default)
2 “Français”
3 “Español”
4 “Italiano”
5 “Deutsch”
6 “Reserved”
7 “Português”
8 “Reserved”
9 “Reserved”
10 “Nederlands”
e
nc
re
R efe
e ed
Sp
A111 [Anlg In 0-10V Hi] Related Parameter(s): b020, P035, P038, A122, A123
Stop drive before changing this parameter.
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 A110 [Anlg In 0-10V Lo].
Values Default: 100.0%
Min/Max: 0.0/100.0%
Display: 0.1%
Frequency Command
Frequency
Drive Output
Frequency
2x Skip
Skip Frequency Frequency Band
Time
A125 [Torque Perf Mode] Related Parameter(s): A084, A085, A086, A087, A127
Stop drive before changing this parameter.
Enables/disables sensorless vector control operation.
Options 0 “V/Hz”
1 “Sensrls Vect” (Default)
ATTENTION: Rotation of the motor in an undesired direction can occur during this
procedure. To guard against possible injury and/or equipment damage, it is
! recommended that the motor be disconnected from the load before proceeding.
ATTENTION: The loss of analog input, encoder or other feedback may cause
unintended speed or motion. Take appropriate precautions to guard against possible
! unintended speed or motion.
Options 0 “0-10V Input” (Default) The PID will not function with a bipolar input. Negative
voltages are treated as 0 volts.
1 “4-20mA Input”
2 “Comm Port”
3 “Encoder” Encoder or Pulse Train
Programming and Parameters 3-41
The position for any step is programmed using parameters E230 - E245 [Step Units x].
StepLogic Settings
The logic for each function is determined by the four digits for each StepLogic parameter. The
following is a listing of the available settings for each digit.
Refer to Appendix E for details.
Frequency
mp
cce
De
A
ce
mp
l
Ra
Minimum Freq
Time
Start EM Brk Stop EM Brk Drive Stops
Commanded Energized (Off) Commanded De-Energized (On)
Programming and Parameters 3-47
Values Default: 2
Min/Max: 0/3
Display: 1
E202 11 “Jog Forward” Drive accelerates to A078 [Jog Frequency] according to A079
Options [Jog Accel/Decel] and ramps to stop when input becomes
(Cont.) inactive. A valid start will override this command.
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.
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 “PID Disable” Disables PID function. Drive uses the next valid non-PID
speed reference.
16 “MOP Up” Increases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
17 “MOP Down” Decreases the value of A069 [Internal Freq] at a rate of 2 Hz
per second. Default for A069 is 60 Hz.
18 “Timer Start” Clears and starts the timer function. May be used to control
the relay or opto outputs.
19 “Counter In” Starts the counter function. May be used to control the relay
or opto outputs.
20 “Reset Timer” Clears the active timer.
21 “Reset Countr” Clears the active counter.
22 “Rset Tim&Cnt” Clears the active timer and counter.
23 “Logic In1” Logic function input number 1. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with StepLogic
parameters A140 - A147 [Stp Logic x]. Logically ORed with
E248 [Enh Control Word] bit 7 “Logic In 1”.
24 “Logic In2” Logic function input number 2. May be used to control the
relay or opto outputs (see parameters A055, A058, A061
Options 11-14). May be used in conjunction with StepLogic
parameters A140 - A147 [Stp Logic x]. Logically ORed with
E248 [Enh Control Word] bit 8 “Logic In 2”.
25 “Current Lmt2” When active, A118 [Current Limit 2] determines the drive
current limit level.
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].
27 “EM Brk Rlse” If EM brake function is enabled, this input releases the brake.
Refer to A160 [EM Brk Off Delay] for additional information.
E213 [P Jump]
Seconds
Time
ATTENTION: The loss of analog input, encoder or other feedback may cause
unintended speed or motion. Take appropriate precautions to guard against possible
! unintended speed or motion.
Values Default: 0
Min/Max: 0/5
Display: 1
Values Default: 64
Min/Max: 1/20000
Display: 1
Programming and Parameters 3-55
Values Default: 0
Min/Max: 0/4
Display: 1
Values Default: 0
Min/Max: 0/1
Display: 1
Bit 1 “Home Limit” In Positioning mode, this indicates the drive is at the home
position.
2 “Find Home” When set, the next start command causes the drive to find
home. Set this bit to 0 after completing the homing routine.
3 “Hold Step” In Positioning mode, this input over-rides other inputs and
causes the drive to remain at its current step (running at zero
speed once it reaches its position) until released.
4 “Pos Redefine” In Positioning mode, this input resets the home position to the
current position of the machine. Set this bit to 0 after
completing the homing routine.
5 “Sync Enable” Must be used in order to hold the existing frequency when
Sync Time is set to enable speed synchronization. When this
bit is reset to zero the drive will accelerate to the new
commanded frequency based on E214 [Sync Time] setting.
6 “Traverse Disable” When set the traverse function will be disabled.
7 “Logic In 1” This provides an identical function as the Digital Input option
with the same name. This bit is logically ORed with the digital
input. It can be used to move through the Step-Logic
functions (speed or position) via comms control without
requiring actual digital input transitions.
8 “Logic In 2” This provides and identical function as the Digital Input option
with the same name. This bit is logically ORed with the digital
input. It can be used to move through the Step-Logic
functions (speed or position) via comms control without
requiring actual digital input transitions.
Programming and Parameters 3-59
Troubleshooting
Chapter 4 provides information to guide you in troubleshooting the
PowerFlex 40P 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 4-6
Corrective Actions
Drive Status
The condition or state of your drive is constantly monitored. Any
changes will be indicated through the integral LED display.
LED Indications
See page 2-3 for information on drive status indicators and controls.
Faults
A fault is a condition that stops the drive. There are two fault types.
Fault Indication
Condition Display
Drive is indicating a fault.
The integral LED display provides visual
RUN
notification of a fault condition by displaying the REV
FAULT
following.
• Flashing fault number
• Flashing fault indicator
Press the Up Arrow key to regain control of the
display.
Fault Descriptions
Table 4.B Fault Types, Descriptions and Actions
Type(1)
No. Fault Description Action
F2 Auxiliary Input ➀ Auxiliary input interlock is open. 1. Check remote wiring.
2. Verify communications
programming for intentional fault.
F3 Power Loss ➁ DC bus voltage remained below 1. Monitor the incoming AC line for
85% of nominal or single phase low voltage or line power
operation detected. interruption.
2. Check input fuses.
F4 UnderVoltage ➀ DC bus voltage fell below the Monitor the incoming AC line for low
minimum value. voltage or line power interruption.
F5 OverVoltage ➀ DC bus voltage exceeded Monitor the AC line for high line
maximum value. voltage or transient conditions. Bus
overvoltage can also be caused by
motor regeneration. Extend the
decel time or install dynamic brake
option.
F6 Motor Stalled ➀ Drive is unable to accelerate Increase P039 - A067 [Accel Time x]
motor. or reduce load so drive output
current does not exceed the current
set by parameter A089 [Current
Limit 1].
F7 Motor Overload ➀ Internal electronic overload trip. 1. An excessive motor load exists.
Reduce load so drive output
current does not exceed the
current set by parameter P033
[Motor OL Current].
2. Verify A084 [Boost Select] setting
F8 Heatsink ➀ Heatsink temperature exceeds a 1. Check for blocked or dirty heat
OvrTmp predefined value. 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.
2. Check fan.
F12 HW OverCurrent ➁ The drive output current has Check programming. Check for
exceeded the hardware current excess load, improper A084 [Boost
limit. Select] setting, DC brake volts set
too high or other causes of excess
current.
F13 Ground Fault ➁ A current path to earth ground Check the motor and external wiring
has been detected at one or to the drive output terminals for a
more of the drive output grounded condition.
terminals.
F29 Analog Input ➀ An analog input is configured to 1. Check parameters.
Loss fault on signal loss. A signal loss 2. Check for broken/loose
has occurred. connections at inputs.
Configure with A122 [Analog In
Loss].
(1)
See page 4-1 for a description of fault types.
4-4 Troubleshooting
Type(1)
No. Fault Description Action
F33 Auto Rstrt Tries ➁ Drive unsuccessfully attempted Correct the cause of the fault and
to reset a fault and resume manually clear.
running for the programmed
number of A092 [Auto Rstrt
Tries].
F38 Phase U to Gnd ➁ A phase to ground fault has been 1. Check the wiring between the
F39 Phase V to Gnd detected between the drive and drive and motor.
F40 Phase W to Gnd motor in this phase. 2. Check motor for grounded
phase.
3. Replace drive if fault cannot be
cleared.
F41 Phase UV Short ➁ Excessive current has been 1. Check the motor and drive output
F42 Phase UW Short detected between these two terminal wiring for a shorted
F43 Phase VW Short output terminals. condition.
2. Replace drive if fault cannot be
cleared.
F48 Params The drive was commanded to 1. Clear the fault or cycle power to
Defaulted write default values to EEPROM. the drive.
2. Program the drive parameters as
needed.
F63 SW OverCurrent ➀ Programmed A098 [SW Current Check load requirements and A098
Trip] has been exceeded. [SW Current Trip] setting.
F64 Drive Overload ➁ Drive rating of 150% for 1 minute Reduce load or extend Accel Time.
or 200% for 3 seconds has been
exceeded.
F70 Power Unit ➁ Failure has been detected in the 1. Cycle power.
drive power section. 2. Replace drive if fault cannot be
cleared.
F71 Net Loss The communication network has 1. Cycle power.
faulted. 2. Check communications cabling.
3. Check network adapter setting.
4. Check external network status.
F80 SVC Autotune The autotune function was either Restart procedure.
cancelled by the user or failed.
F81 Comm Loss ➁ RS485 (DSI) port stopped 1. If adapter was not intentionally
communicating. 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 A105 [Comm Loss
Action].
5. Connecting I/O Terminal 04 to
ground may improve noise
immunity.
F91 Encoder Loss Requires differential encoder. 1. Check Wiring.
One of the 2 encoder channel 2. Replace encoder.
signals is missing.
Troubleshooting 4-5
Type(1)
No. Fault Description Action
F100 Parameter ➁ The checksum read from the Set P041 [Reset To Defalts] to option
Checksum board does not match the 1 “Reset Defaults”.
checksum calculated.
F111 Enable DriveGuard Safe-Off Option 1. Remove the ENBL enable
Hardware (Series B) board is installed and jumper.
the ENBL enable jumper has not 2. Cycle power.
been removed.
DriveGuard Safe-Off Option 1. Remove power to the drive.
(Series B) board has failed. 2. Replace DriveGuard Safe-Off
Option (Series B) board.
Hardware Enable circuitry has Replace drive.
failed.
F122 I/O Board Fail ➁ Failure has been detected in the 1. Cycle power.
drive control and I/O section. 2. Replace drive if fault cannot be
cleared.
(1)
See page 4-1 for a description of fault types.
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 and hold Up Arrow key for
3 seconds.
• Cycle power
• Set A100 [Fault Clear] to option 1
“Clear Faults”.
• Cycle digital input if A051 - A054
[Digital Inx Sel] is set to option 7
“Clear Fault”.
Incorrect programming. None Check parameter settings.
• P036 [Start Source] is set to
option 5 “RS485 (DSI) Port”.
Incorrect input wiring. None Wire inputs correctly and/or install
See 1-21 for wiring examples. jumper.
• 2 wire control requires Run If using the DriveGuard Safe-Off
Forward, Run Reverse or Jog Option (Series B) board, verify that
input. inputs are active.
• 3 wire control requires Start and
Stop inputs
• Stop input is always required.
Incorrect Sink/Source DIP switch None Set switch to match wiring scheme.
setting.
Notes:
Appendix A
(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
Specifications
Table A.A Drive Ratings
Output Ratings Input Ratings Branch Circuit Protection
Catalog
Number(1) Voltage 140M Motor
kW (HP) Amps Range kVA Amps Fuses Protectors(2) Contactors
200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output
22D-B2P3 0.4 (0.5) 2.3 180-264 1.15 2.5 6 140M-C2E-B40 100-C07
22D-B5P0 0.75 (1.0) 5.0 180-264 2.45 5.7 10 140M-C2E-C10 100-C09
22D-B8P0 1.5 (2.0) 8.0 180-264 4.0 9.5 15 140M-C2E-C16 100-C12
22D-B012 2.2 (3.0) 12.0 180-264 5.5 15.5 25 140M-C2E-C16 100-C23
22D-B017 3.7 (5.0) 17.5 180-264 8.6 21.0 30 140M-F8E-C25 100-C23
22D-B024 5.5 (7.5) 24.0 180-264 11.8 26.1 40 140M-F8E-C32 100-C37
22D-B033 7.5 (10.0) 33.0 180-264 16.3 34.6 60 140M-G8E-C45 100-C60
380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output
22D-D1P4 0.4 (0.5) 1.4 342-528 1.4 1.8 3 140M-C2E-B25 100-C07
22D-D2P3 0.75 (1.0) 2.3 342-528 2.3 3.2 6 140M-C2E-B40 100-C07
22D-D4P0 1.5 (2.0) 4.0 342-528 4.0 5.7 10 140M-C2E-B63 100-C09
22D-D6P0 2.2 (3.0) 6.0 342-528 5.9 7.5 15 140M-C2E-C10 100-C09
22D-D010 4.0 (5.0) 10.5 342-528 10.3 13.0 20 140M-C2E-C16 100-C23
22D-D012 5.5 (7.5) 12.0 342-528 11.8 14.2 25 140M-D8E-C20 100-C23
22D-D017 7.5 (10.0) 17.0 342-528 16.8 18.4 30 140M-D8E-C20 100-C23
22D-D024 11.0 (15.0) 24.0 342-528 23.4 26.0 50 140M-F8E-C32 100-C43
460 - 600V AC (±10%) – 3-Phase Input, 0 - 575V 3-Phase Output
22D-E1P7 0.75 (1.0) 1.7 414-660 2.1 2.3 6 140M-C2E-B25 100-C09
22D-E3P0 1.5 (2.0) 3.0 414-660 3.65 3.8 6 140M-C2E-B40 100-C09
22D-E4P2 2.2 (3.0) 4.2 414-660 5.2 5.3 10 140M-C2E-B63 100-C09
22D-E6P6 4.0 (5.0) 6.6 414-660 8.1 8.3 15 140M-C2E-C10 100-C09
22D-E9P9 5.5 (7.5) 9.9 414-660 12.1 11.2 20 140M-C2E-C16 100-C16
22D-E012 7.5 (10.0) 12.2 414-660 14.9 13.7 25 140M-C2E-C16 100-C23
22D-E019 11.0 (15.0) 19.0 414-660 23.1 24.1 40 140M-D8E-C25 100-C30
(1)
Ratings apply to all drive types; Panel Mount (N104), Flange Mount (F104), and Plate Drive
(H204).
(2)
Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to
determine the frame and breaking capacity required for your application.
Supplemental Drive Information A-3
EN 50178
Bauart geprüft
Functional
..
TUV Safety
Rheinland Type approved
The drive is also designed to meet the appropriate portions of the following specifications:
NFPA 70 - US National Electrical Code
NEMA ICS 3.1 - Safety standards for Construction and Guide for Selection, Installation and
Operation of Adjustable Speed Drive Systems.
IEC 146 - International Electrical Code.
Protection Bus Overvoltage Trip
200-240V AC Input: 405V DC bus (equivalent to 290V AC incoming line)
380-460V AC Input: 810V DC bus (equivalent to 575V AC incoming line)
460-600V AC Input: 1005V DC bus (equivalent to 711V AC incoming line)
Bus Undervoltage Trip
200-240V AC Input: 210V DC bus (equivalent to 150V AC incoming line)
380-480V AC Input: 390V DC bus (equivalent to 275V AC incoming line)
460-600V AC Input
P042 = 3 “High Voltage”: 487V DC bus (equivalent to 344V AC incoming line)
P042 = 2 “Low Voltage”: 390V DC bus (equivalent to 275V AC incoming line)
Power Ride-Thru: 100 milliseconds
Logic Control Ride-Thru: 0.5 seconds minimum, 2 seconds typical
Electronic Motor Overload Protection: I2t protection - 150% for 60 seconds, 200% for 3
seconds (Provides Class 10 protection)
Overcurrent: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Environment Altitude: 1000 m (3300 ft) max. without derating. Above 1000 m
(3300 ft) derate 3% for every 305 m (1000 ft).
Maximum Surrounding Air Temperature
without derating:
IP20, Open Type: –10 to 50° C (14 to 122° F)
IP30, NEMA Type 1, UL Type 1: –10 to 40° C (14 to 104° F)
Flange and Plate Mount: Heatsink: –10 to 40° C (14 to 104° F)
Drive: –10 to 50° C (14 to 122° F)
Cooling Method
Convection: 0.4 kW (0.5 HP) drives and all Flange and Plate drives
Fan: All other drive ratings
Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)
Atmosphere: Important: Drive must 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.
Relative Humidity: 0 to 95% non-condensing
Shock (operating): 15G peak for 11ms duration (±1.0 ms)
Vibration (operating): 1G peak, 5 to 2000 Hz
A-4 Supplemental Drive Information
Category Specification
Electrical Voltage Tolerance: 200-240V ±10%
380-480V ±10%
460-600V ±10%
Frequency Tolerance: 48-63 Hz
Displacement Power Factor: 0.98 across entire speed range
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit
breaker
Transistor Type: Isolated Gate Bipolar (IGBT)
Control Method: Sinusoidal PWM, Volts/Hertz, and Sensorless Vector
Carrier Frequency 2-16 kHz, Drive rating based on 4 kHz.
Frequency Accuracy
Digital Input: Within ±0.05% of set output frequency
Analog Input: Within 0.5% of maximum output frequency, 10-Bit
resolution
Analog Output: ±2% of full scale, 10-Bit resolution
Speed Regulation - Open Loop with Slip ±1% of base speed across a 60:1 speed range
Compensation:
Output Frequency: 0-500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes including - Ramp,
Coast, DC-Brake, and Ramp-to-Stop
Accel/Decel: Four independently programmable accel and decel
times. Each time may be programmed from 0 - 600
seconds in 0.1 second increments.
Intermittent Overload: 150% Overload capability for up to 1 minute
200% Overload capability for up to 3 seconds
Electronic Motor Overload Protection Class 10 protection with selectable speed sensitive
response and power-down overload retention function
when enabled.
Control Inputs Digital: Quantity: (2) Semi-programmable
(5) Programmable
Current: 6 mA
Type
Source Mode (SRC): 18-24V = ON, 0-6V = OFF
Sink Mode (SNK): 0-6V = ON, 18-24V = OFF
Analog: Quantity: (2) Isolated, –10 to 10V and 4-20mA
Specification
Resolution: 10-bit
0 to 10V DC Analog: 100k ohm input impedance
4-20mA Analog: 250 ohm input impedance
External Pot: 1-10k ohm, 2 Watt minimum
Control Outputs Relay: Quantity: (1) Programmable Form C
Specification
Resistive Rating: 3.0A at 30V DC, 3.0A at 125V, 3.0A at 240V AC
Inductive Rating: 0.5A at 30V DC, 0.5A at 125V, 0.5A at 240V AC
Opto: Quantity: (2) Programmable
Specification: 30V DC, 50mA Non-inductive
Analog: Quantity: (1) Non-Isolated 0-10V or 4-20mA
Specification
Resolution: 10-bit
0 to 10V DC Analog: 1k ohm minimum
4-20mA Analog: 525 ohm maximum
Supplemental Drive Information A-5
Table A.C PowerFlex 40P Estimated Watts Loss (Rated Load, Speed & PWM)
Voltage kW (HP) External Watts Internal Watts Total Watts Loss
200–240V 0.4 (0.5) 22 18 40
0.75 (1.0) 40 20 60
1.1 (2.0) 63 22 85
2.2 (3.0) 100 25 125
3.7 (5.0) 150 30 180
5.5 (7.5) 200 35 235
7.5 (10) 265 40 305
380–480V 0.4 (0.5) 17 18 35
0.75 (1.0) 30 20 50
1.1 (2.0) 48 22 70
2.2 (3.0) 75 25 100
3.7 (5.0) 135 25 160
5.5 (7.5) 140 35 175
7.5 (10) 175 35 210
11 (15) 260 40 300
460–600V 0.75 (1.0) 30 20 50
1.5 (2.0) 48 22 70
2.2 (3.0) 75 25 100
4.0 (5.0) 135 25 160
5.5 (7.5) 140 35 175
7.5 (10) 175 35 210
11 (15) 260 40 300
A-6 Supplemental Drive Information
Notes:
Appendix B
22D - B 2P3 N 1 0 4
Drive Voltage Rating Rating Enclosure HIM Emission Class Version
Table B.B PowerFlex 40P Drives
IP20 Flange
Drive Ratings IP20/NEMA Type Open Mount(1) Plate Drive
Output Frame
Input Voltage kW HP Current Catalog Number Size Catalog Number Catalog Number
240V 50/60 Hz 0.4 0.5 2.3A 22D-B2P3N104 B 22D-B2P3F104 22D-B2P3H204
3-Phase
0.75 1.0 5.0A 22D-B5P0N104 B 22D-B5P0F104 22D-B5P0H204
No Filter
1.5 2.0 8.0A 22D-B8P0N104 B 22D-B8P0F104 22D-B8P0H204
2.2 3.0 12.0A 22D-B012N104 B 22D-B012F104 22D-B012H204
3.7 5.0 17.5A 22D-B017N104 B 22D-B017F104 22D-B017H204
5.5 7.5 24.0A 22D-B024N104 C 22D-B024F104 22D-B024H204
7.5 10.0 33.0A 22D-B033N104 C 22D-B033F104 22D-B033H204
480V 50/60 Hz 0.4 0.5 1.4A 22D-D1P4N104 B 22D-D1P4F104 22D-D1P4H204
3-Phase
0.75 1.0 2.3A 22D-D2P3N104 B 22D-D2P3F104 22D-D2P3H204
No Filter
1.5 2.0 4.0A 22D-D4P0N104 B 22D-D4P0F104 22D-D4P0H204
2.2 3.0 6.0A 22D-D6P0N104 B 22D-D6P0F104 22D-D6P0H204
4.0 5.0 10.5A 22D-D010N104 B 22D-D010F104 22D-D010H204
5.5 7.5 12.0A 22D-D012N104 C 22D-D012F104 22D-D012H204
7.5 10.0 17.0A 22D-D017N104 C 22D-D017F104 22D-D017H204
11.0 15.0 24.0A 22D-D024N104 C 22D-D024F104 (2) 22D-D024H204 (2)
600V 50/60 Hz 0.75 1.0 1.7A 22D-E1P7N104 B 22D-E1P7F104 22D-E1P7H204
3-Phase
1.5 2.0 3.0A 22D-E3P0N104 B 22D-E3P0F104 22D-E3P0H204
No Filter
2.2 3.0 4.2A 22D-E4P2N104 B 22D-E4P2F104 22D-E4P2H204
4.0 5.0 6.6A 22D-E6P6N104 B 22D-E6P6F104 22D-E6P6H204
5.5 7.5 9.9A 22D-E9P9N104 C 22D-E9P9F104 22D-E9P9H204
7.5 10.0 12.0A 22D-E012N104 C 22D-E012F104 22D-E012H204
11.0 15.0 19.0A 22D-E019N104 C 22D-E019F104 22D-E019H204
(1)
Meets IP40/54/65 (NEMA 1/12/4/4X) when installed in an enclosure of like rating.
(2)
Requires use of external DC Bus Inductor or AC Line Reactor. See Table B.E for details.
B-2 Accessories and Dimensions
(1)
The resistors listed in this tables are rated for 5% duty cycle.
(2)
Use of Rockwell resistors is always recommended. The resistors listed have been carefully
selected for optimizing performance in a variety of applications. Alternative resistors may be used,
however care must be taken when making a selection. Refer to the PowerFlex Dynamic Braking
Resistor Calculator, publication PFLEX-AT001.
(3)
Requires two resistors wired in parallel.
Accessories and Dimensions B-3
Table B.G Human Interface Module (HIM) Option Kits and Accessories
Item Description Catalog Number
LCD Display, Remote Panel Digital speed control 22-HIM-C2S
Mount CopyCat capable
IP66 (NEMA Type 4X/12) indoor use only
Includes 2.9 meter cable
LCD Display, Remote Handheld Digital speed control 22-HIM-A3
Full numeric keypad
CopyCat capable
IP30 (NEMA Type 1)
Includes 1.0 meter cable
Panel mount with optional Bezel Kit
Bezel Kit Panel mount for LCD Display, Remote 22-HIM-B1
Handheld unit, IP30 (NEMA Type 1)
DSI HIM Cable 1.0 Meter (3.3 Feet) 22-HIM-H10
(DSI HIM to RJ45 cable) 2.9 Meter (9.51 Feet) 22-HIM-H30
Product Dimensions
Table B.K PowerFlex 40P Frames – Ratings are in kW and (HP)
240V AC – 480V AC – 600V AC –
Frame 3-Phase 3-Phase 3-Phase
B 0.4 (0.5) 2.2 (3.0) 0.4 (0.5) 2.2 (3.0) 0.75 (1.0) 2.2 (3.0)
0.75 (1.0) 3.7 (5.0) 0.75 (1.0) 4.0 (5.0) 1.5 (2.0) 4.0 (5.0)
1.5 (2.0) 1.5 (2.0)
C 5.5 (7.5) 5.5 (7.5) 11.0 (15.0) 5.5 (7.5) 11.0 (15.0)
7.5 (10.0) 7.5 (10.0) 7.5 (10.0)
Figure B.1 IP 30/NEMA 1/UL Type 1 Option Kit without Communication Option –
Dimensions are in millimeters and (inches)
20A-DG01
∅ 22.2 RUN
REV
FAULT (3.44)
(0.87) 213
(8.39)
180
(7.09)
109.9
(4.33) 168
(6.61)
74.3
(2.93)
Frame B - 22-JBAB
192.0 (7.56)
130.0 (5.1) 180.0 (7.1)
116.0 (4.57)
20A-DG01
RUN
REV
FAULT
152.2
(5.99)
111.2
(4.38)
Frame C - 22-JBAC
B-8 Accessories and Dimensions
Figure B.2 IP 30/NEMA 1/UL Type 1 Option Kit with Communication Option –
Dimensions are in millimeters and (inches)
RUN
87.4
REV
FAULT (3.44)
244
(9.61)
134.3 180
(5.29) (7.09)
105.3 168
(4.15) (6.61)
76.3
(3.00)
Frame B - 22-JBCB
205.0 (8.07)
108.7 (4.28)
130.0 (5.1) 180.0 (7.1)
92.2 (3.63)
116.0 (4.57)
69.2 (2.72) ∅ 28.5
45.7 (1.80) (1.12)
22.2 (0.87) ∅ 22.2 RUN
(0.87) REV
FAULT
320
(12.6)
260
(10.2)
179.8
(7.08) 246
(9.7)
144.8
(5.70)
109.8
(4.32)
Frame C - 22-JBCC
Accessories and Dimensions B-9
Figure B.3 PowerFlex 40P Flange Mount Drives – Dimensions are in millimeters and
(inches)
106.3
(4.19)
244 94.3 63.1
(9.61) (3.71) (2.48)
214
(8.43)
RUN
REV
FAULT 20A-DG01
250
(9.84)
22D-CCB
119.3
(4.70)
Frame B
117.8
(4.64)
300 105.8 138.2
(11.81) (4.17) (5.44)
RUN
REV
FAULT
20A-DG01
325
(12.8)
22D-CCC
130.3
(5.13)
Frame C
B-10 Accessories and Dimensions
Figure B.4 PowerFlex 40P Flange Mount Cutout Dimensions – Dimensions are in
millimeters and (inches)
145
6.5 (5.71)
(0.26) 23.5
(0.93)
197
(7.76)
210
225 (8.27)
(8.86)
98.5
(3.88)
5.3
(0.21)
14 31 49 7.5
(0.55) (1.22) (1.93) (0.30)
98
(3.86)
160
(6.30)
Frame B
8 164 5.3
(0.31) (6.46) (0.21)
307.5
(12.11)
230.6
(9.08) 291.5
(11.48)
153.8
(6.06)
76.9
(3.03)
90 8
(3.54) (0.31)
180
(7.09)
Frame C
Accessories and Dimensions B-11
Figure B.5 PowerFlex 40P Plate Drive Dimensions – Dimensions are in millimeters
and (inches)
125
(4.92)
112 100
(4.41) (3.94)
80
(3.15) 88 9.5
(3.46) (0.37)
RUN
REV
FAULT
192 20A-DG01
(7.56)
204 180
(8.03) (7.09)
22D-CCB
96
(3.78)
155
(6.10)
142 110.5
(5.59) (4.35)
80
(3.15) 98.5 9.5
(3.88) (0.37)
RUN
REV
FAULT 272 20A-DG01
(10.71)
284 260
(11.18) (10.24)
22D-CCC
136
(5.35)
Figure B.6 Dynamic Brake Modules – Dimensions are in millimeters and (inches).
Weights are in kilograms and (pounds).
Frame A Frame B
30.0 61.0
17.0 (1.18) 60.0 31.0 (2.40) 59.0
(0.67) (2.36) (1.22) (2.32)
US
C
US
C
316.0 335.0 386.0 405.0
(12.44) (13.19) (15.20) (15.94)
AUTOMATION
ROCKWELL
SURFACES MAY BE
AUTOMATION
ROCKWELL
13.0
(0.51)
Three-Phase
AC Input
RUN
REV
FAULT
(Input Contactor) M
R (L1)
S (L2)
T (L3)
Figure B.8 Bulletin 1321-3R Series Line Reactors – Dimensions are in millimeters and
(inches). Weights are in kilograms and (pounds).
A
B
E
D
C
Figure B.9 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
50 100
(1.97) 78 (3.94)
29.8
(1.17) (3.07)
217 229
(8.54) (9.02)
216
(8.50)
Figure B.10 Frame C EMC Line Filters – Dimensions are in millimeters and (inches)
Catalog Numbers: 22-RF018-CS, -CL; 22-RF025-CL; 22-RF026-CS, -CL; 22-RF034-CS,
-CL
60 130
(2.36) 90 (5.12)
32
(1.26) (3.54)
297 309
(11.69) (12.17)
297
(11.69)
17 5.5 (0.22)
(0.67) 30
(1.18)
B-16 Accessories and Dimensions
Figure B.11 Remote (Panel Mount) HIM – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-C2S
25 93
(0.98) (3.66)
180
(7.09)
2m
67
(2.64)
60
(2.36)
154
(6.06)
77
19.1 (3.03)
(0.75)
4.8
(0.19)
23.5
(0.93)
Accessories and Dimensions B-17
Figure B.12 NEMA Type 1 Bezel – Dimensions are in millimeters and (inches)
Catalog Number: 22-HIM-B1
11.1
93 (0.44)
25.2 (3.66)
(0.99)
180
(7.09)
2m
67
(2.64)
60
(2.36)
154
(6.06)
4.8
(0.19)
77
(3.03)
19.1
(0.75)
23.5
(0.93)
B-18 Accessories and Dimensions
Notes:
Appendix C
Controller
Network Wiring
Network wiring consists of a shielded 2-conductor cable that is
daisy-chained from node to node.
Only pins 4 and 5 on the RJ45 plug should be wired. The other pins on
the PowerFlex 40P RJ45 socket contain power, etc. for other Rockwell
Automation peripheral devices and must not be connected.
Parameter Configuration
The following PowerFlex 40P parameters are used to configure the drive
to operate on a network.
Logic Command
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
00 = No Command
01 = Forward Command
5,4
10 = Reverse Command
11 = No Command
6 Not Used
7 Not Used
00 = No Command
01 = Accel Rate 1 Enable
9,8
10 = Accel Rate 2 Enable
8192 11 = Hold Accel Rate Selected
00 = No Command
01 = Decel Rate 1 Enable
11,10
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)
14,13,12
100 = A070 [Preset Freq 0]
101 = A071 [Preset Freq 1]
110 = A072 [Preset Freq 2]
111 = A073 [Preset Freq 3]
15 Not Used
Reference
Address (Decimal) Description
A decimal value entered as xxx.x where the decimal point is fixed. For
8193
example, a decimal “100” equals 10.0 Hz and “543” equals 54.3 Hz.
C-4 RS485 (DSI) Protocol
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
7 1 = Faulted, 0 = Not Faulted
8448
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 Digital Input 3 Status
15 Digital Input 4 Status
Feedback(1)
Address (Decimal) Description
A xxx.x decimal value where the decimal point is fixed. For example, a decimal
8451 “123” equals 12.3 Hz and “300” equals 30.0 Hz.
(1)
Returns the same data as Reading (03) Parameter d001 [Output Freq].
RS485 (DSI) Protocol C-5
Logic Status
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
38 Phase U to Ground Short
39 Phase V to Ground Short
8449 40 Phase W to Ground Short
41 Phase UV Short
42 Phase UW Short
43 Phase VW Short
48 Parameters Defaulted
63 Software Overcurrent
64 Drive Overload
70 Power Unit Fail
71 Network Loss Fault
80 AutoTune Fail
81 Communication Loss
94 Encoder Loss Fault
100 Parameter Checksum Error
111 Hardware Enable Fault
122 I/O Board Fail
Additional Information
Refer to http://www.ab.com/drives/ for additional information.
C-6 RS485 (DSI) Protocol
Notes:
Appendix D
The PowerFlex 40P 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
S
Slave Port
Master Port
M
PIN 1 PIN 8
TB1
(PIN 4) PIN 1
PIN 8
PIN 1
RJ45 DSI Splitter Cable D-3
DSI / MDI
Serial Converter Hand Held
or
M DSI
or DSI
or
M
Parameter 9 [Device Type] set to
"Master" and connected to Master
port (M) on RJ45 Splitter Cable
S
AK-U0-RJ45-TB2P
Two-position
Terminal Block
AK-U0-RJ45-TR1
Terminating Resistor
(end of network) or or
Both the Master (M) and Slave (S) ports on the RJ45 Splitter
Cable operate as standard RS-485 ports in this configuration.
Appendix E
• Timer Function
A digital input can be programmed for “Timer Start”. A digital
output can be programmed as a “Timer Out” with an output level
programmed to the desired time. When the timer reaches the time
programmed into the output level the output will change state. The
timer can be reset via a digital input programmed as “Reset Timer”.
• Counter Function
A digital input can be programmed for “Counter In”. A digital output
can be programmed as “Counter Out” with an output level
programmed to the desired number of counts. When the counter
reaches the count programmed into the output level the output will
change state. The counter can be reset via a digital input
programmed as “Reset Counter”.
E-2 Velocity StepLogic™, Basic Logic and Timer/Counter Functions
Forward
0
Reverse
Time
Example
• Run at Step 0.
• Transition to Step 1 when Logic In1 is true.
Logic senses the edge of Logic In1 when it transitions from off to on.
Logic In1 is not required to remain “on”.
• Transition to Step 2 when both Logic In1 and Logic In2 are true.
The drive senses the level of both Logic In1 and Logic In2 and
transitions to Step 2 when both are on.
• Transition to Step 3 when Logic In2 returns to a false or off state.
Inputs are not required to remain in the “on” condition except under
the logic conditions used for the transition from Step 2 to Step 3.
Start Step 0 Step 1 Step 2 Step 3
Frequency
Logic In1
Logic In2
Time
The step time value and the basic logic may be used together to satisfy
machine conditions. For instance, the step may need to run for a
minimum time period and then use the basic logic to trigger a transition
to the next step.
Start Step 0 Step 1
Frequency
Logic In1
Logic In2
Time
E-4 Velocity StepLogic™, Basic Logic and Timer/Counter Functions
Timer Function
Digital inputs and outputs control the timer function and are configured
with parameters A051-A054 [Digital Inx Sel] set to 18 “Timer Start” and
20 “Reset Timer”.
Digital outputs (relay and opto type) define a preset level and indicate
when the level is reached. Level parameters A056 [Relay Out Level],
A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the
desired time in seconds.
Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061
[Opto Out2 Sel] are set to option 16 “Timer Out” and causes the output
to change state when the preset level is reached.
Example
Output
Frequency
Start
Relay Out
Photo Eye
Digital In1
Counter In
Digital In2
Reset Counter
Limit Switch
Note that a “Reset Timer” input is not required for this example since the
“Timer Start” input both clears and starts the timer.
E-6 Velocity StepLogic™, Basic Logic and Timer/Counter Functions
Counter Function
Digital inputs and outputs control the counter function and are
configured with parameters A051-A054 [Digital Inx Sel] set to 19
“Counter In” and 21 “Reset Counter”.
Digital outputs (relay and opto type) define a preset level and indicate
when the level is reached. Level parameters A056 [Relay Out Level],
A059 [Opto Out1 Level] and A062 [Opto Out2 Level] are used to set the
desired count value.
Parameters A055 [Relay Out Sel], A058 [Opto Out1 Sel] and A061
[Opto Out2 Sel] are set to 17 “Counter Out” which causes the output to
change state when the level is reached.
Example
Table E.B Digit 3 – Defines the action during the step currently executing.
Accel/Decel StepLogic Output
Setting Parameters Used State Commanded Direction
0 1 Off FWD
1 1 Off REV
2 1 Off No Output
3 1 On FWD
4 1 On REV
5 1 On No Output
6 2 Off FWD
7 2 Off REV
8 2 Off No Output
9 2 On FWD
A 2 On REV
b 2 On No Output
Table E.C Digit 2 – Defines what step to jump to or how to end program when the
logic conditions specified in Digit 1 are met.
Setting Logic
0 Jump to Step 0
1 Jump to Step 1
2 Jump to Step 2
3 Jump to Step 3
4 Jump to Step 4
5 Jump to Step 5
6 Jump to Step 6
7 Jump to Step 7
8 End Program (Normal Stop)
9 End Program (Coast to Stop)
A End Program and Fault (F2)
E-8 Velocity StepLogic™, Basic Logic and Timer/Counter Functions
Table E.D Digit 1 – Defines what logic must be met to jump to a step other than the
very next step.
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] TIMED
parameter.
2 Step if “Logic In1” is active (logically true) TRUE
3 Step if “Logic In2” is active (logically true) TRUE
4 Step if “Logic In1” is not active (logically false) FALSE
5 Step if “Logic In2” is not active (logically false) FALSE
6 Step if either “Logic In1” or “Logic In2” is active (logically true) OR
7 Step if both “Logic In1” and “Logic In2” is active (logically true) AND
8 Step if neither “Logic In1” or “Logic In2” is active (logically true) NOR
9 Step if “Logic In1” is active (logically true) and “Logic In2” is not active XOR
(logically false)
A Step if “Logic In2” is active (logically true) and “Logic In1” is not active XOR
(logically false)
b Step after [Stp Logic Time x] and “Logic In1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In2” is active (logically true) TIMED AND
d Step after [Stp Logic Time x] and “Logic In1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In2” is not active (logically false) TIMED OR
F Do not step OR no “jump to”, so use Digit 0 logic IGNORE
Table E.E Digit 0 – Defines what logic must be met to jump to the very next step.
Setting Description Logic
0 Skip Step (jump immediately) SKIP
1 Step based on the time programmed in the respective [Stp Logic Time x] TIMED
parameter.
2 Step if “Logic In1” is active (logically true) TRUE
3 Step if “Logic In2” is active (logically true) TRUE
4 Step if “Logic In1” is not active (logically false) FALSE
5 Step if “Logic In2” is not active (logically false) FALSE
6 Step if either “Logic In1” or “Logic In2” is active (logically true) OR
7 Step if both “Logic In1” and “Logic In2” is active (logically true) AND
8 Step if neither “Logic In1” or “Logic In2” is active (logically true) NOR
9 Step if “Logic In1” is active (logically true) and “Logic In2” is not active XOR
(logically false)
A Step if “Logic In2” is active (logically true) and “Logic In1” is not active XOR
(logically false)
b Step after [Stp Logic Time x] and “Logic In1” is active (logically true) TIMED AND
C Step after [Stp Logic Time x] and “Logic In2” is active (logically true) TIMED AND
d Step after [Stp Logic Time x] and “Logic In1” is not active (logically false) TIMED OR
E Step after [Stp Logic Time x] and “Logic In2” is not active (logically false) TIMED OR
F Use logic programmed in Digit 1 IGNORE
Appendix F
Encoder Usage
The PowerFlex 40P includes a pulse-train/encoder input. When E216
[Motor Fdbk Type] is set to a value other than zero, the drive is set to use
an encoder. The drive will use the encoder in several ways depending on
the settings of other parameters. The drive will use the encoder as shown
below (listed in order of priority):
Wiring Notes
The encoder can supply 5V or 12V power (250 mA maximum) for an
encoder. Be sure the DIP switch is set properly for the encoder. In
general, 12V will provide higher noise immunity.
The pulse-train/encoder inputs can handle 5V, 12V, or 24V inputs. The
inputs will automatically adjust to the voltage applied and no additional
drive adjustment is necessary. If a pulse-train or single-channel input is
used, it must be wired between the A (signal) and A- (signal common)
channels.
Positioning Overview
The PowerFlex 40P includes a simple position regulator which can be
used in a variety of position applications without the need for multiple
limit switches or photo-eyes. This can be used as a stand-alone controller
for simple applications (up to 8 positions) or in conjunction with a
controller for more flexibility.
Please note that this is not intended to replace high end servo controllers
or any application that needs high bandwidth or very high torque at low
speeds.
Encoder usage and Position/Step Logic Application F-3
E216 [Motor Fdbk Type] must be set to the match the feedback device.
Positioning mode must use E216 [Motor Fdbk Type] option 4.
E217 [Motor NP Poles] must be set to match the number of motor poles
on the motor driven by the PowerFlex 40P drive.
E218 [Encoder PPR] must be set to match the number of pulses per
revolution of the encoder used (i.e., 1024 PPR Encoder).
E226 [Counts Per Unit] sets the number of encoder counts that will be
used to define one position unit. This allows the encoder positions to be
defined in terms of units important to the application. For example, if
1cm of travel on a conveyor belt requires 0.75 turns of the motor, the
motor encoder is 1024 PPR, and the Motor Feedback type is set to
Quadrature, then this parameter would need to be set to (4 x 1024 x 0.75)
= 3072 counts for 1cm of travel. Then all other positions could be setup
in units of “cm”.
E225 [Encoder Pos Tol] indicates the desired position tolerance for the
system. This will determine how close the drive must be to the
commanded position before the drive will indicate “At Home” or “At
Position” in units of raw encoder pulses. This has no effect on the actual
positioning control of the motor.
Encoder usage and Position/Step Logic Application F-5
Positioning Operation
Parameter E222 [Positioning Mode] must be set to properly match the
desired operation of the positioning function.
0 “Time Steps” uses Step Logic times. This mode ignores the Step
Logic settings and moves through the steps (Step 0 to Step 7 and back to
Step 0) based on the times programmed into A150-A157 [Stp Logic
Time]. This can be used when the desired position is based only on time.
In addition, this mode only accepts absolute positions in a positive
direction from “home”. This option provides an easy way to implement a
simple positioning program or to test the basic positioning setup. For
additional flexibility one of the other settings should be used.
Important: The default value for A070 [Preset Freq 0] is 0.0 Hz. This
value needs to be changed or the drive will not be able to
move during Step 0.
Note: Incremental move commands will cause the drive to move the
amount specified based on the current position. Absolute commands are
always with reference to “Home”.
E246 [Pos Reg Filter] provides a low pass filter at the input of the
position regulator.
F-8 Encoder usage and Position/Step Logic Application
Homing Routine
This drive supports incremental encoders only. Therefore, when the drive
powers up it will reset the current position to zero. If this is known to be
correct the position routine can be started without further adjustment.
However, in most applications the drive will need to be “homed” after
each power-up and prior to starting the position routine.
To begin the automatic homing routine, activate the “Find Home” input
and then initiate a valid start command. The drive will then ramp to the
speed set in E223 [Find Home Freq] and in the direction set in E224
[Find Home Dir] until the digital input defined as “Home Limit” is
activated. If the drive passes this point too quickly it will then reverse
direction at 1/10th E223 [Find Home Freq] to the point where the Home
Limit switch reactivates. Approximately one second after the routine
finds home the drive will stop. Alternately, the “Find Home Freq” and/or
“Home Limit” bits in E248 [Enh Control Word] can be activated instead
of utilizing a digital input. The inputs or bits should be returned to
inactive after the routine is complete.
Important: After the position is reached the drive will stop. If the Find
Home is removed before the homing is complete, the drive
will begin running the position routine without the proper
home. In this case Home will not be reset and the position
will be in relation to the power up position.
Bit 0 “Dir Traveled” indicates the current direction the drive has moved
from Home.
Bit 1 “At Home” indicates whether the drive is at Home. If the drive is
within E225 [Encoder Pos Tol] of “Home”, this bit will be active.
Bit 3 “Drive Homed” indicates whether the drive has been homed since
power-up. This bit will be active once the drive has been homed either
manually or automatically. It will remain active until the next power
down.
Setup Notes
The RA computer tools (DriveExplorer and DriveTools SP) can make
setup of the positioning functions much easier. Please refer to the latest
versions for additional tools or wizards which can aid in the setup.
F-12 Encoder usage and Position/Step Logic Application
Notes:
Appendix G
PID Set Up
PID Loop
The PowerFlex 40P has a built-in PID (proportional, integral,
differential) control loop. The PID loop is used to maintain a process
feedback (such as pressure, flow or tension) at a desired set point. The
PID loop works by subtracting the PID feedback from a reference and
generating an error value. The PID loop reacts to the error, based on the
PID Gains, and outputs a frequency to try to reduce the error value to 0.
To enable the PID loop, parameter A132 [PID Ref Sel] must be set to an
option other than 0 “PID Disabled”.
Exclusive Control and Trim Control are two basic configurations where
the PID loop may be used.
G-2 PID Set Up
Exclusive Control
In Exclusive Control, the Speed Reference becomes 0, and the PID
Output becomes the entire Freq Command. Exclusive Control is used
when A132 [PID Ref Sel] is set to option 1, 2, 3, 4 or 5. This
configuration does not require a master reference, only a desired set
point, such as a flow rate for a pump.
PID Loop
PID Ref PID Prop Gain
+ PID + PID
– Error + Output Accel/Decel Freq
PID Fdbk PID Integ Time Ramp Command
+
PID Diff Rate
PID Enabled
Example
PID Feedback =
Pressure Transducer Signal
Pump
PID Reference =
Desired System Pressure
PID Set Up G-3
Trim Control
In Trim Control, the PID Output is added to the Speed Reference. In
Trim mode, the output of the PID loop bypasses the accel/decel ramp as
shown. Trim Control is used when A132 [PID Ref Sel] is set to option 6,
7, 8, 9 or 10.
P038 [Speed Reference]
PID Loop Accel/Decel
PID Ref Ramp
PID Prop Gain
+ PID + PID +
– Error + Output + Output
PID Fdbk PID Integ Time Freq
+
PID Diff Rate
PID Enabled
Example
0 Volts
10 Volts
A133 [PID Feedback Sel] is used to select the source of the PID
feedback.
Table G.B A133 [PID Feedback Sel] Options
Option Description
0 “0-10V Input” Selects the 0-10V Input (default setting). Note that the PID will not
function with a bipolar analog input. It will ignore any negative voltages
and treat them like a zero.
1 “4-20mA Input“ Selects the 4-20mA Input.
2 “Comm Port” The reference word from a communication network (see Appendix C of
the PowerFlex 40P User Manual for details on the reference word) such
as Modbus RTU or DeviceNet becomes the PID Feedback. The value
sent over the network is scaled so that P035 [Maximum Freq] x 10 =
100% Feedback. For example, with [Maximum Freq] = 60 Hz, a value of
600 sent over the network would represent 100% Feedback.
3 “Encoder” Encoder or Pulse train will be used as an input for the PID Feedback.
PID Set Up G-5
Examples
Scale Function
For a 0-5 volt signal, the following parameter settings are used so that a 0
volt signal = 0% PID Reference and a 5 volt signal = 100% PID
Reference.
• A110 [Anlg In 0-10V Lo] = 0.0%
• A111 [Anlg In 0-10V Hi] = 50.0%
• A132 [PID Ref Sel] = 0 “0-10V Input”
12
10
8
Input Volts
6
4
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
Invert Function
For a 4-20mA signal, the following parameter settings are used so that a
20mA signal = 0% PID Reference and a 4mA signal = 100% PID
Reference.
• A112 [Anlg In 4-20mA Lo] = 100.0%
• A113 [Anlg In 4-20mA Hi] = 0.0%
• A132 [PID Ref Sel] = 3 “4-20mA Input”
24
20
4-20mA Input
16
12
8
4
0 10 20 30 40 50 60 70 80 90 100
PID Reference (%)
G-6 PID Set Up
PID Deadband
Parameter A138 [PID Deadband] is used to set a range, in percent, of the
PID Reference that the drive will ignore.
Example
PID Preload
The value set in A139 [PID Preload], in Hertz, will be pre-loaded into
the integral component of the PID at any start or enable. This will cause
the drive’s frequency command to initially jump to that preload
frequency, and the PID loop starts regulating from there.
PID Enabled
Freq Cmd
PID Limits
A130 [PID Trim Hi] and A131 [PID Trim Lo] are used to limit the PID
output and are only used in trim mode. [PID Trim Hi] sets the maximum
frequency for the PID output in trim mode. [PID Trim Lo] sets the
reverse frequency limit for the PID output in trim mode. Note that when
the PID reaches the Hi or Lo limit, the PID regulator stops integrating so
that windup does not occur.
PID Set Up G-7
PID Gains
The proportional, integral, and differential gains make up the PID
regulator.
The following figures show some typical responses of the PID loop at
different points during adjustment of the PID Gains.
PID Reference
PID Feedback
Time
PID Reference
PID Feedback
Time
PID Reference
PID Feedback
Time
PID Reference
PID Feedback
Time
G-10 PID Set Up
Notes:
Appendix H
Introduction
The PowerFlex 40P is available in a plate drive version without heatsink.
This is designed to allow mounting to a customer supplied heatsink. This
may be a large heatsink to be shared by multiple drives, a large thermal
mass that is part of a system, or some other heat-sinking system. Care
must be taken to insure the heatsink used provides adequate cooling for
the drive power components as well as a flat and clean surface for a
proper thermal interface.
General Requirements
The drive is designed to operate with the drive enclosed and the heatsink
exposed for improved cooling. Therefore, it is expected that the drive
control section will experience a higher ambient temperature than the
heatsink.
Figure H.1 Approximate Heatsink Dimensions for One Drive without Heatsink Fan –
Dimensions are in millimeters and (inches)
+0.5 mil
–0.5 mil
5.0 mil
–1.5 mil
H-4 Plate Drive Installation Instructions
1
2
Isopropyl
Alcohol
3
4
2.0 N-m
(18 lb.-in.)
1 4
6
5
3 2
Verification
Once the drive is mounted, a worst-case test should be run to verify the
design. The drive should run at its maximum load conditions at the
highest expected surrounding air temperature. After four hours in this
condition, the temperature of the drive plate should be measured. It
should not exceed 75° C (167° F) at its hottest point. Also, parameter
b024 [Drive Temp] should be monitored and should not exceed 80° C
(176° F).
Index
A D
AC Supply Dimensions
Ground, 1-5 Drive, B-7
Source, 1-3 Minimum Clearances, 1-2
Ungrounded, 1-3 Discharging Bus Capacitors, P-3
Advanced Display Group Parameters, Display, 2-3
3-59 Distribution Systems, Ungrounded,
Advanced Program Group 1-3
Parameters, 3-15 Drive Frame Size, P-2, B-7
Ambient Temperatures, 1-2 Drive Grounding, 1-5
Armored Cable, 1-8 Drive Overload Fault, 4-4
Auto Rstrt Tries Fault, 4-4 Drive Ratings, A-1
Auxiliary Input Fault, 4-3 DriveExecutive, 3-1
DriveExplorer, 3-1
B
Basic Display Group Parameters, 3-3 E
Basic Program Group Parameters, Earthing, see Grounding
3-9 EMC/RFI
Before Applying Power, 2-1, 2-2
Grounding, Filter, 1-6
Bus Capacitors, Discharging, P-3
Interference, 1-28
C Enclosure Rating, Changing, 1-2
Cable, Power, 1-8 Encoder Interface, 1-17
Capacitors, Discharging, P-3 Wire Routing, 1-17
CE Conformity, 1-28 Encoder Wiring, 1-18
Checklist, Start-Up, 2-1, 2-2 Enhanced Program Group
Parameters, 3-48
Circuit Breakers
ESD, Static Discharge, P-3
Input, 1-6
Comm Loss Fault, 4-4 F
Command Sources for Start and Fault Reset and Display, 2-3
Speed, 1-26
Faults
Common Bus, 1-12
Auto Rstrt Tries, 4-4
Common Symptoms and Corrective
Action, 4-6 Auxiliary Input, 4-3
Contactors, Input, 1-12 Comm Loss, 4-4
Control Wire, 1-13 Drive Overload, 4-4
Control, 2 and 3 Wire, 1-21, 1-25 Ground Fault, 4-3
Conventions, Manual, P-2 Heatsink OvrTmp, 4-3
Cover, Opening, 1-1 HW OverCurrent, 4-3
Cross Reference, Parameter I/O Board Fail, 4-5
by Name, 3-61 Motor Overload, 4-3
Motor Stalled, 4-3
OverVoltage, 4-3
Parameter Checksum, 4-5
Index-2
T
Terminal Block
I/O, 1-13
Power, 1-11
Three Wire Control, 1-21, 1-25
Two Wire Control, 1-21, 1-25
U
UnderVoltage Fault, 4-3
Ungrounded Supply, 1-3
Unshielded Power Cables, 1-8
Index-4
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