PowerFlex 4M

PowerFlex 4M AC Drives are the smallest and most cost effective members of the PowerFlex drives. Easy to feed wiring and easy programming provide the flexibility to handle a broad range of applications. This Module uses Integral RS-485 communications with IP20, NEMA/UL open type enclosures V/Hz control, slip compensation. It is also equipped with Drive overload protection and ramp regulation.

Allen-Bradley PowerFlex 4M Drives

Technical Specifications

  • PowerFlex 4M Drives horsepower ratings range from 0.25-1.5HP, 0.25-10HP or 0.5-15HP
  • Input-voltage range from 100-120V, 200-240V, or 380-480V
  • Output-horsepower ratings range from 0.25-1.5HP, 0.25-3HP, 0.25-10HP, or 0.5-10HP
  • Enclosure types include IP20, NEMA/UL open type V/Hz control and slip compensation

Overview

  • Mounting and Packaging Choices
    • 50 Celsius ambient temperatures allowable with little spacing between drives
    • Side-by-side stacking permissible for ambient temperatures up to 40 Celsius
    • DIN rail mounting for A and B frame drives
  • Simple Set-up and Operation
    • Easy to use integral keypad
    • No programming necessary to use integral keypad out of the box
  • Network Solutions and Easy Programming
    • Software, remote keypad, or LCD keypad programming and configuration 
    • Simplified parameter and tag programming with Logix control platform 

Allen-Bradley PowerFlex 4M Drives

Technical Specifications

  • PowerFlex 4M Drives horsepower ratings range from 0.25-1.5HP, 0.25-10HP or 0.5-15HP
  • Input-voltage range from 100-120V, 200-240V, or 380-480V
  • Output-horsepower ratings range from 0.25-1.5HP, 0.25-3HP, 0.25-10HP, or 0.5-10HP
  • Enclosure types include IP20, NEMA/UL open type V/Hz control and slip compensation

Overview

  • Mounting and Packaging Choices
    • 50 Celsius ambient temperatures allowable with little spacing between drives
    • Side-by-side stacking permissible for ambient temperatures up to 40 Celsius
    • DIN rail mounting for A and B frame drives
  • Simple Set-up and Operation
    • Easy to use integral keypad
    • No programming necessary to use integral keypad out of the box
  • Network Solutions and Easy Programming
    • Software, remote keypad, or LCD keypad programming and configuration 
    • Simplified parameter and tag programming with Logix control platform 

Troubleshooting Your PowerFlex 4M Drive

This page outlines information you will need to troubleshoot your PowerFlex 4M Drive. 

PowerFlex 4M Drive Faults

There are two types of Faults that can affect your PowerFlex 4M Drive: Auto-Reset/Run and Non-Resettable. An Auto-Reset/Run fault, the drive will try to automatically reset the fault. If the fault's cause is not present at the time of reset, the fault will reset and the drive will restart. A Non-Resettable fault will likely require a drive or motor repair. However, this kind of fault can also be caused by wiring or programming errors. Once the cause of the fault is corrected, the fault may be cleared. 

When the drive detects a fault you will see a flashing fault number and a flashing fault indicator on the front of the drive. You must press Escape to regain control of the keypad. 

Fault Codes

Code No. Fault Meaning - Fault Type Action
F2 Aux. Input Auxiliary input interlock is open - AutoReset/Run Check remote wiring. Ensure communications programming is correct
F3 Power Loss Excessive DC Bus Voltage ripple - NonResettable  Look for phase loss/line imbalance. Look at input line fuse.
F4 UnderVoltage  DC Bus Voltage below minimum value - AutoReset/Run Look for low voltage/line power interruption on incoming AC line
F5 OverVoltage DC Bus Voltage above maximum value - AutoReset/Run Look for high line voltage/transient conditions on AC line. This fault can be caused by motor regeneration. You should install a dynamic break or extend the decel time
F6 Stalled Motor Drive cannot accelerate motor - AutoReset/Run Increase Accel Time 1 and/or 2. Or you can reduce the load so the drive output current will not exceed the current set by Bus Reg Mode
F7 Motor Overload Internal electronic overload trip - AutoReset/Run Reduce load so drive output does not exceed current set by the Motor OL Current parameter. Check the Boost Select setting
F8

Heatsink OverTmp

Heatsink temperature exceeds a set value - AutoReset/Run  Ensure heat sink fins are clean and unobstructed. Ensure ambient temperature maximums are not exceeded. Ensure fan is operational
F12 HW Over Current Drive output current exceeds hardware current limit -NonResettable Check the programming and for excess load, improper Boost Select setting or other causes for excess current
F13 Ground Fault Current path to earth ground detected at 1 (or more) drive output terminals - NonResettable Check the motor. Check for a grounded condition with the external wiring to drive output terminals
F33 Auto Rstrt Tries Unsucessful fault reset attempt - NonResettable Manually correct what is causing the fault and clear
F38 Phase U-Gnd Phase to ground fault between the drive and a motor in U, V, or W-phase - NonResettable Check the wiring between the drive and the motor. Chech the motor for grounded phase. If you cannot clear the fault, you must replace the drive.
F39 Phase V-Gnd
F40 Phase W-Gnd
F41 Phase UV Short Excess current detected between two output terminals - NonResettable Ensure the motor and drive output terminal do not have a shorted wiring condition. If you cannot clear the fault, you must replace the drive. 
F42  Phase UW Short
F43 Phase VW Short
F48 Parameters Defaulted Drive commanded to write default values to EEPROM Clear fault/restart the drive. Reprogram parameters as necessary 
F63 SW Over Current Programmed SW Current Trip exceeded - AutoReset/Run Review load requirements and SW Current Trip settings.
F64 Drive Overload Drive rating has been exceeded - NonResettable Either reduce the drive's load or extend the Accel Time setting
F70 Power Unit Detected failure in the drive power section - NonResettable Restart the drive. If you cannot clear the fault, the drive must be replaced.
F71 Net Loss Communication Network Faulted Cycle power and check the communication cabling, network adapter setting and external network status
F81 Comm Loss RS-485 port communication stopped - NonResettable Check wiring to the port. If necessary replace the port expander, wiring, adapters or even the entire drive. Turn off using the Comm Loss Action.
F100 Parameter Checksum Checksum from board does not match calculated checksum - NonResettable Reset defaults. 
F122 I/O Board Fail Drive Control and I/O section failure- NonResettable Cycle power. If you are unable to clear the fault, you must replace the drive

How to Manually Clear Faults

  1. Press Escape to regain control of the keypad. To view the most recent fault information, access d007 Fault 1 Code.
  2. Take corrective action to address the cause of the fault. The cause of the fault must be resolved before clearing the fault. See the table above.
  3. To clear the fault either:
    1. Restart the drive (cycle power)
    2. Select Stop if Stop Mode is set between 0 and 3
    3. Set Fault Clear to 1 or 2
    4. OR cycle digital input if the Digital Inx Select is set to option 7 - "Clear Fault"

To automatically clear a fault and reset the drive set the AutoRstrt Tries to any value other than 0. Then, set Auto Rstrt Delay to any value other than 0. Follow the same process to clear a Heatsink OvrTemp, OverVoltage or UnderVoltage fault, just do not restart the drive. 

PowerFlex 4M Drive Common Issues

Drive Power-Up Failure

If your PowerFlex 4M Drive will not power up, always check the power circuit first. Ensure the drive is receiving the proper supply voltage and check all fuses and disconnects. A power up failure may also be caused by failing to install the jumper between the I/O terminals P1 and P2. If necessary, install the jumper and/or connect the DC Bus Inductor. 

Drive Will Not Start from Integral Keypad

If the green indicator above the Start key is off, the keypad has been disabled. In response, set the Start Source parameter to Keypad. Set the Digital Inx Select parameter to option 9 (Local) and activate the input. 

If the I/O Terminal 01 "Stop" input is not there, you must correctly wire the inputs and install a jumper.

Drive Cannot Reverse Motor Direction

First, verify that reverse has not been disabled and that all motor and digital input wiring is properly phased for reverse. Finally, ensure the digital input is selected for reversing control. If it is not, simply check Digital Inx Sel and choose the correct input and program for reverse mode. 

Drive Non-Responsive to Speed Change Command

If the drive "Run" indicator is on and the output is 0 Hz, there is no value coming from the command source. To correct this, check Control Source for the correct source and ensure all wiring is correct. Also, check Command Freq to verify the command is correct. 

If no indicator light is on, the reference source selected is incorrect. Check and verify the settings in the following parameters: Control Source, Dig In Status, Digital Inx Select and Speed Reference. 

Drive Will Not Start From Start/Run Inputs

If the red status indicator light is flashing, the drive is faulted. Clear the fault, see "How to Manually Clear Faults" above for more information. Verify the programming is correct by checking the parameters Start Source and Digital Inx Select settings. Verify all input wiring is correct. 

Failed Motor Start

Always check the power circuit first; the motor may not be receiving output voltage. Ensure the motor is connected properly and check the control input signals. When checking the input signals, confirm that a start signal is present. If you are using a 2-Wire control, ensure only Run Forward or Run Reverse is active. Both should not be simultaneously active. The I/O Terminal 1 should be active and the Start Source should match your configuration. Finally, ensure Reverse Disable is not inhibiting movement. 

A failed start can also be caused by an improper boost setting at initial startup. In response, set Boost Select to 35.0,VT (option 2). 

If a red status light is flashing, the drive is faulted. See "How to Manually Clear Faults" above to clear the fault. 

Unstable Motor Operation

The motor data was entered incorrectly. Enter motor nameplate data into Motor NP Volts, Motor NP Hertz, and Motor OL Current. Then enable Compensation and use Boost select to reduce the boost level.

Motor/Drive Not Accelerating to Command Speed

First, check the acceleration. If this value is excessive, adjust the value. Programming may be preventing the drive output from exceeding limiting values. To check this, look at Maximum Freq and ensure the programming is not limiting the speed. It is also possible that the speed command source or speed command value do not align with the Command Freq or the Control Source. Check both these parameters. 

The excess load or short acceleration times can force the drive int a current limit which results in decreased or stopped acceleration. Compare the Output Current to the Current Limit and remove the excess load. If you do not want to remove the excess load, you can reprogram the Accel 1 or 2 parameters. Be sure to check for an improper Boost Select setting. 

Repair Your PowerFlex 4M Drive

Here at DO Supply, we offer repair services for your Allen-Bradley products, such as the Allen-Bradley PowerFlex 4M Drive. Please click here for more information or to request a quote.


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PowerFlex 4MDescriptionStock Level
PowerFlex 4MDescriptionStock Level
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