PowerFlex 4M

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. 

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.