Allen-Bradley PowerFlex 400 Instruction manual

RGB ELEKTRONIKA AGACIAK CIACIEK
SPÓŁKA JAWNA
Jana Dlugosza 2-6 Street
51-162 Wrocław
Poland
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www.rgbelektronika.pl
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www.rgbelektronika.pl
OTHER SYMBOLS:
22-RFD050
22RFD050, 22 RFD050, 22-RFD050
ALLEN BRADLEY

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PowerFlex®400
AdjustableFrequency
AC Drives for Fan &
Pump Applications
Technical Data

2
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Product Description
Providing users with easy installation in mechanical fan and
pump systems, the Allen-Bradley PowerFlex® 400 AC drive
offers a wide range of built-in features allowing for seamless
building system integration. Available in power ratings of 3.0-
350HP @ 480VAC and 3.0-50HP @ 240V AC, the PowerFlex 400
is designed to meet global OEM, contractor and end-user
demands for flexibility, space savings and ease-of-use. The
PowerFlex 400 is a cost-effective solution for speed control in
variable torque fan and pump applications.
Table of Contents
Description Page
PowerFlex 400 Standard Product
Product Overview
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operator Keypad and Programming . . . . . . . . . . . . . . . . . . . . . . 3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PC Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application Features
Configurable Keypad Hand-Off-Auto Functions . . . . . . . . . . . . . 5
Connectivity to Building Fire and Life Safety Systems. . . . . . . . 5
Proportional, Integral, Differential Control Loop . . . . . . . . . . . . 6
Product Selection Guide
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PowerFlex 400 Standard Drives . . . . . . . . . . . . . . . . . . . . . . . . . 9
User Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Considerations
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Specifications
Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
PowerFlex 400 Packaged Product
Packaged Product Overview
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Main Input Disconnect / Circuit Breaker . . . . . . . . . . . . . . . . . 35
3 Contactor Full Feature Bypass with Disconnect / Circuit Breaker35
3 Contactor Basic Bypass with Disconnect . . . . . . . . . . . . . . . 35
Product Selection Guide
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PowerFlex 400 NEMA/UL Type 1 Enclosure (Position d = A) . . 37
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3
Product Overview
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Packaging
•IP20, NEMA/UL Type 1 - For conventional mounting inside or
outside a control cabinet in a 45°C (113°F) ambient.
•Flange Type - Frame C ratings through 15 kW (20 HP) @ 380-
480V AC and 7.5 kW (10 HP) @ 200-240V AC allow for mounting
heatsink through back of an enclosure, thus removing a large
portion of the heat inside a cabinet. The backside is rated IP66,
NEMA/UL Type 4X/12 for both indoor and outdoor use.
• Installation flexibility is enhanced by the UL Plenum rating
allowing for direct mounting in an air handling system.
I/O
• Three (3) semi-programmable and four (4) fully programmable
digital inputs provide application versatility.
• Two (2) programmable form C relay outputs and one (1) opto
output can be used to indicate various drive or motor conditions.
• Two (2) analog outputs are DIP Switch selectable for either
voltage (0-10V) or current (0-20 mA). These scalable, 10-bit
outputs are suitable for metering or as a speed reference for
another drive.
• Two (2) analog inputs (one unipolar and one bipolar) are DIP
switch selectable for either voltage or current. One input is
isolated from the rest of the drive I/O.
• Six (6) programmable form A relay outputs are available via user
installed Auxiliary Relay Board (Frames D through H only).
Operator Keypad and Programming
• Integral keypad features 2 line, 16 character LCD display.
• LED indicators provide system configuration and fault status.
• Configurable Hand/Off/Auto function buttons.
• Digital increase/decrease speed control.
• Parameter names are displayed as text.
• Parameters are grouped into files based upon function, making
programming fast and easy.
Function Loss
Run/FWD
Software Enable
Digital Common
Digital Input 1 (Purge)
Digital Input 2 (Local)
Digital Input 3 (Clear Fault)
Digital Input 4 (Comm Port)
Digital Common
Opto Common
+ 24VDC
+ 10VDC
Analog Input #1
Analog Common #1
Analog Output #1 (Frequency 0-10V)
Analog Output #2 (Output Current 0-10V)
Analog Input #2
Analog Common #2
Opto Output (At Frequency)
RJ-45 Shield
#1 Relay N.O. (Ready/Fault)
#1 Relay Common
#1 Relay N.C.
#2 Relay N.O. (Motor Running)
#2 Relay Common
#2 Relay N.C.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R1 R2 R3 R4 R5 R6
AO1
10V 20MA AO2
10V 20MA AI1
10V 20MA AI2
10V 20MA SNK
SRC
Control Board
Hand Auto
Purge
Interlocks
Auto Start
Freeze/Fire
Stats + –
Speed Ref. Input

4
Product Overview
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Communications
• Supports Drive Serial Interface (DSI)
communication modules (DeviceNet™,
EtherNet/IP™, PROFIBUS™DP,
LonWorks®, BACnet®) and accessories.
• Embedded Modbus RTU, P1-FLN and
Metasys N2 protocols are parameter
selectable and require no additional
hardware or software.
•Integral RS485 communications can be
used for programming from a PC. It can also
be used in a multi-drop network
configuration. A serial converter module
provides connectivity to any controller with a
DF1 port.
PC Programming Software
Through the use of a Serial Converter Module and DriveExplorer™
or DriveTools™SP software, programming can be greatly simplified.
DriveExplorer Software
• View and modify drive and adapter parameters in a method similar to
the file management capability of Microsoft Windows Explorer.
• Operate the drive via an on-screen Control Bar, which is a tool that
allows you to start, stop, and change the speed reference of the drive.
• Save, restore and print parameter information.
• Compare current parameters with factory defaults or previously saved
parameter values.
• Edit, upload and download parameters.
DriveTools SP Software
• Online and offline programming capability.
• In-grid and dialog-based parameter editing.
• Immediate visual indication of drive and communication status when
viewing online drive.
• Integrated HTML Help architecture.

5
Application Features
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Configurable Keypad Hand-Off-Auto Functions
Parameter P042 [Auto Mode] defines the operating configuration of the
control keys.
Hand-Off-Auto Configuration
Hand Mode: Start command and speed reference come from the integral
keypad. Auto key switches control from Hand mode to Auto
mode in a bumpless transfer as long as there is an active run
command.
Auto Mode: Start command is defined by P036 [Start Source] (keypad,
terminal block, comm port) and speed reference is defined
by P038 [Speed Reference] (analog inputs, preset frequency,
comm port). Start/Hand key switches control and speed
reference to the integral keypad in a bumpless transfer.
Local/Remote Configuration
Local Mode: Start command and speed reference come from the integral keypad. Auto key stops the drive and the drive
switches to Remote mode.
Remote Mode:Start command is defined by P036 [Start Source] and speed reference is defined by P038 [Speed
Reference]. Auto key stops the drive and the drive switches to Local mode.
Auto/Manual Configuration
Manual Mode:Start command is defined by P036 [Start Source] and the speed reference comes from the integral keypad.
Auto key toggles frequency control to Auto mode in a bumpless transfer.
Auto Mode: Start command is defined by P036 [Start Source] and speed reference is defined by P038 [Speed
Reference]. Auto key switches frequency control to the integral keypad in a bumpless transfer.
Connectivity to Building Fire and Life Safety Systems
Purge
The PowerFlex 400 drive has an input which can be wired to a fire control panel or other fire/life safety systems allowing
control of the drive to be overridden. A purge input will start the drive at a programmable purge speed regardless of the
selected start source. Purge can occur and is operational at any time whether the drive is running or stopped. A purge
command will take precedence over a stop command from the comm port/network and over a “SW Enable” command from
the terminal block.
Fire/Freeze Status
The PowerFlex 400 drive can be tied into fire alarm systems or interlocked with cooling coils via a “Function Loss” input on
the drive. Upon opening of the input, the drive will immediately coast to a stop if running and issue a fault. The drive will
only be allowed to restart once the alarm state is cleared and the drive fault is reset.

6
Application Features
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Proportional, Integral, Differential Control Loop
The PowerFlex 400 has a built-in PID (Proportional, Integral, Differential) control loop. The PID loop is used to maintain a
process variable, such as pressure or flow, 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 zero.
Damper Control
The PowerFlex 400 allows damper control logic to be imbedded within the drive reducing cost associated with external
control hardware and software. A system Run command can be wired directly into one of the drive inputs. Relay outputs
can be used to energize the damper to either open or close. A damper limit switch can be wired back to the drive providing
indication that the damper is in the proper position and that it is safe for the drive to run at commanded speed.
Return Fan
Supply Fan
Air Flow
Air Flow
Room Room Room
Heating
Cooling P
PID Feedback = Pressure Transducer Signal
PID Reference = Desired Static Pressure
Outside Air
Damper
Exhaust Air
Damper
Recirculation
Damper
Dampers
P
PID Feedback = Pressure Transducer SignalPID Reference = Output Frequency from Supply VFD
Supply Fan
Air Flow
Damper Limit Switch
Damper Position Command System Run Command
Outside Air
Damper

7
Product Selection Guide
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Auxiliary Motor Control
The PowerFlex 400 has a built in Auxiliary Motor Control feature. This feature allows operation of up to three (3) line-
started motors in addition to the motor controlled directly by the PowerFlex 400 drive. System output can vary from 0%
(auxiliary motors off and drive-controlled motor at zero speed) to 400% (3 auxiliary motors and drive-controlled motor at full
speed). When Auxiliary Motor Control is enabled, the internal PID controller in the PowerFlex 400 uses a reference and
feedback signal to adjust the speed of the drive controlled motor such that the feedback signal follows the reference
signal. When demand exceeds the first motors capacity, the PowerFlex 400 Auxiliary Motor Control automatically starts an
auxiliary motor. The speed of the drive controlled motor is reduced to account for the auxiliary motors additional output to
the system. If demand continues to increase, the PowerFlex Auxiliary Motor Control starts additional motors using the
same process. When demand decreases, an auxiliary motor is stopped and the PowerFlex Auxiliary Motor Control
increases the speed of the drive controlled motor to account for lost system output. A Motor Interlock input identifies
motors that are out of service and causes them to skipped over to the next available motor.
An AutoSwap function also can be used which allows equal wear to be placed on each motor by periodically swapping the
drive controlled and auxiliary motors. Each motor in the system will over time be connected to the PowerFlex 400 drive and
also directly to the AC line. During an AutoSwap, the motor directly connected to the PowerFlex 400 drive is stopped and
the contactor is opened. The contactor of the next motor that will be controlled by the PowerFlex 400 drive is opened if
running across the AC line. A contactor is closed connecting this motor directly to the PowerFlex 400 drive and is started.
An additional motor is line started if required.
PID Reference
PID Feedback
Three-Phase Power
M2L
M1 M2
M2L
PID Reference
PID Feedback
Three-Phase Power
One External Motor
without AutoSwap One External Motor
with AutoSwap
M1D
M1 M2
M2DM1D M2L
M1L
M2D
M2L
M1L

8
Product Selection Guide
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Catalog Number Explanation
Position Number
1-3 4 5 6-8 9 10 11 12
22C – D 038 A 1 0 3
a bcde f g
a
Drive
Code Type
22C PowerFlex 400
b
Voltage Rating
Code Voltage Ph.
B 240V ac 3
D 480V ac 3
c1
Rating
200…240V Input
Code Amps kW (Hp) Frame
012 12 2.2 (3.0) C
017 17.5 3.7 (5.0) C
024 24 5.5 (7.5) C
033 33 7.5 (10) C
049 49 11 (15) D
065 65 15 (20) D
075 75 18.5 (25) D
090 90 22 (30) D
120 120 30 (40) E
145 145 37 (50) E
c2
Rating
380…480V Input
Code Amps kW (Hp) Frame
6P0 6.0 2.2 (3.0) C
010 10.5 4.0 (5.0) C
012 12 5.5 (7.5) C
017 17 7.5 (10) C
022 22 11 (15) C
030 30 15 (20) C
038 38 18.5 (25) D
045 45.5 22 (30) D
060 60 30 (40) D
072 72 37 (50) E
088 88 45 (60) E
105 105 55 (75) E
142 142 75 (100) E
170 170 90 (125) F
208 208 110 (150) F
260 260 132 (200) G
310 310 160 (250) G
370 370 200 (300) H
460 460 250 (350) H
d
Enclosure
Code Enclosure
NPanel Mount - IP20,
NEMA/UL Type Open
APanel Mount - IP30,
NEMA/UL Type 1
FFlange Mount - IP20,
NEMA/UL Type Open ‡
Frame C drives only available with IP20,
NEMA/UL Type Open enclosure. Field installed
conversion kit available to achieve IP30,
NEMA/UL Type 1 rating.
Frame D, E and F drives only available with
IP30, NEMA/UL Type 1 enclosure.
‡ Frame C drives only.
e
HIM
Code Interface Module
1 Fixed Keypad
f
Emission Class
Code Rating
0 Not Filtered
g
Version
Code Version
3 RS485

9
Product Selection Guide
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
PowerFlex 400 Standard Drives
200-240V AC, Three Phase Drives
380-480V AC, Three Phase Drives
➊IP30, NEMA/UL Type 1 can be achieved for panel mount drives with top cover and optional conduit box kit installed. Field installed conversion kit specified under
User Installed Options.
➋Drive terminals are sized according to UL. Depending on operating ambient and wire used, some local or national codes may require a larger wire size than what the
power terminals can accept. Multiple conductors, 90°C wire, and/or lugs may be required. Refer to the PowerFlex 400 User Manual for details on terminal block wire
ranges.
➌11 and 15 kW (15 and 20 HP) Frame C flange mount drives require external DC series bus inductor.
Drive Ratings
Rating
Catalog Number
kW HP
Output
Current ➋Frame Size Panel Mount Flange Mount
2.2 3.0 12A C IP20, NEMA/UL Open Type ➊22C-B012N103 22C-B012F103
3.7 5.0 17.5A C IP20, NEMA/UL Open Type ➊22C-B017N103 22C-B017F103
5.5 7.5 24A C IP20, NEMA/UL Open Type ➊22C-B024N103 22C-B024F103
7.5 10 33A C IP20, NEMA/UL Open Type ➊22C-B033N103 22C-B033F103
11 15 49A D IP30, NEMA/UL Type 1 22C-B049A103 –
15 20 65A D IP30, NEMA/UL Type 1 22C-B065A103 –
18.5 25 75A D IP30, NEMA/UL Type 1 22C-B075A103 –
22 30 90A D IP30, NEMA/UL Type 1 22C-B090A103 –
30 40 120A E IP30, NEMA/UL Type 1 22C-B120A103 –
37 50 145A E IP30, NEMA/UL Type 1 22C-B145A103 –
Drive Ratings
Rating
Catalog Number
kW HP
Output
Current ➋Frame Size Panel Mount Flange Mount
2.2 3.0 6.0A C IP20, NEMA/UL Open Type ➊22C-D6P0N103 22C-D6P0F103
4.0 5.0 10.5A C IP20, NEMA/UL Open Type ➊22C-D010N103 22C-D010F103
5.5 7.5 12A C IP20, NEMA/UL Open Type ➊22C-D012N103 22C-D012F103
7.5 10 17A C IP20, NEMA/UL Open Type ➊22C-D017N103 22C-D017F103
11 15 22A C IP20, NEMA/UL Open Type ➊22C-D022N103 22C-D022F103 ➌
15 20 30A C IP20, NEMA/UL Open Type ➊22C-D030N103 22C-D030F103 ➌
18.5 25 38A D IP30, NEMA/UL Type 1 22C-D038A103 –
22 30 45.5A D IP30, NEMA/UL Type 1 22C-D045A103 –
30 40 60A D IP30, NEMA/UL Type 1 22C-D060A103 –
37 50 72A E IP30, NEMA/UL Type 1 22C-D072A103 –
45 60 88A E IP30, NEMA/UL Type 1 22C-D088A103 –
55 75 105A E IP30, NEMA/UL Type 1 22C-D105A103 –
75 100 142A E IP30, NEMA/UL Type 1 22C-D142A103 –
90 125 170A F IP30, NEMA/UL Type 1 22C-D170A103 –
110 150 208A F IP30, NEMA/UL Type 1 22C-D208A103 –
132 200 260A G IP30, NEMA/UL Type 1 22C-D260A103 –
160 250 310A G IP30, NEMA/UL Type 1 22C-D310A103 –
200 300 370A H IP30, NEMA/UL Type 1 22C-D370A103 –
250 350 460A H IP30, NEMA/UL Type 1 22C-D460A103 –

10
Product Selection Guide
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
User Installed Options
IP30, NEMA/UL Type 1 Conversion Kit
Human Interface Module Option Kits and Accessories
PC Programming Software
➊See www.ab.com/drive/ for support devices.
Spare Parts
Other Options
Description Drive Frame Catalog Number
IP30, NEMA/UL Type 1 Kit
Description: Field installed kit. Converts drive to IP30, NEMA/UL Type 1 enclosure. Includes conduit box with
mounting screws and plastic top panel.
C 22-JBAC
IP30, NEMA/UL Type 1 Kit with Communication Option
Description: Field installed kit. Converts drive to IP30, NEMA/UL Type 1 enclosure. Includes communication
option conduit box with mounting screws and plastic top panel.
C 22-JBCC
Description Catalog Number
Remote Human Interface Module (HIM) – Panel Mount
Description: LCD Display, Remote Panel Mount, Digital Speed Control, CopyCat capable, IP66, NEMA/UL Type 4X/12) indoor
use only, Includes 2.0 meter cable.
Note: Remote HIM display and keypad are different than PowerFlex 400 integral keypad. See the PowerFlex 400 User Manual
for details.
22-HIM-C2S
Remote Human Interface Module (HIM) – Handheld
Description: LCD Display, Remote Handheld, Digital Speed Control, Full Numeric Keypad, CopyCat capable, IP30, NEMA/UL
Type 1), Includes 1.0 meter cable, Panel Mount with optional Bezel Kit.
Note: Remote HIM display and keypad are different than PowerFlex 400 integral keypad. See the PowerFlex 400 User Manual
for details.
22-HIM-A3
Bezel Kit
Description: Panel Mount for LCD Display, Remote Handheld unit, IP30, NEMA/UL Type 1).
22-HIM-B1
DSI HIM Cable
Description: DSI HIM to RJ45 cable.
1.0 Meter (3.3 Feet)
2.9 Meter (9.51 Feet)
22-HIM-H10
22-HIM-H30
Item Description Catalog Number
DriveTools SP Software “Windows” based software package that provides an intuitive means for monitoring or configuring Allen-Bradley
drives and communications adapters online and offline.
Compatibility: Windows 98, ME, NT, 4.0 (Service Pack 3 or later), 2000 and XP.
9303-4DTE01ENE
DriveExplorer Software “Windows” based software package that provides an intuitive means for monitoring or configuring Allen-Bradley
drives and communications adapters online and offline.
Compatibility: Windows 98, ME, NT, 4.0 (Service Pack 3 or later), 2000 and XP. ➊
9306-4EXP01ENE
Description Catalog Number
PowerFlex 400 Fan Replacement Kit
Description: (1) Fan, 3-10 HP @ 200-240V AC and 3-10 HP @ 380-480V AC SK-U1-FAN1-C1
PowerFlex 400 Fan Replacement Kit
Description: (1) Fan, 15-20 HP @ 380-480V AC SK-U1-FAN1-C2
Description Catalog Number
Auxiliary Relay Board
Description: Field installed kit. Expands drive output capabilities. AK-U9-RLB1

11
Product Selection Guide
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Communication Option Kits
➊If IP30, MENA/UL Type 1 is required, must also order 22-JBCC (Frame C drives only).
Description Catalog No.
Serial Converter Module (RS485 to RS232)
Description: Provides serial communication via DF1 protocol for use with DriveExplorer and DriveExecutive software.
Includes: DSI to RS232 serial converter, 1203-SFC serial cable, 22-RJ45CBL-C20 cable, and DriveExplorer Lite CD.
22-SCM-232
Serial Cable
Description: 2.0 meter serial cable with a locking low profile connector to connect to the serial converter and a 9-pin sub-
miniature D female connector to connect a computer.
1203-SFC
Null Cable Converter
Description: For use when connecting the serial converter to DriveExplorer on a handheld PC.
1203-SNM
DSI Cable
Description: 2.0 meter RJ45 to RJ45 cable, male to male connectors.
22-RJ45CBL-C20
Splitter Cable
Description: RJ45 one to two port splitter cable.
AK-U0-RJ45-SC1
Terminating Resistors
Description: RJ45 120 Ohm resistors (2 pieces)
AK-U0-RJ45-TR1
Terminal Block
Description: RJ45 two position terminal block (5 pieces)
AK-U0-RJ45-TB2P
BACnet® MS/TP RS-485 Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-B
ControlNet™ Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-C
DeviceNet Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-D
EtherNet/IP™ Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-E
LonWorks™ Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-L
PROFIBUS™ DP Communication Adapter
Note: Requires a Communication Adapter Cover when used with Frame C PowerFlex 400 drives (Ordered Separately).
22-COMM-P
External DSI Communications Kit
Description: External mounting kit for 22-COMM communication options
22-XCOMM-DC-BASE
External Comms Power Supply
Description: Optional 100-240V ac Power Supply for External DSI Communications Kit
20-XCOMM-AC-PS1
Communication Adapter Cover
Description: Houses the Communication Adapter for Frame C drives.
Note: This cover adds 25 mm (0.98 in.) to the overall depth of the drive and is only required for Frame C PowerFlex 400 drives.
22C-CCC ➊
Serial Flash Firmware Kit
Description: Use a PC to update drive firmware.
AK-U9-FLSH1

12
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Input and Output Line Reactors (Loose)
208V, 60 Hz, Three-Phase
240V, 60 Hz, Three-Phase
PowerFlex 400 Ratings Catalog Number
kW HP Amps IP00 (NEMA/UL Type Open) IP11 (NEMA/UL Type 1)
3% Impedance
2.2 3.0 12 1321-3R12-A 1321-3RA12-A
3.7 5.0 18 1321-3R18-A 1321-3RA18-A
5.5 7.5 25 1321-3R25-A 1321-3RA25-A
7.5 10 35 1321-3R35-A 1321-3RA35-A
11 15 45 1321-3R45-A 1321-3RA45-A
15 20 55 1321-3R55-A 1321-3RA55-A
18.5 25 80 1321-3R80-A 1321-3RA80-A
22 30 80 1321-3R80-A 1321-3RA80-A
30 40 100 1321-3R100-A 1321-3RA100-A
37 50 130 1321-3R130-A 1321-3RA130-A
5% Impedance
2.2 3.0 12 1321-3R12-B 1321-3RA12-B
3.7 5.0 18 1321-3R18-B 1321-3RA18-B
5.5 7.5 25 1321-3R25-B 1321-3RA25-B
7.5 10 35 1321-3R35-B 1321-3RA35-B
11 15 45 1321-3R45-B 1321-3RA45-B
15 20 55 1321-3R55-B 1321-3RA55-B
18.5 25 80 1321-3R80-B 1321-3RA80-B
22 30 80 1321-3R80-B 1321-3RA80-B
30 40 100 1321-3R100-B 1321-3RA100-B
37 50 130 1321-3R130-B 1321-3RA130-B
PowerFlex 400 Ratings Catalog Number
kW HP Amps IP00 (NEMA/UL Type Open) IP11 (NEMA/UL Type 1)
3% Impedance
2.2 3.0 12 1321-3R12-A 1321-3RA12-A
3.7 5.0 18 1321-3R18-A 1321-3RA18-A
5.5 7.5 25 1321-3R25-A 1321-3RA25-A
7.5 10 35 1321-3R35-A 1321-3RA35-A
11 15 45 1321-3R45-A 1321-3RA45-A
15 20 55 1321-3R55-A 1321-3RA55-A
18.5 25 80 1321-3R80-A 1321-3RA80-A
22 30 80 1321-3R80-A 1321-3RA80-A
30 40 100 1321-3R100-A 1321-3RA100-A
37 50 130 1321-3R130-A 1321-3RA130-A
5% Impedance
2.2 3.0 12 1321-3R12-B 1321-3RA12-B
3.7 5.0 18 1321-3R18-B 1321-3RA18-B
5.5 7.5 25 1321-3R25-B 1321-3RA25-B
7.5 10 35 1321-3R35-B 1321-3RA35-B
11 15 45 1321-3R45-B 1321-3RA45-B
15 20 55 1321-3R55-B 1321-3RA55-B
18.5 25 80 1321-3R80-B 1321-3RA80-B
22 30 80 1321-3R80-B 1321-3RA80-B
30 40 100 1321-3R100-B 1321-3RA100-B
37 50 130 1321-3R130-B 1321-3RA130-B

13
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Input and Output Line Reactors (Loose)
480V, 60 Hz, Three-Phase
DC Series Bus Inductors (Loose)
200-240V, 60 Hz, Three-Phase
380-480V, 60 Hz, Three-Phase
PowerFlex 400 Ratings Catalog Number
kW HP Amps IP00 (NEMA/ULType Open) IP11 (NEMA/UL Type 1)
3% Impedance
2.2 3.0 8.0 1321-3R8-C 1321-3RA8-C
4.0 5.0 12 1321-3R12-B 1321-3RA12-B
5.5 7.5 12 1321-3R12-B 1321-3RA12-B
7.5 10 18 1321-3R18-B 1321-3RA18-B
11 15 25 1321-3R25-B 1321-3RA25-B
15 20 35 1321-3R35-B 1321-3RA35-B
18.5 25 35 1321-3R35-B 1321-3RA35-B
22 30 45 1321-3R45-B 1321-3RA45-B
30 40 55 1321-3R55-B 1321-3RA55-B
37 50 80 1321-3R80-B 1321-3RA80-B
45 60 80 1321-3R80-B 1321-3RA80-B
55 75 100 1321-3R100-B 1321-3RA100-B
75 100 130 1321-3R130-B 1321-3RA130-B
90 125 160 1321-3R160-B 1321-3RA160-B
110 150 200 1321-3R200-B 1321-3RA200-B
132 200 250 1321-3RB250-B 1321-3RAB250-B
160 250 320 1321-3RB320-B 1321-3RAB320-B
200 300 400 1321-3RB400-B 1321-3RAB400-B
250 350 500 1321-3R500-B 1321-3RA500-B
5% Impedance
2.2 3.0 8.0 1321-3R8-D 1321-3RA8-D
4.0 5.0 12 1321-3R12-C 1321-3RA12-B
5.5 7.5 12 1321-3R12-C 1321-3RA12-C
7.5 10 18 1321-3R18-C 1321-3RA18-C
11 15 25 1321-3R25-C 1321-3RA25-C
15 20 35 1321-3R35-C 1321-3RA35-C
18.5 25 35 1321-3R35-C 1321-3RA35-C
22 30 45 1321-3R45-C 1321-3RA45-C
30 40 55 1321-3R55-C 1321-3RA55-C
37 50 80 1321-3R80-C 1321-3RA80-C
45 60 80 1321-3R80-C 1321-3RA80-C
55 75 100 1321-3R100-C 1321-3RA100-C
75 100 130 1321-3R130-C 1321-3RA130-C
90 125 160 1321-3R160-C 1321-3RA160-C
110 150 200 1321-3R200-C 1321-3RA200-C
132 200 250 1321-3RB250-C 1321-3RAB250-C
160 250 320 1321-3RB320-C 1321-3RAB320-C
200 300 400 1321-3RB400-C 1321-3RAB400-C
250 350 500 1321-3R500-C 1321-3RA500-C
PowerFlex 400 Ratings
Inductance (mH)
Catalog Number
kW HP Amps IP00 (NEMA/UL Type Open)
2.2 3.0 12 0.92 1321-DC12-1
3.7 5.0 17.5 0.63 1321-DC18-1
5.5 7.5 24 0.85 1321-DC32-1
7.5 10 33 0.75 1321-DC40-1
PowerFlex 400 Ratings
Inductance (mH)
Catalog Number
kW HP Amps IP00 (NEMA/UL Type Open)
2.2 3.0 6.0 3.68 1321-DC9-2
4.0 5.0 10.5 2.1 1321-DC12-2
5.5 7.5 12 3.75 1321-DC18-4
7.5 10 17 1.75 1321-DC25-4
11 15 22 2.68 1321-DC32-2
15 20 30 2.00 1321-DC40-4

14
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
EMC Filters (Loose)
200-240V, 50/60 Hz, Three-Phase
380-480V, 50/60 Hz, Three-Phase
PowerFlex 400 Ratings Catalog Number
kW HP Amps
2.2 3.0 12 22-RF034-CS
3.7 5.0 17.5 22-RF034-CS
5.5 7.5 24 22-RF034-CS
7.5 10 33 22-RF034-CS
11 15 49 22-RFD070
15 20 65 22-RFD100
18.5 25 75 22-RFD100
22 30 90 22-RFD150
30 40 120 22-RFD150
37 50 145 22-RFD180
PowerFlex 400 Ratings Catalog Number
kW HP Amps
2.2 3.0 6.0 22-RF018-CS
4.0 5.0 10.5 22-RF018-CS
5.5 7.5 12 22-RF018-CS
7.5 10 17 22-RF018-CS
11 15 22 22-RF026-CS
15 20 30 22-RFD036
18.5 25 38 22-RFD050
22 30 45.5 22-RFD050
30 40 60 22-RFD070
37 50 72 22-RFD100
45 60 88 22-RFD100
55 75 105 22-RFD150
75 100 142 22-RFD180
90 125 170 22-RFD208
110 150 208 22-RFD208
132 200 260 22-RFD323
160 250 310 22-RFD480
200 300 370 22-RFD480
250 350 460 22-RFD480

15
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Isolation Transformers (Loose)
208V AC, 3 Phase, 60 Hz Secondary
230V AC, 3 Phase, 60 Hz Secondary
460V AC, 3 Phase, 60 Hz Secondary
PowerFlex 400 Ratings IP32 (NEMA/UL Type 3R) Isolation Transformer
kW HP Amps kVA
Catalog Number
208 Volt Primary
2.2 3.0 12 5.0 1321-3TW005-XX
4.0 5.0 17.5 7.5 1321-3TW007-XX
5.5 7.5 24 11 1321-3TW011-XX
7.5 10 33 14 1321-3TW014-XX
11 15 49 20 1321-3TW020-XX
15 20 65 27 1321-3TW027-XX
18.5 25 75 34 1321-3TW034-XX
PowerFlex 400 Ratings IP32 (NEMA/UL Type 3R) Isolation Transformer
kW HP Amps kVA
Catalog Number
230 Volt Primary 460 Volt Primary 575 Volt Primary
2.2 3.0 12 5.0 1321-3TW005-AA 1321-3TW005-BA 1321-3TW005-CA
3.7 5.0 17.5 7.5 1321-3TW007-AA 1321-3TW007-BA 1321-3TW007-CA
5.5 7.5 24 11 1321-3TW011-AA 1321-3TW011-BA 1321-3TW011-CA
7.5 10 33 14 1321-3TW014-AA 1321-3TW014-BA 1321-3TW014-CA
11 15 49 20 1321-3TW020-AA 1321-3TW020-BA 1321-3TW020-CA
15 20 65 27 1321-3TW027-AA 1321-3TW027-BA 1321-3TW027-CA
18.5 25 75 34 1321-3TW034-AA 1321-3TW034-BA 1321-3TW034-CA
22 30 90 40 1321-3TW040-AA 1321-3TW040-BA 1321-3TW040-CA
30 40 120 51 1321-3TW051-AA 1321-3TW051-BA 1321-3TW051-CA
37 50 145 63 1321-3TH063-AA 1321-3TH063-BA –
PowerFlex 400 Drive Ratings IP32 (NEMA/UL Type 3R) Isolation Transformer
kW HP Amps kVA
Catalog Number
230 Volt Primary 460 Volt Primary 575 Volt Primary
2.2 3.0 6.0 5.0 1321-3TW005-AB 1321-3TW005-BB 1321-3TW005-CB
4.0 5.0 8.7 7.5 1321-3TW007-AB 1321-3TW007-BB 1321-3TW007-CB
5.5 7.5 12 11 1321-3TW011-AB 1321-3TW011-BB 1321-3TW011-CB
7.5 10 17 14 1321-3TW014-AB 1321-3TW014-BB 1321-3TW014-CB
11 15 22 20 1321-3TW020-AB 1321-3TW020-BB 1321-3TW020-CB
15 20 30 27 1321-3TW027-AB 1321-3TW027-BB 1321-3TW027-CB
18.5 25 38 34 1321-3TW034-AB 1321-3TW034-BB 1321-3TW034-CB
22 30 45.5 40 1321-3TW040-AB 1321-3TW040-BB 1321-3TW040-CB
30 40 60 51 1321-3TW051-AB 1321-3TW051-BB 1321-3TW051-CB
37 50 72 63 1321-3TH063-AB 1321-3TH063-BB –
45 60 88 75 1321-3TH075-AB 1321-3TH075-BB –
55 75 105 93 1321-3TH093-AB 1321-3TH093-BB –
75 100 142 118 1321-3TH118-AB 1321-3TH118-BB –
90 125 170 145 1321-3TH145-AB 1321-3TH145-BB –
110 150 208 175 1321-3TH175-AB 1321-3TH175-BB –
132 200 260 200 1321-3TH220-AB 1321-3TH220-BB –
160 250 310 245 1321-3TH275-AB 1321-3TH275-BB –
200 300 370 305 1321-3TH330-AB 1321-3TH330-BB –
250 350 460 390 1321-3TH440-AB 1321-3TH440-BB –

16
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Power Wiring
PowerFlex 400 drives have the following built in protective features to help simplify installation.
• Ground fault protection while starting and running ensures reliable operation
• Electronic motor overload protection increases motor life
• 6kV transient protection provides increased robustness for 380-480V system voltages
There are many other factors that must be considered for optimal performance in any given application. The block diagram below
highlights the primary installation considerations. Consult the PowerFlex 400 User Manual, Publication 22C-UM001…available online
at www.ab.com/manuals/dr, for detailed recommendations on input power conditioning, CE conformance (EMC filtering), FCC
Compliance, reflected wave protection, motor cable types and motor cable distances.
Block Diagram
Branch Circuit Protective Devices – See Specifications on page 21
Class 10 Overload Protection – Provided by the PowerFlex drive
Line (EMC) Filter – See page 14
Motor – See publication MOTORS-CA001...
Motor Cable Type and Length Recommendations –
(Consult the appropriate User Manual)
Integral Keypad
Input Power Conditioning – See Input and Output Line Reactors on page 12
Reflected Wave Protection – (Consult the appropriate User Manual)
Power Terminal Block – (Inside Cover)

17
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Power Terminal Block
Terminal Block Specifications
➊Maximum/minimum sizes that the terminal block will accept - these are not recommendations. If national or local codes require sizes outside this range, lugs may be
used.
Name Frame Description Wire Size Range ➊Recommended
Torque
Maximum Minimum
Power Terminal Block C All power terminals 8.4 mm2(8 AWG) 1.3 mm2(16 AWG) 3.7 N-m (33 lb.-in.)
D All power terminals 33.6 mm2(2 AWG) 8.4 mm2(8 AWG) 5.1 N-m (45 lb.-in.)
E480V
37-45 kW
(50-60 HP)
All power terminals 33.6 mm2(2 AWG) 3.5 mm2(12 AWG) 5.6 N-m (49.5 lb.-in.)
E240V
30-37 kW
(40-50 HP)
480V
55-75 kW
(75-100 HP)
All power terminals 107.2 mm2(4/0 AWG) 53.5 mm2(1/0 AWG) 19.5 N-m (173 lb.-in.)
F All power terminals 152.5 mm2(300 MCM) 85.0 mm2(3/0 AWG) 19.5 N-m (173 lb.-in.)
G All power terminals 152.5 mm2(300 MCM) 85.0 mm2(3/0 AWG) 29.4 N-m (260 lb.-in.)
H All power terminals 253.0 mm2(500 MCM) 127.0 mm2(250 MCM) 40.0 N-m (354 lb.-in.)
I/O Terminal Block All Signal and control connections 1.3 mm2(16 AWG) 0.13 mm2(26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
Terminal (1) Description
R/L1, S/L2, T/L3 3-Phase Input
U/T1 To Motor U/T1
=
Switch any two
motor leads to
change forward
direction.
V/T2 To Motor V/T2
W/T3 To Motor W/T3
P2, P1 DC Bus Inductor Connection
Drives are shipped with a jumper between
Terminals P2 and P1. Remove this jumper only
when a DC Bus Inductor will be connected. Drive
will not power up without a jumper or inductor
connected.
DC–, DC+ DC Bus Connection (Frame C and H Drives)
P2, DC– DC Bus Connection (Frame D, E, F and G Drives)
BR+, BR– Not Used
Safety Ground - PE
(1) Important: Terminal screws may become loose during shipment. Ensure that all terminal
screws are tightened to the recommended torque before applying power to the drive.
Frame C Frame D
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1
BR–BR+DC+DC–
Frame E: 480V, 37-45kW (50-60HP)
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
R/L1 S/L2 T/L3 P1 P2 DC– U/T1V/T2 W/T3
Frame F
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2W/T3
Frame E: 240V, 30-37kW (40-50HP)
480V, 55-75kW (75-100HP)
Frame G
Frame H
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
R/L1 S/L2 T/L3 DC–
DC+ U/T1 V/T2 W/T3

18
Installation Considerations
For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives
Control Wiring
• The control logic is 24V DC and can be set for either Sink or Source control via a DIP switch setting.
• Control terminal screws are sized for a conventional blade screw driver.
• I/O Terminals 1, 2 and 3 are semi-programmable and dedicated for Stop, Start, Reverse, and SW Enable inputs.
These I/O Terminals can be programmed for 2- or 3-Wire operation to meet application requirements.
• I/O Terminals 5, 6, 7 and 8 are fully programmable and provide added flexibility. Programmable functions include Local
Control, Second Accel/Decel, Clear Fault, Preset Frequencies, RS485 Control, Auxiliary Fault, and Purge.
• Speed can be controlled via (2) analog inputs. Both inputs can be configured for either voltage or current and can be used
for applications such as PID. Voltage input can be programmed for bipolar operation.
• The drive is shipped with a jumper installed between I/O Terminals 01 and 11. This jumper can be removed when using
I/O Terminal 01 as a Stop or Enable input.
04
05
06
07
01
02
03
08
09
10
12
13
14
15
16
17
18
19
20
11
Digital Common
Digital Common
Digital Input 1
Digital Input 2
Digital Input 3
Stop/
Function Loss
Start/Run FWD
Direction/Run REV
Digital Input 4
Opto Common
R1
R2
R3
#1 Relay N.O.
#1 Relay Common
#1 Relay N.C.
+24V DC Source
+10V DC Source
Analog Input 1 (AI1)
Analog Common 1
Analog Output 2 (AO2)
Analog Output 1 (AO1)
Analog Input 2 (AI2)
Analog Common 2
Opto Output
RS485 Shield
+24V
+10V
R4
R5
R6
#2 Relay N.O.
#2 Relay Common
#2 Relay N.C.
Typical
SNK Wiring
Typical
SRC Wiring
RS485
(DSI)
Enable
Jumper
30V DC
50mA
Non-inductive
Common
24V
ENBL
Pot must be
1-10k ohm
2 Watt Min.
SRCSNK
SNK
SRC
Earth Referenced
Frames D & E
0-10V
0-20mA
0-10V
0-20mA
0-10V
0-20mA
1 of 7 Digital Input Circuits
10V 20MA
AO1 10V 20MA AO2 10V 20MA
AI1 10V 20MA AI2
Isolated