Allen-Bradley PowerFlex 400 Operator's manual

Quick Start
PowerFlex 400 Adjustable
Frequency AC Drive
FRN 4.xx
This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 400 Adjustable Frequency AC
Drive. The information provided Does Not replace the User Manual
and is intended for qualified drive service personnel only.
For detailed PowerFlex 400 information including EMC instructions,
application considerations and related precautions refer to the
PowerFlex 400 User Manual, Publication 22C-UM001… supplied with
the drive or at www.rockwellautomation.com/literature.
General Precautions
!
ATTENTION: The drive contains high voltage capacitors which take
time to discharge after removal of mains supply. Before working on
drive, ensure isolation of mains supply from line inputs [R, S, T (L1,
L2, L3)]. Wait three minutes for capacitors to discharge to safe voltage
levels. Failure to do so may result in personal injury or death.
A darkened LCD display and LEDs is not an indication that capacitors
have discharged to safe voltage levels.
!
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up and subsequent maintenance of the
system. Failure to comply may result in personal injury and/or
equipment damage.
!
ATTENTION: This drive contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are required
when installing, testing, servicing or repairing this assembly.
Component damage may result if ESD control procedures are not
followed. If you are not familiar with static control procedures,
reference A-B publication 8000-4.5.2, “Guarding Against Electrostatic
Damage” or any other applicable ESD protection handbook.
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English-2 PowerFlex 400 Adjustable Frequency AC Drive Quick Start
•Mount the drive upright on a flat, vertical and level surface.
•Protect the cooling fan by avoiding dust or metallic particles.
•Do not expose to a corrosive atmosphere.
•Protect from moisture and direct sunlight.
Maximum Surrounding Air Temperature
!
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC
supply, or excessive ambient temperatures may result in malfunction of
the system.
!
ATTENTION: The bus regulator function is extremely useful for
preventing nuisance overvoltage faults resulting from aggressive
decelerations, overhauling loads, and eccentric loads. However, it can
also cause either of the following two conditions to occur.
1. Fast positive changes in input voltage or imbalanced input voltages
can cause uncommanded positive speed changes;
2. Actual deceleration times can be longer than commanded
deceleration times
However, a “Stall Fault” is generated if the drive remains in this state
for 1 minute. If this condition is unacceptable, the bus regulator must be
disabled (see parameter A187).
Mounting Considerations
Frame Screw Size Screw Torque
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.)
D M8 (5/16 in.) 6.0-7.4 N-m (53.2-65.0 lb.-in.)
E M8 (5/16 in.) 8.8-10.8 N-m (78.0-95.3 lb.-in.)
F M10 (3/8 in.) 19.6-23.5 N-m (173.6-208.3 lb.-in.)
Frame Enclosure Rating Temperature Range Minimum Mounting
Clearances
C IP 20/UL Open-Type -10° to 45°C (14° to 113°F) Figure 1: Option A
IP 30/NEMA 1/UL Type 1(1)
(1) Frame C drives require installation of the PowerFlex 400 IP 30/NEMA 1/UL Type 1
option kit to achieve this rating.
-10° to 45°C (14° to 113°F) Figure 1: Option B
IP 20/UL Open-Type -10° to 50°C (14° to 122°F) Figure 1: Option B
D, E, F IP 30/NEMA 1/UL Type 1 -10° to 45°C (14° to 113°F) Figure 2:
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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-3
Minimum Mounting Clearances
Figure 1: Frame C Mounting Clearances
Figure 2: Frames D, E and F Mounting Clearances
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
25 mm
(1.0 in.)
Mounting Option B
Mounting Option A
No clearance required
between drives.
150 mm
(6.0 in.)
150 mm
(6.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
250 mm
(9.8 in.)
150 mm
(6.0 in.)
50 mm
(2.0 in.)
50 mm
(2.0 in.)
Frame D & E Frame F
General Grounding Requirements
PE
L1
R
L2
S
L3
T
T1
U
T2
V
T3
W
PE
Required
Input Fusing
Required Branch
Circuit Disconnect
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English-4 PowerFlex 400 Adjustable Frequency AC Drive Quick Start
Ungrounded Distribution Systems
Phase to Ground MOV Removal
Note: Frame D drives do not contain a MOV to ground connection and
are suitable for operation in both grounded and ungrounded distribution
systems without modification.
Refer to the PowerFlex 400 User Manual supplied with the drive for
details on how to comply with the Low Voltage (LV) and
Electromagnetic Compatibility (EMC) Directives.
EMC Line Filters
!
ATTENTION: PowerFlex 400 drives contain protective MOVs that
are referenced to ground. These devices must be disconnected if the
drive is installed on an ungrounded or resistive grounded distribution
system.
Frame C Frame E & F
R/L1
S/L2
T/L3
1234
Important:
Tighten screw after
jumper removal.
CE Conformity
240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase
kW HP
Catalog
Number kW HP
Catalog
Number
2.2 3.0 22-RF034-CS 2.2 3.0 22-RF018-CS
4.0 5.0 22-RF034-CS 4.0 5.0 22-RF018-CS
5.5 7.5 22-RF034-CS 5.5 7.5 22-RF018-CS
7.5 10 22-RF034-CS 7.5 10 22-RF018-CS
11 15 22-RFD070 11 15 22-RF026-CS
15 20 22-RFD100 15 20 22-RFD036
18.5 25 22-RFD100 18.5 25 22-RFD050
22 30 22-RFD150 22 30 22-RFD050
30 40 22-RFD150 30 40 22-RFD070
37 50 22-RFD180 37 50 22-RFD100
45 60 22-RFD100
55 75 22-RFD150
75 100 22-RFD180
90 125 Consult Factory
110 150 Consult Factory
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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-5
Specifications, Fuses and Circuit Breakers
Drive Ratings
Catalog
Number
Output Ratings Input Ratings Branch Circuit Protection Power
Dissipation
kW (HP)
Amps
Voltage
Range kVA Amps
Fuses
(1)
140M Motor
Protectors
(2) (3) Contactors
Min.
Enclosure
Volume(4)
(in.3)IP20 Open Watts50°C
200 - 240V AC – 3-Phase Input, 0 - 230V 3-Phase Output
22C-B012N103 2.2 (3.0) 12 180-265 6.5 15.5 20 140M-F8E-C16 100-C23 5098 146
22C-B017N103 3.7 (5.0) 17.5 180-265 8.8 21 30 140M-F8E-C25 100-C37 5098 207
22C-B024N103 5.5 (7.5) 24 180-265 10.9 26.1 35 140M-F8E-C32 100-C37 5098 266
22C-B033N103 7.5 (10) 33 180-265 14.4 34.6 45 140M-F8E-C45 100-C45 5098 359
22C-B049A103 11 (15) 49 180-265 21.3 51 70 – 100-C60 – 488
22C-B065A103 15 (20) 65 180-265 28.3 68 90 – 100-C85 – 650
22C-B075A103 18.5 (25) 75 180-265 32.5 78 100 – 100-D95 – 734
22C-B090A103 22 (30) 81 180-265 38.3 92 125 – 100-D110 – 778
22C-B120A103 30 (40) 120 180-265 51.6 124 175 – 100-D180 – 1055
22C-B145A103 37 (50) 130 180-265 62.4 150 200 – 100-D180 – 1200
380 - 480V AC – 3-Phase Input, 0 - 460V 3-Phase Output
22C-D6P0N103 2.2 (3.0) 6 340-528 6.3 7.5 10 140M-D8E-C10 100-C09 5098 105
22C-D010N103 4.0 (5.0) 10.5 340-528 10.9 13 20 140M-D8E-C16 100-C16 5098 171
22C-D012N103 5.5 (7.5) 12 340-528 11.9 14.2 20 140M-D8E-C16 100-C23 5098 200
22C-D017N103 7.5 (10) 17 340-528 15.3 18.4 25 140M-D8E-C20 100-C23 5098 267
22C-D022N103 11 (15) 22 340-528 19.2 23 30 140M-F8E-C32 100-C30 5098 329
22C-D030N103 15 (20) 27 340-528 25.8 31 40 140M-F8E-C32 100-C37 5098 435
22C-D038A103 18.5 (25) 38 340-528 33.3 40 50 140M-F8E-C45 100-C60 9086 606
22C-D045A103 22 (30) 45.5 340-528 39.1 47 60 – 100-C60 – 738
22C-D060A103 30 (40) 54 340-528 53.3 64 80 – 100-C85 – 664
22C-D072A103 37 (50) 72 340-528 60.7 73 100 – 100-C85 – 1019
22C-D088A103 45 (60) 88 340-528 74.9 90 125 – 100-D110 – 1245
22C-D105A103 55 (75) 105 340-528 89 107 150 – 100-D140 – 1487
22C-D142A103 75 (100) 128 340-528 124.8 150 200 – 100-D180 – 2043
22C-D170A103 90 (125) 170 340-528 142 170 250 – 100-D250 – 2617
22C-D208A103 110 (150) 208 340-528 167 200 250 – 100-D250 – 3601
(1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(2) The AIC ratings of the Bulletin 140M Motor Protector Circuit Breakers may vary. See Bulletin 140M
Motor Protection Circuit Breakers Application Ratings.
(3) Manual Self-Protected (Type E) Combination Motor Controller, UL listed for 208 Wye or Delta, 240
Wye or Delta, 480Y/277 or 600Y/347. Not UL listed for use on 480V or 600V Delta/Delta, corner
ground, or high-resistance ground systems.
(4) When using a Manual Self-Protected (Type E) Combination Motor Controller, the drive must be
installed in a ventilated or non-ventilated enclosure with the minimum volume specified in this
column. Application specific thermal considerations may require a larger enclosure.
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English-6 PowerFlex 400 Adjustable Frequency AC Drive Quick Start
Category Specification
Agency
Certification
Listed to UL508C and CAN/CSA-22.2
Listed to UL508C for plenums
Certified to AS/NZS, 1997 Group 1, Class A
Marked for all applicable European Directives
EMC Directive (89/336)
EN 61800-3, EN 50081-1, EN 50082-2
Low Voltage Directive (73/23/EEC)
EN 50178, EN 60204
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 voltage (equivalent to 290V AC
incoming line)
380-460V AC Input: 810V DC bus voltage (equivalent to 575V AC
incoming line)
Bus Undervoltage Trip: 200-240V AC Input: 210V DC bus voltage (equivalent to 150V AC
incoming line)
380-480V AC Input: 390V DC bus voltage (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:
Provides class 10 motor overload protection according to NEC
article 430 and motor over-temperature protection according to
NEC article 430.126 (A) (2). UL 508C File 29572.
Overcurrent: 180% hardware limit, 220% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Electrical Efficiency: 97.5% at rated amps, nominal line voltage
Control Output Frequency: 0-320 Hz (programmable)
Control
Inputs
Digital: Quantity: (3) Semi-programmable
(4) Programmable
Type
Source Mode (SRC):
Sink Mode (SNK):
18-24V = ON, 0-6V = OFF
0-6V = ON, 18-24V = OFF
Analog: Quantity: (1) Isolated, –10 to 10V or 4-20mA
(1) Non-isolated, 0 to 10V or 4-20mA
Specification
Resolution:
0 to 10V DC Analog:
4-20mA Analog:
External Pot:
10-bit
100k ohm input impedance
250 ohm input impedance
1-10k ohm, 2 Watt minimum
Control
Outputs
Relay: Quantity: (2) Programmable Form C
Specification
Resistive Rating:
Inductive Rating:
3.0A at 30V DC, 3.0A at 125V, 3.0A at 240V AC
0.5A at 30V DC, 0.5A at 125V, 0.5A at 240V AC
Optional
Relay
Card:
Quantity: (6) Optional Programmable Form A (Drive Frames D, E & F Only)
Specification
Resistive Rating:
Inductive Rating:
0.1A at 30V DC Class II circuits, 3.0A at 125V,
3.0A at 240V AC
0.1A at 30V DC Class II circuits, 3.0A at 125V
3.0A at 240V AC
Opto: Quantity: (1) Programmable
Specification: 30V DC, 50mA Non-inductive
Analog: Quantity: (2) Non-Isolated, 0-10V or 4-20mA
Specification
Resolution:
0 to 10V DC Analog:
4-20mA Analog:
10-bit
1k ohm minimum
525 ohm maximum
UL
®
CUS
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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-7
Figure 3: Power Terminal Blocks
Power Wiring
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 Drives)
P2, DC– DC Bus Connection (Frame D, E, and F 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.
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/T1 V/T2 W/T3
R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1
BR–BR+DC+DC–
R/L1S/L2T/L3 P1 P2 DC– U/T1
V/T2W/T3
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
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English-8 PowerFlex 400 Adjustable Frequency AC Drive Quick Start
Power Terminal Block Specifications
Important: Frame C, D, and F drives utilize a finger guard over the
power wiring terminals. Replace the finger guard when
wiring is complete.
Refer to the PowerFlex 400 User Manual for maximum power cable
length recommendations.
Input Power Conditions
Frame Maximum Wire Size(1)
(1) Maximum/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.
Minimum Wire Size(1) Recommended
Torque
C 8.4 mm2(8 AWG) 1.3 mm2(16 AWG) 2.9 N-m (26 lb.-in.)
D 33.6 mm2(2 AWG) 8.4 mm2(8 AWG) 5.1 N-m (45 lb.-in.)
E 480V
37-45 kW
(50-60 HP)
33.6 mm2(2 AWG) 3.5 mm2(12 AWG) 5.6 N-m (49.5 lb.-in.)
E 240V
30-37 kW
(40-50 HP)
480V
55-75 kW
(75-100 HP)
107.2 mm2(4/0 AWG) 53.5 mm2(1/0 AWG) 19.5 N-m (173 lb.-in.)
F 152.5 mm2(300 MCM) 85.0 mm2(3/0 AWG) 19.5 N-m (173 lb.-in.)
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line
reactance)
•Install Line Reactor(1)
•or Isolation Transformer
(1) Refer to the PowerFlex 400 User Manual for accessory ordering information.
Line has power factor correction capacitors •Install Line Reactor(1)
•or Isolation Transformer
Line has frequent power interruptions
Line has intermittent noise spikes in excess of
6000V (lightning)
Phase to ground voltage exceeds 125% of
normal line to line voltage
•Remove MOV jumper to ground
(Frame C, E & F drives only)
•or Install Isolation Transformer with
grounded secondary if necessary
Ungrounded distribution system
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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-9
I/O Terminal Block Specifications
(2) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Refer to the PowerFlex 400 User Manual for maximum control cable
length recommendations.
I/O Wiring Recommendations
Wire Type(s) Description Minimum
Insulation Rating
Belden 8760/9460
(or equiv.)
0.8 mm2(18AWG), twisted pair, 100%
shield with drain.(1)
(1) If the wires are short and contained within a cabinet which has no sensitive circuits,
the use of shielded wire may not be necessary, but is always recommended.
300V
60 degrees C
(140 degrees F)
Belden 8770
(or equiv.)
0.8 mm2(18AWG), 3 conductor, shielded for
remote pot only.
Frame Maximum Wire Size (2) Minimum Wire Size (2) Torque
C, D, E, F 1.3 mm2(16 AWG) 0.13 mm2(26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
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English-10 PowerFlex 400 Adjustable Frequency AC Drive Quick Start
(1) Important: I/O Terminal 01 is always a coast to stop input
except when P036 [Start Source] is set to option 1 “3-Wire” or
6 “2-W Lvl/Enbl”. In three wire control, I/O Terminal 01 is
controlled by P037 [Stop Mode]. All other stop sources are
controlled by P037 [Stop Mode].
Important: The drive is shipped with a jumper installed
between I/O Terminals 01 and 11. Remove this jumper when
using I/O Terminal 01 as a stop or enable input.
(2) Two wire control shown. For three wire control use a momentary input on I/O Terminal 02 to command a
start. If reverse is enabled by A166, use a maintained input for I/O Terminal 03 to change direction.
(3) 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.
(4) 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.
(5) Most I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to
greatly reduce common mode interference. On Frame D and E drives, Analog Common 1 is referenced to
ground.
(6) Common for Analog Input 2 (AI2). Electronically isolated from digital I/O and opto output. Not to be used with
Analog Input 1 (AI1), Analog Output 1 (AO1) or Analog Output 2 (AO2). With Analog Input 2, provides one fully
isolated analog input channel.
Control Terminal Block
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 (1)(4)
Start/Run FWD (2)
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 (6)
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 (4)
Jumper
30V DC
50mA
Non-inductive
Common
24V
ENBL
(3)
Pot must be
1-10k ohm
2 Watt Min.
SRCSNK
SNK
SRC
Earth Referenced
Frames D & E (5)
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
P036 [Start Source] Stop I/O Terminal 01 Stop
Keypad Per P037 Coast
3-Wire Per P037 Per P037(4)
2-Wire Per P037 Coast
RS485 Port Per P037 Coast
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