Allen-Bradley PowerFlex400 User manual

Adjustable
Frequency AC
Drive for
Fan & Pump
Applications
FRN 4.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.
Important: Identifies information that is critical for successful application and
understanding of the product.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
WARNING: Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment, which may
lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.

Summary of Changes
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the August 2005 release.
New Parameter
The following new parameter has been added with the release of
Firmware Release Number (FRN) 4.xx.
Description of New or Updated Information See Page(s)
Important statement regarding differences in parameter defaults for
packaged drives added to parameter P041 [Reset To Defalts].
3-11
Important statement regarding related parameter added to parameter
A167 [Flying Start En].
3-37
Parameter Name Parameter Number See Page(s)
[Motor NP FLA] A200 3-46

soc-2
Manual Updates
The information below summarizes the changes to the PowerFlex 400
User Manual since the April 2005 release.
New Parameters
The following new parameters have been added with the release of
Firmware Release Number (FRN) 3.xx.
Description of New or Updated Information See Page(s)
Attention statement clarified. 1-6
Min/Max wire sizes for Frame F corrected. 1-15
Note added regarding the function of I/O Terminal 18, Analog Common 2. 1-17
Connection Examples corrected for Analog Input and Analog Output. 1-20
Required filters corrected for 380-480V, 2.2-11 kW (3.0-15 HP) drives in
First Environment Unrestricted.
1-28
Important statement regarding differences in parameter defaults for
packaged drives added to parameter P041 [Reset To Defalts].
3-11
Fault F64 Drive Overload description corrected. 4-4
Overcurrent protection for hardware limit and instantaneous fault levels
corrected.
A-3
Max storage temperatures corrected to 70 degrees C (158 degrees F). A-3
Max and Actual Short Circuit Ratings added to Electrical specification. A-4
Optional Relay specifications added. A-5
Supported communication protocols expanded. A-5
Watts Loss table added. A-6
Power Structure detail added to Appendix A. A-7
Appendix D provides setup information for Damper Control, PID Control,
and Auxiliary Control schemes.
D-1
Appendix G, P1 network protocol added. G-1
Parameter Name Parameter Number See Page(s)
[Motor OL Ret] P043 3-11
[Anlg Loss Delay] T088 3-26
[Start Source 2] C108 3-29
[Speed Ref 2] C109 3-30

Table of Contents
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 . . . . . . . . . . . . . 1-4
AC Supply Source Considerations . . . . . . 1-6
General Grounding Requirements . . . . . . 1-8
Fuses and Circuit Breakers . . . . . . . . . . . . 1-9
Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-11
I/O Wiring Recommendations . . . . . . . . 1-15
Start and Speed Reference Control . . . . . 1-24
RS485 Network Wiring. . . . . . . . . . . . . . 1-26
EMC Instructions . . . . . . . . . . . . . . . . . . 1-27
FCC Instructions . . . . . . . . . . . . . . . . . . . 1-29
Chapter 2 Start Up
Prepare For Drive Start-Up . . . . . . . . . . . . 2-1
Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3
Viewing and Editing Parameters. . . . . . . . 2-5
Keypad Hand-Off-Auto Functions . . . . . . 2-6
Chapter 3 Programming and Parameters
About Parameters . . . . . . . . . . . . . . . . . . . 3-1
Parameter Organization. . . . . . . . . . . . . . . 3-2
Basic Display Group . . . . . . . . . . . . . . . . . 3-4
Basic Program Group . . . . . . . . . . . . . . . . 3-7
Terminal Block Group. . . . . . . . . . . . . . . 3-12
Communications Group . . . . . . . . . . . . . 3-27
Advanced Program Group. . . . . . . . . . . . 3-31
Aux Relay Card Group . . . . . . . . . . . . . . 3-47
Advance Display Group . . . . . . . . . . . . . 3-52
Parameter Cross-Reference – by Name . 3-58
Chapter 4 Troubleshooting
Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3
Common Symptoms and
Corrective Actions . . . . . . . . . . . . . . . . . 4-5

2Table of Contents
Appendix A Supplemental Drive Information
Drive, Fuse & Circuit Breaker Ratings . . . A-1
Specifications. . . . . . . . . . . . . . . . . . . . . . . A-2
Input Power Connections. . . . . . . . . . . . . . A-7
Appendix B Accessories and Dimensions
Product Selection. . . . . . . . . . . . . . . . . . . . B-1
Product Dimensions. . . . . . . . . . . . . . . . . . B-7
Appendix C RJ45 DSI Splitter Cable
Appendix D Application Notes
Damper Control Setup. . . . . . . . . . . . . . . . D-1
PID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Auxiliary Motor Control Setup . . . . . . . . D-11
Appendix E Modbus RTU Protocol
Network Wiring . . . . . . . . . . . . . . . . . . . . . E-1
Parameter Configuration . . . . . . . . . . . . . . E-2
Supported Modbus Function Codes . . . . . E-2
Writing (06) Logic Command Data. . . . . . E-3
Writing (06) Reference . . . . . . . . . . . . . . . E-3
Reading (03) Logic Status Data. . . . . . . . . E-4
Reading (03) Feedback . . . . . . . . . . . . . . . E-4
Reading (03) Drive Error Codes . . . . . . . . E-5
Reading (03) and Writing (06) Drive
Parameters . . . . . . . . . . . . . . . . . . . . . . . E-5
Additional Information . . . . . . . . . . . . . . . E-5
Appendix F Metasys N2
Understanding Metasys N2 . . . . . . . . . . . . F-1
Network Points . . . . . . . . . . . . . . . . . . . . . F-3
Using Percent (%) for the Reference . . . . . F-5
Using Metasys Configurable Objects to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . F-6
Appendix G P1 – Floor Level Network (FLN)
Understanding P1-FLN . . . . . . . . . . . . . . . G-1
Network Points . . . . . . . . . . . . . . . . . . . . . G-2
Using Percent (%) for the Reference. . . . . G-6
Using P1 Configurable Points to Access
Parameters . . . . . . . . . . . . . . . . . . . . . . . G-7
Index

Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to install, start-up and troubleshoot the PowerFlex 400
Adjustable Frequency AC Drive.
This manual is intended for qualified personnel. You must be able to
program and operate Adjustable Frequency AC Drive devices. In
addition, you must have an understanding of the parameter settings and
functions.
The following manuals are recommended for general drive information:
For information on… See page…
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
Who Should Use this Manual?
Reference Materials
Title Publication Available Online at …
Wiring and Grounding
Guidelines for Pulse Width
Modulated (PWM) AC Drives
DRIVES-IN001…
www.rockwellautomation.com/
literature
Preventive Maintenance of
Industrial Control and Drive
System Equipment
DRIVES-TD001…
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State
Control
SGI-1.1
A Global Reference Guide for
Reading Schematic Diagrams
100-2.10

P-2 Overview
•In this manual we refer to the PowerFlex 400 Adjustable Frequency
AC Drive as; drive, PowerFlex 400 or PowerFlex 400 Drive.
•Parameter numbers and names are shown in this format:
•The following words are used throughout the manual to describe an
action:
Similar PowerFlex 400 drive sizes are grouped into frame sizes to
simplify spare parts ordering, dimensioning, etc. A cross reference of
drive catalog numbers and their respective frame sizes is provided in
Appendix B.
Manual Conventions
P031 [Motor NP Volts]
Name
Number
Group
b = Basic Display Group
P = Basic Program Group
T = Terminal Block Group
C = Communications Group
A = Advanced Program Group
R = Aux Relay Card 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
Drive Frame Sizes

Overview P-3
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.
!
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). In addition, installing a properly sized
dynamic brake resistor will provide equal or better performance in most
cases.

P-4 Overview
Catalog Number Explanation
Code Vo l ta g e Ph.
B 240V AC 3
D 480V AC 3
Code Version
3 RS485
Code Interface Module
1 Fixed Keypad
Code Enclosure
N Panel Mount - IP20/UL Open-Type(1)
A Panel Mount - IP30/NEMA 1/UL Type 1(2)
F Flange Mount - IP20/UL Open Type(3)
1-3 4 5 6-8 9 10 11 12
22C - D 038 A 1 0 3
Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Comm Slot
Output Current @ 200-240V 60Hz 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
Code Rating
0 Not Filtered
Output Current @ 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
Code
22C PowerFlex 400
(1) Frame C drives only available with IP20/UL Open-Type enclosure. Field installed conversion kit available
to achieve IP30/NEMA 1/UL Type 1 rating.
(2) Frame D, E and F drives only available with IP30/NEMA 1/UL Type 1 enclosure.
(3) Frame C drives only.
Additional accessories, options and adapters are available. See Appendix B for details.