Allen-Bradley PowerFlex 40P User manual

Quick Start
PowerFlex®40P Adjustable
Frequency AC Drive
FRN 1.xx - 3.xx
This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 40P 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 40P information including EMC instructions,
application considerations and related precautions, refer to the
PowerFlex 40P User Manual, Publication 22D-UM001… 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.
Darkened display LEDs is not an indication that capacitors have
discharged to safe voltage levels.
ATTENTION: Equipment damage and/or personal injury may result
if parameter A092 [Auto Rstrt Tries] or A094 [Start At PowerUp] is
used in an inappropriate application. Do not use this function without
considering applicable local, national and international codes,
standards, regulations or industry guidelines.
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: Risk of injury or equipment damage exists. Drive does
not contain user-serviceable components. Do not disassemble drive
chassis.
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English-2
•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.
Minimum Mounting Clearances
See page 21 for mounting dimensions.
Ambient Operating Temperatures
Mounting Considerations
Frame Screw Size Screw Torque DIN Rail
B M4 (#8-32) 1.56-1.96 N-m (14-17 lb.-in.) 35 mm
C M5 (#10-24) 2.45-2.94 N-m (22-26 lb.-in.) –
Ambient Temperature Enclosure Rating Minimum Mounting
Clearances
Minimum Maximum
-10°C (14°F) 40°C (104°F) IP 20/Open Type Use Mounting Option A IP 30/NEMA 1/UL Type 1(1)
(1) Rating requires installation of the PowerFlex 40P IP 30/NEMA 1/UL Type 1 option kit.
Use Mounting Option B
50°C (122°F) IP 20/Open Type Use Mounting Option B
25 mm
(1.0 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
RUN
REV
FAULT
RUN
REV
FAULT
RUN
REV
FAULT
RUN
REV
FAULT
Mounting Option A
No clearance required
between drives.
Mounting Option B
Closest object that
may restrict air flow
through the drive heat
sink and chassis
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English-3
To prevent drive damage, the MOVs connected to ground shall be
disconnected if the drive is installed on an ungrounded distribution
system where the line-to-ground voltages on any phase could exceed
125% of the nominal line-to-line voltage. To disconnect these devices,
remove the jumper shown in the figures below.
1. Turn the screw counterclockwise to loosen.
2. Pull the jumper completely out of the drive chassis.
3. Tighten the screw to keep it in place.
Jumper Location
Phase to Ground MOV Removal
Important: Tighten screw after jumper removal.
Typical Grounding
SHLD
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
RUN
REV
FAULT
Disconnecting MOVs
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper
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English-4
Refer to the PowerFlex 40P User Manual for details on how to comply
with the Low Voltage (LV) and Electromagnetic Compatibility (EMC)
Directives.
Drive Ratings
CE Conformity
Specifications, Fuses and Circuit Breakers
Catalog
Number(1)
Output Ratings Input Ratings Branch Circuit Protection
kW (HP) Amps Voltage Range kVA Amps Fuses 140M Motor Protectors(2) (3) Contactors Min. Enclosure
Volume(4) (in.3)
200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output
22D-B2P3 0.4 (0.5) 2.3 180-264 1.15 2.5 6 140M-C2E-B40 100-C07 1655
22D-B5P0 0.75 (1.0) 5.0 180-264 2.45 5.7 10 140M-C2E-C10 100-C09 1655
22D-B8P0 1.5 (2.0) 8.0 180-264 4.0 9.5 15 140M-C2E-C16 100-C12 1655
22D-B012 2.2 (3.0) 12.0 180-264 5.5 15.5 25 140M-C2E-C16 100-C23 1655
22D-B017 3.7 (5.0) 17.5 180-264 8.6 21.0 30 140M-F8E-C25 100-C23 1655
22D-B024 5.5 (7.5) 24.0 180-264 11.8 26.1 40 140M-F8E-C32 100-C37 2069
22D-B033 7.5 (10.0) 33.0 180-264 16.3 34.6 60 140M-G8E-C45 100-C60 2069
380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output
22D-D1P4 0.4 (0.5) 1.4 342-528 1.4 1.8 3 140M-C2E-B25 100-C07 1655
22D-D2P3 0.75 (1.0) 2.3 342-528 2.3 3.2 6 140M-C2E-B40 100-C07 1655
22D-D4P0 1.5 (2.0) 4.0 342-528 4.0 5.7 10 140M-C2E-B63 100-C09 1655
22D-D6P0 2.2 (3.0) 6.0 342-528 5.9 7.5 15 140M-C2E-C10 100-C09 1655
22D-D010 4.0 (5.0) 10.5 342-528 10.3 13.0 20 140M-C2E-C16 100-C23 1655
22D-D012 5.5 (7.5) 12.0 342-528 11.8 14.2 25 140M-D8E-C20 100-C23 2069
22D-D017 7.5 (10.0) 17.0 342-528 16.8 18.4 30 140M-D8E-C20 100-C23 2069
22D-D024 11.0 (15.0) 24.0 342-528 23.4 26.0 50 140M-F8E-C32 100-C43 2069
460 - 600V AC (±10%) – 3-Phase Input, 0 - 575V 3-Phase Output
22D-E1P7 0.75 (1.0) 1.7 414-660 2.1 2.3 6 140M-C2E-B25 100-C09 1655
22D-E3P0 1.5 (2.0) 3.0 414-660 3.65 3.8 6 140M-C2E-B40 100-C09 1655
22D-E4P2 2.2 (3.0) 4.2 414-660 5.2 5.3 10 140M-D8E-B63 100-C09 1655
22D-E6P6 4.0 (5.0) 6.6 414-660 8.1 8.3 15 140M-D8E-C10 100-C09 1655
22D-E9P9 5.5 (7.5) 9.9 414-660 12.1 11.2 20 140M-D8E-C16 100-C16 2069
22D-E012 7.5 (10.0) 12.2 414-660 14.9 13.7 25 140M-D8E-C16 100-C23 2069
22D-E019 11.0 (15.0) 19.0 414-660 23.1 24.1 40 140M-F8E-C25 100-C30 2069
(1) Ratings apply to all drive types; Panel Mount (N104), Flange Mount (F104), and Plate Drive
(H204).
(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-5
Category Specification
Agency
Certification
Listed to UL508C and CAN/CSA-22.2
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
Certified to ISO 13849-1; Performance Level d (Safety
Category 3).
Meets Functional Safety (FS) when used with the
DriveGuard Safe-Off Option (Series B).
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:
380-460V AC Input:
460-600V AC Input:
405V DC bus (equivalent to 290V AC incoming line)
810V DC bus (equivalent to 575V AC incoming line)
1005V DC bus (equivalent to 711V AC incoming line)
Bus Undervoltage Trip
200-240V AC Input:
380-480V AC Input:
460-600V AC Input
P042 = 3 “High Voltage”:
P042 = 2 “Low Voltage”:
210V DC bus (equivalent to 150V AC incoming line)
390V DC bus (equivalent to 275V AC incoming line)
487V DC bus (equivalent to 344V AC incoming line)
390V DC bus (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: 200% hardware limit, 300% instantaneous fault
Ground Fault Trip: Phase-to-ground on drive output
Short Circuit Trip: Phase-to-phase on drive output
Environment Altitude: 1000 m (3300 ft) max. without derating. Above 1000 m
(3300 ft) derate 3% for every 305 m (1000 ft).
Maximum Surrounding Air Temperature
without derating:
IP20, Open Type:
IP30, NEMA Type 1, UL Type 1:
Flange and Plate Mount:
–10 to 50° C (14 to 122° F)
–10 to 40° C (14 to 104° F)
Heatsink: –10 to 40° C (14 to 104° F)
Drive: –10 to 50° C (14 to 122° F)
Cooling Method
Convection:
Fan:
0.4 kW (0.5 HP) drives and all Flange and Plate drives
All other drive ratings
Storage Temperature: –40 to 85 degrees C (–40 to 185 degrees F)
Atmosphere: Important: Drive must not be installed in an area
where the ambient atmosphere contains volatile or
corrosive gas, vapors or dust. If the drive is not going
to be installed for a period of time, it must be stored in
an area where it will not be exposed to a corrosive
atmosphere.
Relative Humidity: 0 to 95% non-condensing
Shock (operating): 15G peak for 11ms duration (±1.0 ms)
Vibration (operating): 1G peak, 5 to 2000 Hz
UL
®
CUS
TUV
Rheinland
Product Safety
..
Production inspected
W
E
C
TUV
Rheinland
..
Functional
Safety
Bauart geprüft
Type approved
EN 50178
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English-6
Electrical Voltage Tolerance: 200-240V ±10%
380-480V ±10%
460-600V ±10%
Frequency Tolerance: 48-63 Hz
Input Phases: Three-phase input provides full rating. Single-phase
operation provides 35% rated current.
Displacement Power Factor: 0.98 across entire speed range
Maximum Short Circuit Rating: 100,000 Amps Symmetrical
Actual Short Circuit Rating: Determined by AIC Rating of installed fuse/circuit
breaker
Transistor Type: Isolated Gate Bipolar (IGBT)
Control Method: Sinusoidal PWM, Volts/Hertz, and Sensorless Vector
Carrier Frequency 2-16 kHz, Drive rating based on 4 kHz.
Frequency Accuracy
Digital Input:
Analog Input:
Analog Output:
Within ±0.05% of set output frequency
Within 0.5% of maximum output frequency, 10-Bit
resolution
±2% of full scale, 10-Bit resolution
Speed Regulation
Open Loop with Slip Compensation:
With Encoder:
±1% of base speed across a 80:1 speed range
±0.3% of base speed across a 80:1 speed range
±0.05% of base speed across a 20:1 speed range
Output Frequency: 0-500 Hz (programmable)
Efficiency: 97.5% (typical)
Stop Modes: Multiple programmable stop modes including - Ramp,
Coast, DC-Brake, and Ramp-to-Stop
Accel/Decel: Four independently programmable accel and decel
times. Each time may be programmed from 0 - 600
seconds in 0.1 second increments.
Intermittent Overload: 150% Overload capability for up to 1 minute
200% Overload capability for up to 3 seconds
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.
Control Inputs Digital: Bandwidth: 10 Rad/Secs for open and closed loop
Quantity: (2) Semi-programmable
(5) Programmable
Current: 6 mA
Type
Source Mode (SRC):
Sink Mode (SNK):
18-24V = ON, 0-6V = OFF
0-6V = ON, 18-24V = OFF
Analog: Quantity: (2) Isolated, –10 to 10V and 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
Encoder Type: Incremental, dual channel
Supply: 12V, 250 mA. 12V, 10 mA minimum inputs isolated
with differential transmitter, 250 kHz maximum.
Quadrature: 90°, ±27 degrees at 25 degrees C.
Duty Cycle: 50%, +10%
Requirements: Encoders must be line driver type, quadrature (dual
channel) or pulse (single channel), 3.5-26V DC output,
single-ended or differential and capable of supplying a
minimum of 10 mA per channel. Allowable input is DC
up to a maximum frequency of 250 kHz. The encoder
I/O automatically scales to allow 5V, 12V and 24V DC
nominal voltages.
Category Specification
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Power Terminal Block
Control Outputs Relay: Quantity: (1) 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
Opto: Quantity: (2) Programmable
Specification: 30V DC, 50mA Non-inductive
Analog: Quantity: (1) 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
Category Specification
Power Wiring
Power Wire Rating Recommended Copper Wire
Unshielded 600V, 75°C (167°F) THHN/THWN 15 Mils insulated, dry location
Shielded 600V, 75°C or 90°C (167°F or 194°F) RHH/
RHW-2
Anixter OLF-7xxxxx,
Belden 29501-29507 or
equivalent
Shielded Tray rated 600V, 75°C or 90°C (167°F or
194°F) RHH/RHW-2
Anixter 7V-7xxxx-3G
Shawflex 2ACD/3ACD or
equivalent
Terminal (1) Description
R/L1, S/L2 1-Phase Input (2)
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 (C Frame drives only.)
The C Frame drive is 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
BR+, BR- Dynamic Brake Resistor Connection
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.
(2) Single-phase operation requires a 65% derate of drive rated current.
V/T2T/L3S/L2R/L1 U/T1 W/T3
BR+ BR-DC- DC+
V/T2T/L3S/L2R/L1 U/T1 W/T3 P2 P1
BR+ BR-DC- DC+
B Frame C Frame
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English-8
Power Terminal Block Specifications
Input Power Conditions
If drives with internal precharge are used with a disconnect switch to the
common bus, then an auxiliary contact on the disconnect must be
connected to a digital input of the drive. The corresponding input
(parameter A051-A054) must be set to option 29, “Precharge Enable.”
This provides the proper precharge interlock, guarding against possible
damage to the drive when connected to a common DC bus.
Frame Maximum Wire Size (1) Minimum Wire Size (1) Torque
B 5.3 mm2(10 AWG) 1.3 mm2(16 AWG) 1.7-2.2 N-m (16-19 lb.-in.)
C 8.4 mm2(8 AWG) 1.3 mm2(16 AWG) 2.9-3.7 N-m (26-33 lb.-in.)
(1) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(2)
•or Isolation Transformer
•or Bus Inductor – 5.5 & 11 kW
(7.5 & 15 HP) drives only
(2) Refer to Appendix B of the PowerFlex 40P User Manual for accessory ordering
information.
Greater than 120 kVA supply transformer
Line has power factor correction capacitors •Install Line Reactor
•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.
•or Install Isolation Transformer
with grounded secondary if
necessary.
Ungrounded distribution system
240V open delta configuration (stinger leg)(1)
(1) For drives applied on an open delta with a middle phase grounded neutral system, the
phase opposite the phase that is tapped in the middle to the neutral or earth is
referred to as the “stinger leg,” “high leg,” “red leg,” etc. This leg should be identified
throughout the system with red or orange tape on the wire at each connection point.
The stinger leg should be connected to the center Phase B on the reactor. Refer to the
PowerFlex 40P User Manual for specific line reactor part numbers.
•Install Line Reactor
Common Bus/Precharge Notes
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English-9
Signal and Control Wire Types
Recommended Control Wire for Digital I/O
I/O Terminal Block Specifications
Refer to the PowerFlex 40P User Manual for recommendations on
maximum power and control cable length.
I/O Wiring Recommendations
Signal Type/
Where Used
Belden Wire Type(s)(1)
(or equivalent)
(1) Stranded or solid wire.
Description
Min. Insulation
Rating
Analog I/O & PTC 8760/9460 0.750 mm2(18AWG), twisted
pair, 100% shield with drain(3)
(3) 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,
75-90° C
(167-194° F)
Remote Pot 8770 0.750 mm2(18AWG), 3
cond., shielded
Encoder/Pulse I/O 89730(2)
(2) 9728 or 9730 are equivalent and may be used but may not fit in the drive wire channel.
0.196 mm2(24AWG),
individually shielded pairs
Type Wire Type(s) Description
Minimum
Insulation Rating
Unshielded Per US NEC or applicable
national or local code
– 300V,
60 degrees C
(140 degrees F)
Shielded Multi-conductor shielded
cable such as Belden
8770(or equiv.)
0.750 mm2(18AWG), 3
conductor, shielded.
Frame Maximum Wire Size (1)
(1) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
Minimum Wire Size (1) Torque
B & C 1.3 mm2(16 AWG) 0.2 mm2(24 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
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English-10
Control Wiring Block Diagram
See Control Wiring Block Diagram Notes on next page.
Control Terminal Block
04
05
06
07
01
02
03
08
09
11
12
13
14
15
16
17
18
19
Digital Common
Digital Input 1
Digital Input 2
Digital Input 3
Stop (1)(6)
Start/Run FWD (2)
Direction/Run REV (3)
Digital Input 4
Opto Common
R1
R2
R3
Relay N.O.
Relay Common
Relay N.C.
+24V DC
+10V DC
0-10V (or ±10V) Input (4)
Analog Common
4-20mA Input
Analog Output
Opto Output 1
Opto Output 2
RS485 Shield
+24V
+10V
Typical
SNK Wiring
Typical
SRC Wiring
1
RS485
(DSI)
R1 R2 R3 SNK
SRC
0-10V
0-20mA
01 02 03 04 05
11 12 13 14 15
06 07 08 09
16 17 18 19
(1)
Enable Jumper (6)
30V DC
50mA
Non-inductive
Common
24V
ENBL Enable (6)
Jumper
(5)
Pot must be
1-10k ohm
2 Watt Min.
0-10V
0/4-20mA
Analog Output Select
Voltage Range Select
SRCSNK
10V
+/-10V (4)
30V DC 125V AC 240V AC
Resistive 3.0A 3.0A 3.0A
Inductive 0.5A 0.5A 0.5A
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English-11
Control Wiring Block Diagram Notes
(1) Important: I/O Terminal 01 is always a coast to stop input except when P036 [Start
Source] is set to “3-Wire”, “2-W Lvl Sens” or “Momt FWD/REV” control. 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. Use a maintained input for I/O Terminal 03 to
change direction.
(3) The function of I/O Terminal 03 is fully programmable. Program with E202 [Digital
Ter m 3 ].
(4) Match the Voltage Range Select DIP switch setting with the control scheme for proper
Uni-Polar or Bipolar operation.
(5) 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.
(6) 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.
P036 [Start Source] Stop I/O Terminal 01 Stop
3-Wire Per P037 Per P037(6)
2-Wire Per P037 Coast
2-W Lvl Sens Per P037 Per P037(6)
2-W Hi Speed Per P037 Coast
RS485 Port Per P037 Coast
Momt FWD/REV Per P037 Per P037(6)
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English-12
Control I/O Terminal Designations
No. Signal Default Description Param.
R1 Relay N.O. Fault Normally open contact for output relay. A055
R2 Relay Common – Common for output relay.
R3 Relay N.C. Fault Normally closed contact for output relay. A055
Analog Output Select
DIP Switch
0-10V Sets analog output to either voltage or current. Setting must match
A065 [Analog Out Sel].
Sink/Source
DIP Switch
Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch
setting.
01 Stop (1) Coast The factory installed jumper or a normally closed
input must be present for the drive to start.
P036 (1)
02 Start/Run FWD Not Active I/O Terminal 03 is fully programmable. Program with
E202 [Digital Term 3]. To disable reverse operation,
see A095 [Reverse Disable].
P036, P037
03 Digital Term 3 Not Active P036, P037,
A095, E202
04 Digital Common – For digital inputs. Electronically isolated with digital
inputs from analog I/O and opto outputs.
05 Digital Input 1 Preset Freq Program with A051 [Digital In1 Sel]. A051
06 Digital Input 2 Preset Freq Program with A052 [Digital In2 Sel]. A052
07 Digital Input 3 Local Program with A053 [Digital In3 Sel]. A053
08 Digital Input 4 Jog Forward Program with A054 [Digital In4 Sel]. A054
09 Opto Common – For opto-coupled outputs. Electronically isolated with
opto outputs from analog I/O and digital inputs.
11 +24V DC – Referenced to Digital Common.
Drive supplied power for digital inputs.
Maximum output current is 100mA.
12 +10V DC – Referenced to Analog Common.
Drive supplied power for 0-10V external
potentiometer.
Maximum output current is 15mA.
P038
13 ±10V In (2) Not Active For external 0-10V (unipolar) or ±10V (bipolar) input
supply (input impedance = 100k ohm) or
potentiometer wiper.
P038,
A051-A054,
A123, A132
14 Analog Common – For 0-10V In or 4-20mA In. Electronically isolated
with analog inputs and outputs from digital I/O and
opto outputs.
15 4-20mA In (2) Not Active For external 4-20mA input supply
(input impedance = 250 ohm).
P038,
A051-A054,
A132
16 Analog Output OutFreq 0-10 The default analog output is 0-10V. To covert to a
current value, change the Analog Output Select DIP
Switch to 0-20mA. Program with A065 [Analog Out
Sel]. Max analog value can be scaled with A066
[Analog Out High].
Maximum Load: 4-20mA = 525 ohm (10.5V)
0-10V = 1k ohm (10mA)
A065, A066
17 Opto Output 1 MotorRunning Program with A058 [Opto Out1 Sel] A058, A059,
A064
18 Opto Output 2 At Frequency Program with A061 [Opto Out2 Sel] A061, A062,
A064
19 RS485 (DSI) Shield – Terminal should be connected to safety ground - PE
when using the RS485 (DSI) communications port.
(1) See Footnotes (1) and (6) on page 11.
(2) 0-10V In and 4-20mA In are distinct input channels and may be connected simultaneously.
Inputs may be used independently for speed control or jointly when operating in PID mode.
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Encoder Interface
The PowerFlex 40P Encoder Interface can source 5 or12 volt power and
accept 5, 12 or 24 volt single ended or differential inputs.
Terminal Description
Important: A quadrature encoder provides rotor speed and direction.
Therefore, the encoder must be wired such that the forward
direction matches the motor forward direction. If the drive
is reading encoder speed but the position regulator or other
encoder function is not working properly, remove power to
the drive and swap the A and A (NOT) encoder channels or
swap any two motor leads. Drives using FRN 2.xx and
greater will fault when an encoder is incorrectly wired and
E216 [Motor Fdbk Type] is set to option 5 “Quad Check”.
No. Signal Description
+V 5V-12V Power (1)
(1) When using 12V Encoder power, 24V I/O power, maximum output current at I/O
Terminal 11 is 50 mA.
Internal power source 250 mA (isolated).
Cm Power Return
B- Encoder B (NOT) Quadrature B input.
B Encoder B
A- Encoder A (NOT) Single channel, pulse train, or quadrature A input.
A Encoder A
➊Output DIP switch selects 12 or 5 volt power supplied at terminals “+V”
and “Cm” for the encoder.
+V Cm B- B A- A
12V
5V
➊
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Before Applying Power to the Drive
❏1. Confirm that all inputs are connected to the correct terminals and are
secure.
❏2. Verify that AC line power at the disconnect device is within the rated
value of the drive.
❏3. Verify that any digital control power is 24 volts.
❏4. Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to
match your control wiring scheme. See page 10 for location.
Important: The default control scheme is Source (SRC). The Stop
terminal is jumpered to allow starting from comms. If the
control scheme is changed to Sink (SNK), the jumper must
be removed from I/O Terminals 01 and 11 and installed
between I/O Terminals 01 and 04.
❏5. Verify that the Stop input is present or the drive will not start.
Important: If I/O Terminal 01 is used as a stop input, the jumper
between I/O Terminals 01 and 11 must be removed.
Applying Power to the Drive
❏6. Apply AC power and control voltages to the drive.
Start, Stop, Direction and Speed Control
Factory default parameter values allow the drive to be controlled from
comms. No programming is required to start, stop, change direction and
control speed directly from comms.
Important: To disable reverse operation, see A095 [Reverse Disable].
If a fault appears on power up, refer to page 19 for an explanation of the
fault code. For complete troubleshooting information, refer to the
PowerFlex 40P User Manual.
Prepare For Drive Start-Up
!
ATTENTION: Power must be applied to the drive to perform the
following start-up procedures. Some of the voltages present are at
incoming line potential. To avoid electric shock hazard or damage to
equipment, only qualified service personnel should perform the
following procedure. Thoroughly read and understand the procedure
before beginning. If an event does not occur while performing this
procedure, Do Not Proceed. Remove All Power including user
supplied control voltages. User supplied voltages may exist even when
main AC power is not applied to the drive. Correct the malfunction
before continuing.
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English-15
For additional drive programming and control, a DSI remote HIM or PC
programming tools (DriveExplorer™ or DriveTools™ SP) should be used.
Display/Fault Reset
No. LED LED State Description
➊Run Status Steady Red Indicates drive is running.
Flashing Red Drive has been commanded to change direction.
Direction Status Steady Red Indicates drive is running in reverse direction.
Flashing Red Drive has been commanded to change direction and motor is
decelerating to zero.
Fault Status Flashing Red Indicates drive is faulted.
No. Key Name Description
➋Up Arrow Scroll: Press and release to scroll through user-selectable
Display Group and parameters.
Reset: Press and hold for three seconds to clear active fault.
RUN
REV
FAULT
➊➋
Menu Description
Basic Display Group (View Only)
Commonly viewed drive operating
conditions.
Advanced Display Group (View Only)
Consists of advanced drive operating
conditions.
Fault Designator
Consists of list of codes for specific fault
conditions. Displayed only when fault is
present.
Drive Programming Tools
Description Catalog Number
Converter Module, Serial 22-SCM-232
Converter Module, USB 1203-USB
DriveExplorer Software(1)
(1) Requires a Serial or USB Converter Module.
9306-4EXP02ENE
DriveTools SP Software(1) 9303-4DTS01ENE
Remote Panel Mount, LCD Display 22-HIM-C2S
Remote Handheld, LCD Display 22-HIM-A3
Set Parameter Display Option
E201 [LED Display Opt]
Selects which parameters can be viewed by the drive’s LED interface.
Values Default: 2
Min/Max: 0/3
Display: 1
E201 Option Parameter Set
0
1
2
3
All Basic Display (Group b) and Advanced Display (Group d) parameters
All Basic Display Group (b001-b029) parameters
Basic Display Group parameters b001-b007 and b010
Basic Display Group parameter b001-b004
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Basic Display Group
Output Freq b001
Commanded Freq b002
Output Current b003
Output Voltage b004
DC Bus Voltage b005
Drive Status b006
Fault 1 Code b007
Fault 2 Code b008
Fault 3 Code b009
Process Display b010
Control Source b012
Contrl In Status b013
Dig In Status b014
Comm Status b015
Control SW Ver b016
Drive Type b017
Elapsed Run Time b018
Testpoint Data b019
Analog In 0-10V b020
Analog In 4-20mA b021
Output Power b022
Output Powr Fctr b023
Drive Temp b024
Counter Status b025
Timer Status b026
Stp Logic Status b028
Torque Current b029
Basic Program Group Motor NP Volts P031
Motor NP Hertz P032
Motor OL Current P033
Minimum Freq P034
Maximum Freq P035
Start Source P036
Stop Mode P037
Speed Reference P038
Accel Time 1 P039
Decel Time 1 P040
Reset To Defalts P041
Voltage Class P042
Motor OL Ret P043
Advanced Program Group
Digital In1 Sel A051
Digital In2 Sel A052
Digital In3 Sel A053
Digital In4 Sel A054
Relay Out Sel A055
Relay Out Level A056
Opto Out1 Sel A058
Opto Out1 Level A059
Opto Out2 Sel A061
Opto Out2 Level A062
Opto Out Logic A064
Analog Out Sel A065
Analog Out High A066
Accel Time 2 A067
Decel Time 2 A068
Internal Freq A069
Preset Freq 0 A070
Preset Freq 1 A071
Preset Freq 2 A072
Preset Freq 3 A073
Preset Freq 4 A074
Preset Freq 5 A075
Preset Freq 6 A076
Preset Freq 7 A077
Jog Frequency A078
Jog Accel/Decel A079
DC Brake Time A080
DC Brake Level A081
DB Resistor Sel A082
S Curve % A083
Boost Select A084
Start Boost A085
Break Voltage A086
Break Frequency A087
Maximum Voltage A088
Current Limit 1 A089
Motor OL Select A090
PWM Frequency A091
Auto Rstrt Tries A092
Auto Rstrt Delay A093
Start At PowerUp A094
Reverse Disable A095
Flying Start En A096
Compensation A097
SW Current Trip A098
Process Factor A099
Fault Clear A100
Program Lock A101
Test point Sel A1 02
Comm Data Rate A103
Comm Node Addr A104
Comm Loss Action A105
Comm Loss Time A106
Comm Format A107
Language A108
Anlg Out Setpt A109
Anlg In 0-10V Lo A110
Anlg In 0-10V Hi A111
Anlg In4-20mA Lo A112
Anlg In4-20mA Hi A113
Slip Hertz @ FLA A114
Process Time Lo A115
Process Time Hi A116
Bus Reg Mode A117
Current Limit 2 A118
Skip Frequency A119
Skip Freq Band A120
Stall Fault Time A121
Analog In Loss A122
10V Bipolar Enbl A123
Var PWM Disable A124
Torque Perf Mode A125
Motor NP FLA A126
Autotune A127
IR Voltage Drop A128
Flux Current Ref A129
PID Trim Hi A130
PID Trim Lo A131
PID Ref Sel A132
PID Feedback Sel A133
PID Prop Gain A134
PID Integ Time A135
PID Diff Rate A136
PID Setpoint A137
PID Deadband A138
PID Preload A139
Stp Logic 0 A140
Stp Logic 1 A141
Stp Logic 2 A142
Stp Logic 3 A143
Stp Logic 4 A144
Stp Logic 5 A145
Stp Logic 6 A146
Stp Logic 7 A147
Stp Logic Time 0 A150
Stp Logic Time 1 A151
Stp Logic Time 2 A152
Stp Logic Time 3 A153
Stp Logic Time 4 A154
Stp Logic Time 5 A155
Stp Logic Time 6 A156
Stp Logic Time 7 A157
EM Brk Off Delay A160
EM Brk On Delay A161
MOP Reset Sel A162
DB Threshold A163
PID Invert Error A164
Enhanced Program Group
LED Display Opt E201
Digital Term 3 E202
Accel Time 3 E203
Decel Time 3 E204
Accel Time 4 E205
Decel Time 4 E206
Comm Write Mode E207
Power Loss Mode E208
Half Bus Enable E209
Max Traverse E210
Traverse Inc E211
Traverse Dec E212
P Jump E213
Sync Time E214
Speed Ratio E215
Motor Fdbk Type E216
Motor NP Poles E217
Encoder PPR E218
Pulse In Scale E219
Ki Speed Loop E220
Kp Speed Loop E221
Positioning Mode E222
Find Home Freq E223
Find Home Dir E224
Encoder Pos Tol E225
Counts Per Unit E226
Step Units 0 E230
Step Units 1 E232
Step Units 2 E234
Step Units 3 E236
Step Units 4 E238
Step Units 5 E240
Step Units 6 E242
Step Units 7 E244
Pos Reg Filter E246
Pos Reg Gain E247
Enh Control Word E248
Cmd Stat Select E249
Advanced Display Group Drive Status 2 d301
Fibers Status d302
Slip Hz Meter d303
Speed Feedback d304
Encoder Speed d306
Units Traveled H d308
Units Traveled L d309
Fault 4 Code d310
Fault 5 Code d311
Fault 6 Code d312
Fault 7 Code d313
Fault 8 Code d314
Fault 9 Code d315
Fault 10 Code d316
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English-17
The PowerFlex 40P is designed so that start up is simple and efficient. The Program Group
contains the most commonly used parameters.
Display Group Parameters
No. Parameter Min/Max Display/Options
b001 [Output Freq] 0.00/[Maximum Freq] 0.01 Hz
b002 [Commanded Freq] 0.00/[Maximum Freq] 0.01 Hz
b003 [Output Current] 0.00/(Drive Amps ×2) 0.01 Amps
b004 [Output Voltage] 0/Drive Rated Volts 1 VAC
b005 [DC Bus Voltage] Based on Drive Rating 1 VDC
b006 [Drive Status] 0/1 (1 = Condition True) Bit 3 Bit 2 Bit 1 Bit 0
Decelerating Accelerating Forward Running
b007-
b009
[Fault x Code] F2/F122 F1
b010 [Process Display] 0.00/9999 0.01 – 1
b012 [Control Source] 0/112 Digit 4 Digit 2 & 3 = Speed Command
Reserved 01-11
Digit 1 = Start Command
1, 2 & 9
b013 [Contrl In Status] 0/1 (1 = Input Present) Bit 3 Bit 2 Bit 1 Bit 0
DB Trans On Stop Input Dir/REV In Start/FWD In
b014 [Dig In Status] 0/1 (1 = Input Present) Bit 3 Bit 2 Bit 1 Bit 0
Digital In 4 Digital In 3 Digital In 2 Digital In 1
b015 [Comm Status] 0/1 (1 = Condition True) Bit 3 Bit 2 Bit 1 Bit 0
Comm Error DSI Option Transmitting Receiving
b016 [Control SW Ver] 1.00/99.99 0.01
b017 [Drive Type] 1001/9999 1
b018 [Elapsed Run Time] 0/9999 Hrs 1 = 10 Hrs
b019 [Testpoint Data] 0/FFFF 1 Hex
b020 [Analog In 0-10V] 0.0/100.0% 0.1%
b021 [Analog In 4-20mA] 0.0/100.0% 0.1%
b022 [Output Power] 0.00/(Drive Power ×2) 0.01 kW
b023 [Output Powr Fctr] 0.0/180.0 deg 0.1 deg
b024 [Drive Temp] 0/120 degC 1 degC
b025 [Counter Status] 0/9999 1
b026 [Timer Status] 0.0/9999 Secs 0.1 Secs
b028 [Stp Logic Status] 0/8 1
b029 [Torque Current] 0.00/(Drive Amps ×2) 0.01 Amps
Smart Start-Up with Program Group Parameters
= Stop drive before changing this parameter.
No. Parameter Min/Max Display/Options Default
P031 [Motor NP Volts] 20/Drive Rated Volts 1 VAC Based on Drive Rating
Set to the motor nameplate rated volts.
P032 [Motor NP Hertz] 15/500 Hz 1 Hz 60 Hz
Set to the motor nameplate rated frequency.
P033 [Motor OL Current] 0.0/(Drive Rated Amps×2) 0.1 Amps Based on Drive Rating
Set to the maximum allowable motor current.
P034 [Minimum Freq] 0.00/500.0 Hz 0.01 Hz 0.00 Hz
Sets the lowest frequency the drive will output
continuously.
P035 [Maximum Freq] 0.00/500.0 Hz 0.01 Hz 60.00 Hz
Sets the highest frequency the drive will output.
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English-18
P036 [Start Source] 1/6 1 = “3-Wire”
2 = “2-Wire”
3 = “2-W Lvl Sens”
4 = “2-W Hi Speed”
5 = “Comm Port”
6 = “Momt FWD/REV”
5
Sets the control scheme used to start the drive.
P037 [Stop Mode] 0/9 0 = “Ramp, CF”(1)
1 = “Coast, CF”(1)
2 = “DC Brake, CF”(1)
3 = “DCBrkAuto,CF”(1)
4 = “Ramp”
5 = “Coast”
6 = “DC Brake”
7 = “DC BrakeAuto”
8 = “Ramp+EM B,CF”
9 = “Ramp+EM Brk”
(1) Stop input also clears active fault.
0
Active stop mode for all stop sources [e.g. run
forward (I/O Terminal 02), run reverse (I/O
Terminal 03), RS485 port] except as noted.
Important: I/O Terminal 01 is always a coast to
stop input except when P036 [Start Source] is set
for “3-Wire” control. When in three wire control, I/O
Terminal 01 is controlled by P037 [Stop Mode].
P038 [Speed Reference] 1/9 1 = “InternalFreq”
2 = “0-10V Input”
3 = “4-20mA Input”
4 = “Preset Freq”
5 = “Comm Port”
6 = “Stp Logic”
7 = “Anlg In Mult”
8 = “Encoder”
9 = “Positioning”
5
Sets the source of the speed reference to the
drive.
Important: When A051 or A052 [Digital Inx Sel] is
set to option 2, 4, 5, 6, 13 or 14 and the digital
input is active, A051, A052, A053 or A054 will
override the speed reference commanded by this
parameter. Refer to Chapter 1 of the PowerFlex
40P User Manual for details.
P039 [Accel Time 1] 0.0/600.0 Secs 0.1 Secs 10.0 Secs
Sets the rate of accel for all speed increases.
P040 [Decel Time 1] 0.0/600.0 Secs 0.1 Secs 10.0 Secs
Sets the rate of decel for all speed decreases.
P041 [Reset To Defalts] 0/1 0 = “Ready/Idle”
1 = “Factory Rset”
0
Resets all parameter values to factory defaults.
P042 [Voltage Class] 2/3 2 = “Low Voltage” (480V)
3 = “High Voltage” (600V)
3
Sets the voltage class of 600V drives.
P043 [Motor OL Ret] 0/1 1 = “Enabled” 0 = “Disabled”
Enables/disables the Motor Overload Retention function.
= Stop drive before changing this parameter.
No. Parameter Min/Max Display/Options Default
Advanced Program Group Parameters
= Stop drive before changing this parameter.
No. Parameter Min/Max Display/Options Default
A125 [Torque Perf Mode] 0/1 0 = “V/Hz”
1 = “Sensrls Vect”
1
Enables/disables sensorless vector control
operation.
A126 [Motor NP FLA] 0.1/(Drive Rated Amps x 2) 0.1 Amps Drive Rated Amps
Set to the motor nameplate rated full load amps.
A127 [Autotune] 0/2 0 = “Ready/Idle”
1 = “Static Tune”
2 = “Rotate Tune”
0
Provides an automatic method for setting A128 [IR
Voltage Drop] and A129 [Flux Current Ref], which
affect sensorless vector performance. Parameter
A126 [Motor NP FLA] must be set to the motor
nameplate full load amps before running the
Autotune procedure.
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English-19
Refer to the PowerFlex 40P User Manual supplied with the drive for
complete listing of parameters.
To clear a fault, press the Stop key, cycle power or set A100 [Fault Clear] to 1 or
2.
Enhanced Program Group Parameters
= Stop drive before changing this parameter.
No. Parameter Min/Max Display/Options Default
E216 [Motor Fdbk Type] 0/5 0 = “None”
1 = “Pulse Train”
2 = “Single Chain”
3 = “Single Check”
4 = “Quadrature”
5 = “Quad Check”
0
Selects the encoder type.
E217 [Motor NP Poles] 2/40 1 4
Defines the number of poles in the motor.
E218 [Encoder PPR] 1/20000 1 1024
Specifies the encoder pulses per revolution when
an encoder is used. For additional information refer
to Appendix F of the PowerFlex 40P User Manual.
Program Group Parameters
Advanced Display Group Parameters
No. Parameter Min/Max Display/Options
d301 [Drive Status 2] 0/1 1
d302 [Fibers Status] 0/1 1
d303 [Slip Hz Meter] 0.0/25.0 Hz 0.1 Hz
d304 [Speed Feedback] 0/64000 RPM 1 RPM
d305 [Speed Feedback F] 0.0/0.9 0.1
d306 [Encoder Speed] 0/64000 1
d307 [Encoder Speed F] 0.0/0.9 0.1
d308 [Units Traveled H] 0/64000 1
d309 [Units Traveled L] 0.00/0.99 0.01
d310 [Fault 4 Code] 0/122 1
d311 [Fault 5 Code] 0/122 1
d312 [Fault 6 Code] 0/122 1
d313 [Fault 7 Code] 0/122 1
d314 [Fault 8 Code] 0/122 1
d315 [Fault 9 Code] 0/122 1
d316 [Fault 10Code] 0/122 4
Fault Codes
No. Fault Description
F2 Auxiliary Input(1) Check remote wiring.
Verify communications programming for intentional fault.
F3 Power Loss Monitor the incoming AC line for low voltage or line power interruption.
Check input fuses.
F4 UnderVoltage(1) Monitor the incoming AC line for low voltage or line power interruption.
F5 OverVoltage(1) Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be
caused by motor regeneration. Extend the decel time or install dynamic brake option.
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F6 Motor Stalled(1) Increase [Accel Time x] or reduce load so drive output current does not exceed the current set
by parameter A089 [Current Limit].
F7 Motor Overload(1) An excessive motor load exists. Reduce load so drive output current does not exceed the
current set by parameter P033 [Motor OL Current]. Verify A084 [Boost Select] setting.
F8 Heatsink OvrTmp(1) Check for blocked or dirty heat sink fins. Verify that ambient temperature has not exceeded
40°C (104°F) for IP 30/NEMA 1/UL Type 1 installations or 50°C (122°F) for Open type installations.
Check fan.
F12 HW OverCurrent Check programming. Check for excess load, improper DC boost setting, DC brake volts set too
high or other causes of excess current.
F13 Ground Fault Check the motor and external wiring to the drive output terminals for a grounded condition.
F29 Analog Input Loss(1) An analog input is configured to fault on signal loss. A signal loss has occurred.
Check parameters. Check for broken/loose connections at inputs.
F33 Auto Rstrt Tries Correct the cause of the fault and manually clear.
F38 Phase U to Gnd Check the wiring between the drive and motor.
Check motor for grounded phase.
Replace drive if fault cannot be cleared.
F39 Phase V to Gnd
F40 Phase W to Gnd
F41 Phase UV Short Check the motor and drive output terminal wiring for a shorted condition.
Replace drive if fault cannot be cleared.
F42 Phase UW Short
F43 Phase VW Short
F48 Params Defaulted The drive was commanded to write default values to EEPROM.
Clear the fault or cycle power to the drive. Program the drive parameters as needed.
F63 SW OverCurrent(1) Check load requirements and A098 [SW Current Trip] setting.
F64 Drive Overload Reduce load or extend Accel Time.
F70 Power Unit Cycle power. Replace drive if fault cannot be cleared.
F71 Net Loss The communication network has faulted.
Cycle power. Check communications cabling.
Check network adapter setting. Check external network status.
F80 SVC Autotune The autotune function was either cancelled by the user of failed. Restart procedure.
F81 Comm Loss If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port
expander, adapters or complete drive as required.
Check connection.
An adapter was intentionally disconnected. Turn off using A105 [Comm Loss Action].
Connecting I/O Terminal 04 to ground may improve noise immunity.
F91 Encoder Loss Requires differential encoder. One of the 2 encoder channel signals is missing.
Check Wiring.
If P038 [Speed Reference] = 9 “Positioning” and E216 [Motor Fdbk Type] = 5 “Quad Check”
swap the Encoder channel inputs (see page 13) or swap any two motor leads.
Replace encoder.
F100 Parameter Checksum Restore factory defaults.
F111 Enable Hardware DriveGuard Safe-Off Option (Series B) board is installed and the ENBL enable jumper has not
been removed.
Remove the ENBL enable jumper. Cycle power.
DriveGuard Safe-Off Option (Series B) board has failed.
Remove power to the drive. Replace DriveGuard Safe-Off Option (Series B) board.
Hardware Enable circuitry has failed.
Replace drive.
F122 I/O Board Fail Cycle power. Replace drive if fault cannot be cleared.
(1) Auto-Reset/Run type fault. Configure with parameters A092 and A093.
No. Fault Description
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