Rockwell Automation Allen-Bradley PowerFlex 400P Series User manual

400P
Adjustable
Frequency AC
Drive for
General Industrial
Applications
FRN 1.xx - 4.xx
Quick Start
400P
www.abpowerflex.com
fcover.fm Page 1 Wednesday, November 23, 2016 4:24 PM

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.
Allen-Bradley, Rockwell Automation, and PowerFlex are registered trademarks of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
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.
fcover.fm Page 2 Wednesday, November 23, 2016 4:24 PM

Quick Start
PowerFlex 400P Adjustable
Frequency AC Drive
FRN 4.xx
This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 400P 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 400P information including EMC instructions,
application considerations and related precautions refer to the
PowerFlex 400P User Manual, publication 22P-UM001.
General Precautions
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing any
work on the drive. Measure the DC bus voltage at the –DC and +DC
terminals or at the –DC and P2 terminals on the Power Terminal Block
(refer to Chapter 1 of the User Manual for Power Terminal
descriptions). The voltage must be zero.
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.
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English-2 PowerFlex 400P 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: 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.)
G M12 (1/2 in.) 33.5-41.0 N-m (296.5-262.9 lb.-in.)
H M12 (1/2 in.) 33.5-41.0 N-m (296.5-262.9 lb.-in.)
Frame Enclosure Rating Temperature Range Minimum Mounting
Clearances
C IP 20 -10° to 45°C (14° to 113°F) Figure 1: Option A
IP 30(1)
(1) Frame C drives require installation of the PowerFlex 400P IP 30 option kit to achieve
this rating.
-10° to 45°C (14° to 113°F) Figure 1: Option B
IP 20 -10° to 50°C (14° to 122°F) Figure 1: Option B
D, E, F,
G and H
IP 30 -10° to 45°C (14° to 113°F) Figure 2:
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PowerFlex 400P Adjustable Frequency AC Drive Quick Start English-3
Minimum Mounting Clearances
Figure 1: Frame C Mounting Clearances
Figure 2: Frames D, E, F, G, and H Mounting Clearances
120 mm
(4.7 in.)
120 mm
(4.7 in.)
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.)
120 mm
(4.7 in.)
120 mm
(4.7 in.)
Mounting Option BMounting Option A
No clearance required
between drives.
Closest object that
may restrict air flow
through the drive heat
sink and chassis.
150 mm
(6.0 in.)
150 mm
(6.0 in.)
50 mm
(2.0 in.)
250 mm
(9.8 in.)
150 mm
(6.0 in.)
300 mm
(11.8 in.)
300 mm
(11.8 in.)
300 mm
(11.8 in.)
300 mm
(11.8 in.)
50 mm
(2.0 in.) 50 mm (2.0 in.) 50 mm (2.0 in.)
Frame D and E Frame F Frame G and H
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English-4 PowerFlex 400P Adjustable Frequency AC Drive Quick Start
Ungrounded Distribution Systems
Phase to Ground MOV Removal
Jumper Location
Note: Frame D, G and H drives do not contain a MOV to ground
connection and are suitable for operation in both grounded and
ungrounded distribution systems without modification.
General Grounding Requirements
PE
L1
R
L2
S
L3
T
T1
U
T2
V
T3
W
PE
Required
Input Fusing
Required Branch
Circuit Disconnect
!
ATTENTION: PowerFlex 400P 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.
R/L1
S/L2
T/L3
1234
Three-Phase
AC Input
Jumper
Frame C Frame E and F
Important:
Tighten screw
after jumper removal.
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PowerFlex 400P Adjustable Frequency AC Drive Quick Start English-5
Refer to the PowerFlex 400P User Manual, publication 22P-UM001
for details on how to comply with the Low Voltage (LV) and
Electromagnetic Compatibility (EMC) Directives.
EMC Line Filters
CE Conformity
480V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase
kW HP Catalog Number kW HP Catalog Number
2.2 3.0 22-RF018-CS 45 60 22-RFD100
4.0 5.0 22-RF018-CS 55 75 22-RFD150
5.5 7.5 22-RF018-CS 75 100 22-RFD180
7.5 10 22-RF018-CS 90 125 22-RFD208
11 15 22-RF026-CS 110 150 22-RFD208
15 20 22-RFD036 132 200 22-RFD323
18.5 25 22-RFD050 160 250 22-RFD480
22 30 22-RFD050 200 300 22-RFD480
30 40 22-RFD070 250 350 22-RFD480
37 50 22-RFD100
Drive Ratings
Catalog
Number
Output Ratings Input Ratings Branch Circuit Protection Power
Dissipation
kW (HP)(1) Amps(2) Voltage
Range kVA Amps Fuses(3) 140M Motor
Protectors(4) Contactors IP20 Open
Watts
380 - 480V AC – 3-Phase Input, 0 - 460V 3-Phase Output
22P-D6P0N103 2.2 (3.0) 6 340-528 6.3 7.5 10 140M-D8E-C10 100-C09 105
22P-D010N103 4.0 (5.0) 10.5 340-528 10.9 13 20 140M-D8E-C16 100-C16 171
22P-D012N103 5.5 (7.5) 12 340-528 11.9 14.2 20 140M-D8E-C16 100-C23 200
22P-D017N103 7.5 (10) 17 340-528 15.3 18.4 25 140M-D8E-C20 100-C23 267
22P-D022N103 11 (15) 22 340-528 19.2 23 30 140M-F8E-C32 100-C30 329
22P-D030N103 15 (20) 30 340-528 25.8 31 40 140M-F8E-C32 100-C37 435
22P-D038A103 18.5 (25) 38 340-528 33.3 40 50 140M-F8E-C45 100-C60 606
22P-D045A103 22 (30) 45.5 340-528 39.1 47 60 140-CMN-6300 100-C60 738
22P-D060A103 30 (40) 60 340-528 53.3 64 80 140-CMN-9000 100-C85 664
22P-D072A103 37 (50) 72 340-528 60.7 73 100 140-CMN-9000 100-C85 1019
22P-D088A103 45 (60) 88 340-528 74.9 90 125 – 100-D110 1245
22P-D105A103 55 (75) 105 340-528 89 107 150 – 100-D140 1487
22P-D142A103 75 (100) 142 340-528 124.8 150 200 – 100-D180 2043
22P-D170A103 90 (125) 170 340-528 142 170 250 – 100-D250 2617
22P-D208A103 110 (150) 208 340-528 167 200 250 – 100-D250 3601
22P-D260A103 132 (200) 260 340-528 196 235 300 – 100-D300 3711
22P-D310A103 160 (250) 310 340-528 242 290 400 – 100-D420 4208
22P-D370A103 200 (300) 370 340-528 304 365 500 – 100-D420 4916
22P-D460A103 250 (350) 460 340-528 387 465 600 – 100-D630 6167
(1) Ratings based on Normal Duty application only.
(2) Current ratings based on ambient temperature of 45°C.
(3) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
(4) Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to
determine the frame and breaking capacity required for your application.
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English-6 PowerFlex 400P Adjustable Frequency AC Drive Quick Start
Specifications, Fuses and Circuit Breakers
Category Specification
Agency
Certification
Marked for all applicable European Directives
EMC Directive (2014/30/EU)
EN 61800-3
Low Voltage Directive (2014/35/EU)
EN 61800-5-1
Protection Bus Overvoltage Trip: 380-460V AC Input: 810V DC bus voltage (equivalent to 575V AC
incoming line)
Bus Undervoltage Trip: 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:
I2t protection - 110% for 60 seconds (Provides Class 10
protection)
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 4-20 mA
(1) Non-isolated, 0 to 10V or 4-20 mA
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
(Not available for Frame C drives)
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
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PowerFlex 400P Adjustable Frequency AC Drive Quick Start English-7
Figure 3: Power Terminal Blocks
Power Wiring
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
Frame E:
480V
55-75kW
(75-100HP)
Frame D
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
Frame C
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/L1S/L2T/L3 P1 P2 DC– U/T1V/T2W/T3
R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3
Frame F
Frame G
Frame H
R/L1
R/L1
S/L2
S/L2
T/L3
T/L3
P1 P2 DC–
DC–
DC+
U/T1
U/T1
V/T2
V/T2
W/T3
W/T3
See note on the
following page.
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English-8 PowerFlex 400P Adjustable Frequency AC Drive Quick Start
Important: For Frame E, 480V 55-75 kW (75-100 HP) drives, take care
to place the wire beneath the jumper and not above it when
connecting to terminals P1 and P2.
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.
P1 P2 DC- P1 P2 DC-
Wire
Jumper Wire
Jumper
Correct Incorrect
Bottom view of terminal block and wire
22P-QS001C-EN-P.fm Page 8 Thursday, March 30, 2017 5:55 PM