Rockwell Automation PowerFlex 40 User manual

Quick Start
PowerFlex 40 Adjustable
Frequency AC Drive
FRN 3.xx
This Quick Start guide summarizes the basic steps needed to install,
start-up and program the PowerFlex 40 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 40 information including EMC instructions,
application considerations and related precautions refer to the
PowerFlex 40 User Manual, Publication 22B-UM001… on the CD
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.
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.

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•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
Ambient Operating Temperatures
Refer to the PowerFlex 40 User Manual on the CD supplied with the
drive for details on how to comply with the Low Voltage (LV) and
Electromagnetic Compatibility (EMC) Directives.
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 40 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.)
Mounting Option A
No clearance required
between drives.
Mounting Option B
See page 16 for mounting dimensions.
General Grounding Requirements
U/T1
V/T2
W/T3
R/L1
S/L2
T/L3
SHLD
Important: The MOV to ground jumper must be
removed if the drive is installed on an ungrounded or
resistive grounded distribution system.
Tighten screw after jumper removal.
Jumper
Location
CE Conformity

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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
140M Motor
Protectors(2) Contactors
IP20 Open
Watts
100 - 120V AC (±10%) – 1-Phase Input, 0 - 230V 3-Phase Output
22B-V2P3N104 0.4 (0.5) 2.3 90-132 1.15 9.0 15 140M-C2E-C16 100-C12 40
22B-V5P0N104 0.75 (1.0) 5.0 90-132 2.45 20.3 35 140M-D8E-C20 100-C23 60
22B-V6P0N104 1.1 (1.5) 6.0 90-132 3.0 24.0 40 140M-F8E-C32 100-C37 80
200 - 240V AC (±10%) – 1-Phase(1) Input, 0 - 230V 3-Phase Output
22B-A2P3N104 0.4 (0.5) 2.3 180-264 1.15 6.0 10 140M-C2E-B63 100-C09 40
22B-A5P0N104 0.75 (1.0) 5.0 180-264 2.45 12.0 20 140M-C2E-C16 100-C12 60
22B-A8P0N104 1.5 (2.0) 8.0 180-264 4.0 18.0 30 140M-D8E-C20 100-C23 85
22B-A012N104 2.2 (3.0) 12.0 180-264 5.5 25.0 40 140M-F8E-C32 100-C37 125
200 - 240V AC (±10%) – 3-Phase Input, 0 - 230V 3-Phase Output
22B-B2P3N104 0.4 (0.5) 2.3 180-264 1.15 2.5 6 140M-C2E-B40 100-C07 40
22B-B5P0N104 0.75 (1.0) 5.0 180-264 2.45 5.7 10 140M-C2E-C10 100-C09 60
22B-B8P0N104 1.5 (2.0) 8.0 180-264 4.0 9.5 15 140M-C2E-C16 100-C12 85
22B-B012N104 2.2 (3.0) 12.0 180-264 5.5 15.5 25 140M-C2E-C16 100-C23 125
22B-B017N104 3.7 (5.0) 17.5 180-264 8.6 21.0 30 140M-F8E-C25 100-C23 180
22B-B024N104 5.5 (7.5) 24.0 180-264 11.8 26.1 40 140M-F8E-C32 100-C37 235
22B-B033N104 7.5 (10.0) 33.0 180-264 16.3 34.6 60 140M-G8E-C45 100-C60 305
380 - 480V AC (±10%) – 3-Phase Input, 0 - 460V 3-Phase Output
22B-D1P4N104 0.4 (0.5) 1.4 342-528 1.4 1.8 3 140M-C2E-B25 100-C07 35
22B-D2P3N104 0.75 (1.0) 2.3 342-528 2.3 3.2 6 140M-C2E-B40 100-C07 50
22B-D4P0N104 1.5 (2.0) 4.0 342-528 4.0 5.7 10 140M-C2E-B63 100-C09 70
22B-D6P0N104 2.2 (3.0) 6.0 342-528 5.9 7.5 15 140M-C2E-C10 100-C09 100
22B-D010N104 4.0 (5.0) 10.5 342-528 10.3 13.0 20 140M-C2E-C16 100-C23 160
22B-D012N104 5.5 (7.5) 12.0 342-528 11.8 14.2 25 140M-D8E-C20 100-C23 175
22B-D017N104 7.5 (10.0) 17.0 342-528 16.8 18.4 30 140M-D8E-C20 100-C23 210
22B-D024N104 11.0 (15.0) 24.0 342-528 23.4 26.0 50 140M-F8E-C32 100-C43 300
460 - 600V AC (±10%) – 3-Phase Input, 0 - 575V 3-Phase Output
22B-E1P7N104 0.75 (1.0) 1.7 414-660 2.1 2.3 6 140M-C2E-B25 100-C09 50
22B-E3P0N104 1.5 (2.0) 3.0 414-660 3.65 3.8 6 140M-C2E-B40 100-C09 70
22B-E4P2N104 2.2 (3.0) 4.2 414-660 5.2 5.3 10 140M-C2E-B63 100-C09 100
22B-E6P6N104 4.0 (5.0) 6.6 414-660 8.1 8.3 15 140M-C2E-C10 100-C09 160
22B-E9P9N104 5.5 (7.5) 9.9 414-660 12.1 11.2 20 140M-C2E-C16 100-C16 175
22B-E012N104 7.5 (10.0) 12.2 414-660 14.9 13.7 25 140M-C2E-C16 100-C23 210
22B-E019N104 11.0 (15.0) 19.0 414-660 23.1 24.1 40 140M-D8E-C25 100-C30 300
(1) 200-240V AC - 1-Phase drives are also available with an integral EMC filter. Catalog suffix
changes from N104 to N114.
(2) Refer to the Bulletin 140M Motor Protectors Selection Guide, publication 140M-SG001… to
determine the frame and breaking capacity required for your application.

English-4
Input/Output Ratings Approvals
Output Frequency: 0-400 Hz (Programmable)
Efficiency: 97.5% (Typical)
Digital Control Inputs (Input Current = 6mA) Analog Control Inputs
SRC (Source) Mode:
18-24V = ON
0-6V = OFF
SNK (Sink) Mode:
0-6V = ON
18-24V = OFF
4-20mA Analog: 250 ohm input impedance
0-10V DC Analog: 100k ohm input impedance
External Pot: 1-10k ohms, 2 Watt minimum
Control Output
Programmable Output (form C relay)
Resistive Rating: 3.0A at 30V DC, 3.0A at 125V AC, 3.0A at 240V AC
Inductive Rating: 0.5A at 30V DC, 0.5A at 125V AC, 0.5A at 240V AC
Opto Outputs
30V DC, 50mA
Non-inductive
Analog Outputs (10 bit)
0-10V, 1k ohm Min.
4-20mA, 525 ohm Max.
Fuses and Circuit Breakers
Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.
Recommended Circuit Breakers: HMCP circuit breakers or equivalent.
Protective Features
Motor Protection: I2t overload protection - 150% for 60 Secs, 200% for 3 Secs (Provides Class 10 protection)
Overcurrent: 200% hardware limit, 300% instantaneous fault
Over Voltage: 100-120V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 150V AC incoming line)
200-240V AC Input – Trip occurs at 405V DC bus voltage (equivalent to 290V AC incoming line)
380-460V AC Input – Trip occurs at 810V DC bus voltage (equivalent to 575V AC incoming line)
460-600V AC Input – Trip occurs at 1005V DC bus voltage (equivalent to 711V AC incoming line)
Under Voltage: 100-120V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 75V AC incoming line)
200-240V AC Input – Trip occurs at 210V DC bus voltage (equivalent to 150V AC incoming line)
380-480V AC Input – Trip occurs at 390V DC bus voltage (equivalent to 275V AC incoming line)
460-600V AC Input – If P042 = 3 “High Voltage” trip occurs at 487V DC bus voltage (344V AC incoming line);
If P042 = 2 “Low Voltage” trip occurs at 390V DC bus voltage (275V AC incoming line)
Control Ride Through: Minimum ride through is 0.5 Secs - typical value 2 Secs
Faultless Power Ride Through: 100 milliseconds
Dynamic Braking
Internal brake IGBT included with all ratings except No Brake versions. Refer to Appendix B of the PowerFlex 40 User Manual
on CD for DB resistor ordering information.
UL
®
L
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T
E
D
9
6
6
X
I
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D
C
O
N
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Q
UL508C
UL
®
L
I
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9
6
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CSA 22.2
EMC Directive 89/336
LV: EN 50178, EN 60204
EMC: EN 61800-3, EN 50081-1, EN 50082-2

English-5
Power Terminal Block
Power Terminal Block Specifications
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
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.
Frame Maximum Wire Size (2) Minimum Wire Size (2) To rq ue
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.)
(2) Maximum/minimum sizes that the terminal block will accept - these are not
recommendations.
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

English-6
Input Power Conditions
I/O Terminal Block Specifications
Refer to the PowerFlex 40 User Manual on CD for maximum power and
control cable length recommendations.
Input Power Condition Corrective Action
Low Line Impedance (less than 1% line reactance) •Install Line Reactor(1)
•or Isolation Transformer
•or Bus Inductor – 5.5-11 kW
(7.5-15 HP) drives only
(1) Refer to Appendix B of the PowerFlex 40 User Manual on CD 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) •Install Line Reactor
I/O Wiring Recommendations (2)
Wire Type(s)(3) Description Minimum Insulation
Rating
Belden 8760/9460
(or equiv.)
0.8 mm2(18 AWG), twisted pair, 100% shield
with drain. 300V
60 degrees C
(140 degrees F)
Belden 8770
(or equiv.)
0.8 mm2(18AWG), 3 conductor, shielded for
remote pot only.
(2) 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.
(3) Standed or solid wire.
Frame Maximum Wire Size (4) Minimum Wire Size (4) Torque
B & C 1.3 mm2(16 AWG) 0.13 mm2(26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)
(4) Maximum / minimum that the terminal block will accept - these are not
recommendations.

English-7
Control Wiring Block Diagram
(1) Important: I/O Terminal 01 is always a coast to stop
input except when P036 [Start Source] is set to
“3-Wire” 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) 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 jumper is removed, I/O Terminal 01 will always act as a hardware enable, causing
a coast to stop. Refer to the PowerFlex 40 User Manual on CD for more information.
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)(4)
Start/Run FWD (2)
Direction/Run REV
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
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 (4)
Jumper
30V DC
50mA
Non-inductive
Common
24V
ENBL Enable (4)
Jumper
(3)
Pot must be
1-10k ohm
2 Watt Min.
0-10V
0/4-20mA
Analog Output Select
SRCSNK
30V DC 125V AC 240V AC
Resistive 3.0A 3.0A 3.0A
Inductive 0.5A 0.5A 0.5A
P036 [Start Source] Stop I/O Terminal 01 Stop
Keypad Per P037 Coast
3-Wire Per P037 Per P037
2-Wire Per P037 Coast
RS485 Port Per P037 Coast

English-8
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 Command comes from the integral keypad by default.
To disable reverse operation, see A095 [Reverse
Disable].
P036, P037
03 Direction/Run REV Not Active P036, P037,
A095
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 (4) on page 7.
(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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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 7 for location.
Important: The default control scheme is Source (SRC). The Stop
terminal is jumpered (I/O Terminals 01 and 11) to allow
starting from the keypad. 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.
❏7. Familiarize yourself with the integral keypad features (see next page)
before setting any Program Group parameters.
Start, Stop, Direction and Speed Control
Factory default parameter values allow the drive to be controlled from
the integral keypad. No programming is required to start, stop, change
direction and control speed directly from the integral keypad.
Important: To disable reverse operation, see A095 [Reverse Disable].
If a fault appears on power up, refer to page 17 for an explanation of the
fault code. For complete troubleshooting information, refer to the
PowerFlex 40 User Manual on the CD supplied with the drive.
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.

English-10
Integral Keypad
No. LED LED State Description
➊Run/Direction
Status
Steady Red Indicates drive is running and commanded motor direction.
Flashing Red Drive has been commanded to change direction. Indicates
actual motor direction while decelerating to zero.
➋Alphanumeric
Display
Steady Red Indicates parameter number, parameter value, or fault code.
Flashing Red Single digit flashing indicates that digit can be edited.
All digits flashing indicates a fault condition.
➌Displayed Units Steady Red Indicates the units of the parameter value being displayed.
➍Program Status Steady Red Indicates parameter value can be changed.
➎Fault Status Flashing Red Indicates drive is faulted.
➏Pot Status Steady Green Indicates potentiometer on Integral Keypad is active.
➐Start Key Status Steady Green Indicates Start key on Integral Keypad is active.
The Reverse key is also active unless disabled by A095
[Reverse Disable].
No. Key Name Description
➑Escape Back one step in programming menu.
Cancel a change to a parameter value and exit Program
Mode.
Select Advance one step in programming menu.
Select a digit when viewing parameter value.
Up Arrow
Down Arrow
Scroll through groups and parameters.
Increase/decrease the value of a flashing digit.
Enter Advance one step in programming menu.
Save a change to a parameter value.
➒Potentiometer Used to control speed of drive. Default is active.
Controlled by parameter P038.
Start Used to start the drive. Default is active.
Controlled by parameter P036.
Reverse Used to reverse direction of the drive. Default is active.
Controlled by parameters P036 and A095.
Stop Used to stop the drive or clear a fault.
This key is always active.
Controlled by parameter P037.
FAULT
VOLTS
AMPS
HERTZ
RUN
FWD
REV
PROGRAM
➊➋
➍
➏
➒
➎
Menu Description
Display Group (View Only)
Consists of commonly viewed drive operating
conditions.
Basic Program Group
Consists of most commonly used
programmable functions.
Advanced Program Group
Consists of remaining programmable functions.
Fault Designator
Consists of list of codes for specific fault
conditions. Displayed only when fault is present.
➌
➑
➐