Allen-Bradley PowerFlex 400 Instruction manual

RGB ELEKTRONIKA AGACIAK CIACIEK

SPÓŁKA JAWNA

Jana Dlugosza 2-6 Street

51-162 Wrocław

Poland

biuro@rgbelektronika.pl

+48 71 325 15 05

www.rgbautomatyka.pl

www.rgbelektronika.pl

DATASHEET

www.rgbautomatyka.pl

www.rgbelektronika.pl

OTHER SYMBOLS:

22-RFD050

22RFD050, 22 RFD050, 22-RFD050

ALLEN BRADLEY

YOUR

PARTNER IN

MAINTENANCE

At our premises in Wrocław, we have a fully equipped servicing facility. Here we perform all the repair

works and test each later sold unit. Our trained employees, equipped with a wide variety of tools and

having several testing stands at their disposal, are a guarantee of the highest quality service.

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PowerFlex®400

AdjustableFrequency

AC Drives for Fan &

Pump Applications

Technical Data

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Product Description

Providing users with easy installation in mechanical fan and

pump systems, the Allen-Bradley PowerFlex® 400 AC drive

offers a wide range of built-in features allowing for seamless

building system integration. Available in power ratings of 3.0-

350HP @ 480VAC and 3.0-50HP @ 240V AC, the PowerFlex 400

is designed to meet global OEM, contractor and end-user

demands for flexibility, space savings and ease-of-use. The

PowerFlex 400 is a cost-effective solution for speed control in

variable torque fan and pump applications.

Table of Contents

Description Page

PowerFlex 400 Standard Product

Product Overview

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Operator Keypad and Programming . . . . . . . . . . . . . . . . . . . . . . 3

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PC Programming Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Application Features

Configurable Keypad Hand-Off-Auto Functions . . . . . . . . . . . . . 5

Connectivity to Building Fire and Life Safety Systems. . . . . . . . 5

Proportional, Integral, Differential Control Loop . . . . . . . . . . . . 6

Product Selection Guide

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PowerFlex 400 Standard Drives . . . . . . . . . . . . . . . . . . . . . . . . . 9

User Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation Considerations

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Specifications

Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Parameter List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

PowerFlex 400 Packaged Product

Packaged Product Overview

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Main Input Disconnect / Circuit Breaker . . . . . . . . . . . . . . . . . 35

3 Contactor Full Feature Bypass with Disconnect / Circuit Breaker35

3 Contactor Basic Bypass with Disconnect . . . . . . . . . . . . . . . 35

Product Selection Guide

Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . 36

PowerFlex 400 NEMA/UL Type 1 Enclosure (Position d = A) . . 37

Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Product Overview

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Packaging

•IP20, NEMA/UL Type 1 - For conventional mounting inside or

outside a control cabinet in a 45°C (113°F) ambient.

•Flange Type - Frame C ratings through 15 kW (20 HP) @ 380-

480V AC and 7.5 kW (10 HP) @ 200-240V AC allow for mounting

heatsink through back of an enclosure, thus removing a large

portion of the heat inside a cabinet. The backside is rated IP66,

NEMA/UL Type 4X/12 for both indoor and outdoor use.

• Installation flexibility is enhanced by the UL Plenum rating

allowing for direct mounting in an air handling system.

I/O

• Three (3) semi-programmable and four (4) fully programmable

digital inputs provide application versatility.

• Two (2) programmable form C relay outputs and one (1) opto

output can be used to indicate various drive or motor conditions.

• Two (2) analog outputs are DIP Switch selectable for either

voltage (0-10V) or current (0-20 mA). These scalable, 10-bit

outputs are suitable for metering or as a speed reference for

another drive.

• Two (2) analog inputs (one unipolar and one bipolar) are DIP

switch selectable for either voltage or current. One input is

isolated from the rest of the drive I/O.

• Six (6) programmable form A relay outputs are available via user

installed Auxiliary Relay Board (Frames D through H only).

Operator Keypad and Programming

• Integral keypad features 2 line, 16 character LCD display.

• LED indicators provide system configuration and fault status.

• Configurable Hand/Off/Auto function buttons.

• Digital increase/decrease speed control.

• Parameter names are displayed as text.

• Parameters are grouped into files based upon function, making

programming fast and easy.

Function Loss

Run/FWD

Software Enable

Digital Common

Digital Input 1 (Purge)

Digital Input 2 (Local)

Digital Input 3 (Clear Fault)

Digital Input 4 (Comm Port)

Digital Common

Opto Common

+ 24VDC

+ 10VDC

Analog Input #1

Analog Common #1

Analog Output #1 (Frequency 0-10V)

Analog Output #2 (Output Current 0-10V)

Analog Input #2

Analog Common #2

Opto Output (At Frequency)

RJ-45 Shield

#1 Relay N.O. (Ready/Fault)

#1 Relay Common

#1 Relay N.C.

#2 Relay N.O. (Motor Running)

#2 Relay Common

#2 Relay N.C.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 R1 R2 R3 R4 R5 R6

AO1

10V 20MA AO2

10V 20MA AI1

10V 20MA AI2

10V 20MA SNK

SRC

Control Board

Hand Auto

Purge

Interlocks

Auto Start

Freeze/Fire

Stats + –

Speed Ref. Input

Product Overview

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Communications

• Supports Drive Serial Interface (DSI)

communication modules (DeviceNet™,

EtherNet/IP™, PROFIBUS™DP,

LonWorks®, BACnet®) and accessories.

• Embedded Modbus RTU, P1-FLN and

Metasys N2 protocols are parameter

selectable and require no additional

hardware or software.

•Integral RS485 communications can be

used for programming from a PC. It can also

be used in a multi-drop network

configuration. A serial converter module

provides connectivity to any controller with a

DF1 port.

PC Programming Software

Through the use of a Serial Converter Module and DriveExplorer™

or DriveTools™SP software, programming can be greatly simplified.

DriveExplorer Software

• View and modify drive and adapter parameters in a method similar to

the file management capability of Microsoft Windows Explorer.

• Operate the drive via an on-screen Control Bar, which is a tool that

allows you to start, stop, and change the speed reference of the drive.

• Save, restore and print parameter information.

• Compare current parameters with factory defaults or previously saved

parameter values.

• Edit, upload and download parameters.

DriveTools SP Software

• Online and offline programming capability.

• In-grid and dialog-based parameter editing.

• Immediate visual indication of drive and communication status when

viewing online drive.

• Integrated HTML Help architecture.

Application Features

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Configurable Keypad Hand-Off-Auto Functions

Parameter P042 [Auto Mode] defines the operating configuration of the

control keys.

Hand-Off-Auto Configuration

Hand Mode: Start command and speed reference come from the integral

keypad. Auto key switches control from Hand mode to Auto

mode in a bumpless transfer as long as there is an active run

command.

Auto Mode: Start command is defined by P036 [Start Source] (keypad,

terminal block, comm port) and speed reference is defined

by P038 [Speed Reference] (analog inputs, preset frequency,

comm port). Start/Hand key switches control and speed

reference to the integral keypad in a bumpless transfer.

Local/Remote Configuration

Local Mode: Start command and speed reference come from the integral keypad. Auto key stops the drive and the drive

switches to Remote mode.

Remote Mode:Start command is defined by P036 [Start Source] and speed reference is defined by P038 [Speed

Reference]. Auto key stops the drive and the drive switches to Local mode.

Auto/Manual Configuration

Manual Mode:Start command is defined by P036 [Start Source] and the speed reference comes from the integral keypad.

Auto key toggles frequency control to Auto mode in a bumpless transfer.

Auto Mode: Start command is defined by P036 [Start Source] and speed reference is defined by P038 [Speed

Reference]. Auto key switches frequency control to the integral keypad in a bumpless transfer.

Connectivity to Building Fire and Life Safety Systems

Purge

The PowerFlex 400 drive has an input which can be wired to a fire control panel or other fire/life safety systems allowing

control of the drive to be overridden. A purge input will start the drive at a programmable purge speed regardless of the

selected start source. Purge can occur and is operational at any time whether the drive is running or stopped. A purge

command will take precedence over a stop command from the comm port/network and over a “SW Enable” command from

the terminal block.

Fire/Freeze Status

The PowerFlex 400 drive can be tied into fire alarm systems or interlocked with cooling coils via a “Function Loss” input on

the drive. Upon opening of the input, the drive will immediately coast to a stop if running and issue a fault. The drive will

only be allowed to restart once the alarm state is cleared and the drive fault is reset.

Application Features

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Proportional, Integral, Differential Control Loop

The PowerFlex 400 has a built-in PID (Proportional, Integral, Differential) control loop. The PID loop is used to maintain a

process variable, such as pressure or flow, at a desired set point. The PID loop works by subtracting the PID feedback from

a reference and generating an error value. The PID loop reacts to the error, based on the PID gains, and outputs a frequency

to try to reduce the error value to zero.

Damper Control

The PowerFlex 400 allows damper control logic to be imbedded within the drive reducing cost associated with external

control hardware and software. A system Run command can be wired directly into one of the drive inputs. Relay outputs

can be used to energize the damper to either open or close. A damper limit switch can be wired back to the drive providing

indication that the damper is in the proper position and that it is safe for the drive to run at commanded speed.

Return Fan

Supply Fan

Air Flow

Room Room Room

Heating

Cooling P

PID Feedback = Pressure Transducer Signal

PID Reference = Desired Static Pressure

Outside Air

Damper

Exhaust Air

Damper

Recirculation

Damper

Dampers

PID Feedback = Pressure Transducer SignalPID Reference = Output Frequency from Supply VFD

Supply Fan

Air Flow

Damper Limit Switch

Damper Position Command System Run Command

Outside Air

Damper

Product Selection Guide

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Auxiliary Motor Control

The PowerFlex 400 has a built in Auxiliary Motor Control feature. This feature allows operation of up to three (3) line-

started motors in addition to the motor controlled directly by the PowerFlex 400 drive. System output can vary from 0%

(auxiliary motors off and drive-controlled motor at zero speed) to 400% (3 auxiliary motors and drive-controlled motor at full

speed). When Auxiliary Motor Control is enabled, the internal PID controller in the PowerFlex 400 uses a reference and

feedback signal to adjust the speed of the drive controlled motor such that the feedback signal follows the reference

signal. When demand exceeds the first motors capacity, the PowerFlex 400 Auxiliary Motor Control automatically starts an

auxiliary motor. The speed of the drive controlled motor is reduced to account for the auxiliary motors additional output to

the system. If demand continues to increase, the PowerFlex Auxiliary Motor Control starts additional motors using the

same process. When demand decreases, an auxiliary motor is stopped and the PowerFlex Auxiliary Motor Control

increases the speed of the drive controlled motor to account for lost system output. A Motor Interlock input identifies

motors that are out of service and causes them to skipped over to the next available motor.

An AutoSwap function also can be used which allows equal wear to be placed on each motor by periodically swapping the

drive controlled and auxiliary motors. Each motor in the system will over time be connected to the PowerFlex 400 drive and

also directly to the AC line. During an AutoSwap, the motor directly connected to the PowerFlex 400 drive is stopped and

the contactor is opened. The contactor of the next motor that will be controlled by the PowerFlex 400 drive is opened if

running across the AC line. A contactor is closed connecting this motor directly to the PowerFlex 400 drive and is started.

An additional motor is line started if required.

PID Reference

PID Feedback

Three-Phase Power

M2L

M1 M2

M2L

PID Reference

PID Feedback

Three-Phase Power

One External Motor

without AutoSwap One External Motor

with AutoSwap

M1D

M1 M2

M2DM1D M2L

M1L

M2D

M2L

M1L

Product Selection Guide

For further information visit: www.abpowerflex.com or www.ab.com/support/abdrives

Catalog Number Explanation

Position Number

1-3 4 5 6-8 9 10 11 12

22C – D 038 A 1 0 3

a bcde f g

Drive

Code Type

22C PowerFlex 400

Voltage Rating

Code Voltage Ph.

B 240V ac 3

D 480V ac 3

Rating

200…240V 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

Rating

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

260 260 132 (200) G

310 310 160 (250) G

370 370 200 (300) H

460 460 250 (350) H

Enclosure

Code Enclosure

NPanel Mount - IP20,

NEMA/UL Type Open

APanel Mount - IP30,

NEMA/UL Type 1

FFlange Mount - IP20,

NEMA/UL Type Open ‡

Frame C drives only available with IP20,

NEMA/UL Type Open enclosure. Field installed

conversion kit available to achieve IP30,

NEMA/UL Type 1 rating.

Frame D, E and F drives only available with

IP30, NEMA/UL Type 1 enclosure.

‡ Frame C drives only.

HIM

Code Interface Module

1 Fixed Keypad

Emission Class

Code Rating

0 Not Filtered

Version

Code Version

3 RS485

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