Allen-Bradley PowerFlex 400 Operator's manual

Quick Start

PowerFlex 400 Adjustable

Frequency AC Drive

FRN 4.xx

This Quick Start guide summarizes the basic steps needed to install,

start-up and program the PowerFlex 400 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 400 information including EMC instructions,

application considerations and related precautions refer to the

PowerFlex 400 User Manual, Publication 22C-UM001… 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.

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.

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English-2 PowerFlex 400 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: An incorrectly applied or installed drive can result in

component damage or a reduction in product life. Wiring or application

errors, such as, undersizing the motor, incorrect or inadequate AC

supply, or excessive ambient temperatures may result in malfunction of

the system.

ATTENTION: The bus regulator function is extremely useful for

preventing nuisance overvoltage faults resulting from aggressive

decelerations, overhauling loads, and eccentric loads. However, it can

also cause either of the following two conditions to occur.

1. Fast positive changes in input voltage or imbalanced input voltages

can cause uncommanded positive speed changes;

2. Actual deceleration times can be longer than commanded

deceleration times

However, a “Stall Fault” is generated if the drive remains in this state

for 1 minute. If this condition is unacceptable, the bus regulator must be

disabled (see parameter A187).

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.)

Frame Enclosure Rating Temperature Range Minimum Mounting

Clearances

C IP 20/UL Open-Type -10° to 45°C (14° to 113°F) Figure 1: Option A

IP 30/NEMA 1/UL Type 1(1)

(1) Frame C drives require installation of the PowerFlex 400 IP 30/NEMA 1/UL Type 1

option kit to achieve this rating.

-10° to 45°C (14° to 113°F) Figure 1: Option B

IP 20/UL Open-Type -10° to 50°C (14° to 122°F) Figure 1: Option B

D, E, F IP 30/NEMA 1/UL Type 1 -10° to 45°C (14° to 113°F) Figure 2:

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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-3

Minimum Mounting Clearances

Figure 1: Frame C Mounting Clearances

Figure 2: Frames D, E and F Mounting Clearances

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

120 mm

(4.7 in.)

25 mm

(1.0 in.)

Mounting Option B

Mounting Option A

No clearance required

between drives.

150 mm

(6.0 in.)

150 mm

(6.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

250 mm

(9.8 in.)

150 mm

(6.0 in.)

50 mm

(2.0 in.)

50 mm

(2.0 in.)

Frame D & E Frame F

General Grounding Requirements

Required

Input Fusing

Required Branch

Circuit Disconnect

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English-4 PowerFlex 400 Adjustable Frequency AC Drive Quick Start

Ungrounded Distribution Systems

Phase to Ground MOV Removal

Note: Frame D drives do not contain a MOV to ground connection and

are suitable for operation in both grounded and ungrounded distribution

systems without modification.

Refer to the PowerFlex 400 User Manual supplied with the drive for

details on how to comply with the Low Voltage (LV) and

Electromagnetic Compatibility (EMC) Directives.

EMC Line Filters

ATTENTION: PowerFlex 400 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.

Frame C Frame E & F

R/L1

S/L2

T/L3

1234

Important:

Tighten screw after

jumper removal.

CE Conformity

240V 50/60 Hz 3-Phase 480V 50/60 Hz 3-Phase

kW HP

Catalog

Number kW HP

Catalog

Number

2.2 3.0 22-RF034-CS 2.2 3.0 22-RF018-CS

4.0 5.0 22-RF034-CS 4.0 5.0 22-RF018-CS

5.5 7.5 22-RF034-CS 5.5 7.5 22-RF018-CS

7.5 10 22-RF034-CS 7.5 10 22-RF018-CS

11 15 22-RFD070 11 15 22-RF026-CS

15 20 22-RFD100 15 20 22-RFD036

18.5 25 22-RFD100 18.5 25 22-RFD050

22 30 22-RFD150 22 30 22-RFD050

30 40 22-RFD150 30 40 22-RFD070

37 50 22-RFD180 37 50 22-RFD100

45 60 22-RFD100

55 75 22-RFD150

75 100 22-RFD180

90 125 Consult Factory

110 150 Consult Factory

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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-5

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

(1)

140M Motor

Protectors

(2) (3) Contactors

Min.

Enclosure

Volume(4)

(in.3)IP20 Open

Watts50°C

200 - 240V AC – 3-Phase Input, 0 - 230V 3-Phase Output

22C-B012N103 2.2 (3.0) 12 180-265 6.5 15.5 20 140M-F8E-C16 100-C23 5098 146

22C-B017N103 3.7 (5.0) 17.5 180-265 8.8 21 30 140M-F8E-C25 100-C37 5098 207

22C-B024N103 5.5 (7.5) 24 180-265 10.9 26.1 35 140M-F8E-C32 100-C37 5098 266

22C-B033N103 7.5 (10) 33 180-265 14.4 34.6 45 140M-F8E-C45 100-C45 5098 359

22C-B049A103 11 (15) 49 180-265 21.3 51 70 – 100-C60 – 488

22C-B065A103 15 (20) 65 180-265 28.3 68 90 – 100-C85 – 650

22C-B075A103 18.5 (25) 75 180-265 32.5 78 100 – 100-D95 – 734

22C-B090A103 22 (30) 81 180-265 38.3 92 125 – 100-D110 – 778

22C-B120A103 30 (40) 120 180-265 51.6 124 175 – 100-D180 – 1055

22C-B145A103 37 (50) 130 180-265 62.4 150 200 – 100-D180 – 1200

380 - 480V AC – 3-Phase Input, 0 - 460V 3-Phase Output

22C-D6P0N103 2.2 (3.0) 6 340-528 6.3 7.5 10 140M-D8E-C10 100-C09 5098 105

22C-D010N103 4.0 (5.0) 10.5 340-528 10.9 13 20 140M-D8E-C16 100-C16 5098 171

22C-D012N103 5.5 (7.5) 12 340-528 11.9 14.2 20 140M-D8E-C16 100-C23 5098 200

22C-D017N103 7.5 (10) 17 340-528 15.3 18.4 25 140M-D8E-C20 100-C23 5098 267

22C-D022N103 11 (15) 22 340-528 19.2 23 30 140M-F8E-C32 100-C30 5098 329

22C-D030N103 15 (20) 27 340-528 25.8 31 40 140M-F8E-C32 100-C37 5098 435

22C-D038A103 18.5 (25) 38 340-528 33.3 40 50 140M-F8E-C45 100-C60 9086 606

22C-D045A103 22 (30) 45.5 340-528 39.1 47 60 – 100-C60 – 738

22C-D060A103 30 (40) 54 340-528 53.3 64 80 – 100-C85 – 664

22C-D072A103 37 (50) 72 340-528 60.7 73 100 – 100-C85 – 1019

22C-D088A103 45 (60) 88 340-528 74.9 90 125 – 100-D110 – 1245

22C-D105A103 55 (75) 105 340-528 89 107 150 – 100-D140 – 1487

22C-D142A103 75 (100) 128 340-528 124.8 150 200 – 100-D180 – 2043

22C-D170A103 90 (125) 170 340-528 142 170 250 – 100-D250 – 2617

22C-D208A103 110 (150) 208 340-528 167 200 250 – 100-D250 – 3601

(1) Recommended Fuse Type: UL Class J, CC, T or Type BS88; 600V (550V) or equivalent.

(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-6 PowerFlex 400 Adjustable Frequency AC Drive Quick Start

Category Specification

Agency

Certification

Listed to UL508C and CAN/CSA-22.2

Listed to UL508C for plenums

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

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: 405V DC bus voltage (equivalent to 290V AC

incoming line)

380-460V AC Input: 810V DC bus voltage (equivalent to 575V AC

incoming line)

Bus Undervoltage Trip: 200-240V AC Input: 210V DC bus voltage (equivalent to 150V AC

incoming line)

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:

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: 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 4-20mA

(1) Non-isolated, 0 to 10V or 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

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 (Drive Frames D, E & F Only)

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

CUS

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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-7

Figure 3: Power Terminal Blocks

Power Wiring

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 Drives)

P2, DC– DC Bus Connection (Frame D, E, and F 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.

R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3

R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 P2 P1

BR–BR+DC+DC–

R/L1S/L2T/L3 P1 P2 DC– U/T1

V/T2W/T3

R/L1 S/L2 T/L3 P1 P2 DC– U/T1 V/T2 W/T3

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English-8 PowerFlex 400 Adjustable Frequency AC Drive Quick Start

Power Terminal Block Specifications

Important: Frame C, D, and F drives utilize a finger guard over the

power wiring terminals. Replace the finger guard when

wiring is complete.

Refer to the PowerFlex 400 User Manual for maximum power cable

length recommendations.

Input Power Conditions

Frame Maximum Wire Size(1)

(1) Maximum/minimum sizes that the terminal block will accept - these are not

recommendations. If national or local codes require sizes outside this range, lugs may

be used.

Minimum Wire Size(1) Recommended

Torque

C 8.4 mm2(8 AWG) 1.3 mm2(16 AWG) 2.9 N-m (26 lb.-in.)

D 33.6 mm2(2 AWG) 8.4 mm2(8 AWG) 5.1 N-m (45 lb.-in.)

E 480V

37-45 kW

(50-60 HP)

33.6 mm2(2 AWG) 3.5 mm2(12 AWG) 5.6 N-m (49.5 lb.-in.)

E 240V

30-37 kW

(40-50 HP)

480V

55-75 kW

(75-100 HP)

107.2 mm2(4/0 AWG) 53.5 mm2(1/0 AWG) 19.5 N-m (173 lb.-in.)

F 152.5 mm2(300 MCM) 85.0 mm2(3/0 AWG) 19.5 N-m (173 lb.-in.)

Input Power Condition Corrective Action

Low Line Impedance (less than 1% line

reactance)

•Install Line Reactor(1)

•or Isolation Transformer

(1) Refer to the PowerFlex 400 User Manual for accessory ordering information.

Line has power factor correction capacitors •Install Line Reactor(1)

•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

(Frame C, E & F drives only)

•or Install Isolation Transformer with

grounded secondary if necessary

Ungrounded distribution system

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PowerFlex 400 Adjustable Frequency AC Drive Quick Start English-9

I/O Terminal Block Specifications

(2) Maximum/minimum sizes that the terminal block will accept - these are not

recommendations.

Refer to the PowerFlex 400 User Manual for maximum control cable

length recommendations.

I/O Wiring Recommendations

Wire Type(s) Description Minimum

Insulation Rating

Belden 8760/9460

(or equiv.)

0.8 mm2(18AWG), twisted pair, 100%

shield with drain.(1)

(1) 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

60 degrees C

(140 degrees F)

Belden 8770

(or equiv.)

0.8 mm2(18AWG), 3 conductor, shielded for

remote pot only.

Frame Maximum Wire Size (2) Minimum Wire Size (2) Torque

C, D, E, F 1.3 mm2(16 AWG) 0.13 mm2(26 AWG) 0.5-0.8 N-m (4.4-7 lb.-in.)

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English-10 PowerFlex 400 Adjustable Frequency AC Drive Quick Start

(1) Important: I/O Terminal 01 is always a coast to stop input

except when P036 [Start Source] is set to option 1 “3-Wire” or

6 “2-W Lvl/Enbl”. 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. If reverse is enabled by A166, 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 enable jumper is removed, I/O Terminal 01 will always act as a hardware enable, causing a

coast to stop without software interpretation.

(5) Most I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to

greatly reduce common mode interference. On Frame D and E drives, Analog Common 1 is referenced to

ground.

(6) Common for Analog Input 2 (AI2). Electronically isolated from digital I/O and opto output. Not to be used with

Analog Input 1 (AI1), Analog Output 1 (AO1) or Analog Output 2 (AO2). With Analog Input 2, provides one fully

isolated analog input channel.

Control Terminal Block

Digital Common

Digital Input 1

Digital Input 2

Digital Input 3

Stop/

Function Loss (1)(4)

Start/Run FWD (2)

Direction/Run REV

Digital Input 4

Opto Common

#1 Relay N.O.

#1 Relay Common

#1 Relay N.C.

+24V DC Source

+10V DC Source

Analog Input 1 (AI1)

Analog Common 1

Analog Output 2 (AO2)

Analog Output 1 (AO1)

Analog Input 2 (AI2)

Analog Common 2 (6)

Opto Output

RS485 Shield

+24V

+10V

#2 Relay N.O.

#2 Relay Common

#2 Relay N.C.

Typical

SNK Wiring

Typical

SRC Wiring

RS485

(DSI)

Enable (4)

Jumper

30V DC

50mA

Non-inductive

Common

24V

ENBL

(3)

Pot must be

1-10k ohm

2 Watt Min.

SRCSNK

SNK

SRC

Earth Referenced

Frames D & E (5)

0-10V

0-20mA

0-10V

0-20mA

0-10V

0-20mA

1 of 7 Digital Input Circuits

10V 20MA

AO1

10V 20MA

AO2

10V 20MA

AI1

10V 20MA

AI2

Isolated

P036 [Start Source] Stop I/O Terminal 01 Stop

Keypad Per P037 Coast

3-Wire Per P037 Per P037(4)

2-Wire Per P037 Coast

RS485 Port Per P037 Coast

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