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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•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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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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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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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

CUS

TUV

Rheinland

Product Safety

Production inspected

TUV

Rheinland

Functional

Safety

Bauart geprüft

Type approved

EN 50178

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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

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

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

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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