Allen-Bradley PowerFlex400 User manual

Adjustable

Frequency AC

Drive for

Fan & Pump

Applications

FRN 4.xx

User Manual

www.abpowerflex.com

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.

PowerFlex is a registered trademark of Rockwell Automation, Inc.

DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.

PLC is a registered trademark of Rockwell Automation, Inc.

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.

Summary of Changes

Manual Updates

The information below summarizes the changes to the PowerFlex 400

User Manual since the August 2005 release.

New Parameter

The following new parameter has been added with the release of

Firmware Release Number (FRN) 4.xx.

Description of New or Updated Information See Page(s)

Important statement regarding differences in parameter defaults for

packaged drives added to parameter P041 [Reset To Defalts].

3-11

Important statement regarding related parameter added to parameter

A167 [Flying Start En].

3-37

Parameter Name Parameter Number See Page(s)

[Motor NP FLA] A200 3-46

soc-2

Manual Updates

The information below summarizes the changes to the PowerFlex 400

User Manual since the April 2005 release.

New Parameters

The following new parameters have been added with the release of

Firmware Release Number (FRN) 3.xx.

Description of New or Updated Information See Page(s)

Attention statement clarified. 1-6

Min/Max wire sizes for Frame F corrected. 1-15

Note added regarding the function of I/O Terminal 18, Analog Common 2. 1-17

Connection Examples corrected for Analog Input and Analog Output. 1-20

Required filters corrected for 380-480V, 2.2-11 kW (3.0-15 HP) drives in

First Environment Unrestricted.

1-28

Important statement regarding differences in parameter defaults for

packaged drives added to parameter P041 [Reset To Defalts].

3-11

Fault F64 Drive Overload description corrected. 4-4

Overcurrent protection for hardware limit and instantaneous fault levels

corrected.

A-3

Max storage temperatures corrected to 70 degrees C (158 degrees F). A-3

Max and Actual Short Circuit Ratings added to Electrical specification. A-4

Optional Relay specifications added. A-5

Supported communication protocols expanded. A-5

Watts Loss table added. A-6

Power Structure detail added to Appendix A. A-7

Appendix D provides setup information for Damper Control, PID Control,

and Auxiliary Control schemes.

D-1

Appendix G, P1 network protocol added. G-1

Parameter Name Parameter Number See Page(s)

[Motor OL Ret] P043 3-11

[Anlg Loss Delay] T088 3-26

[Start Source 2] C108 3-29

[Speed Ref 2] C109 3-30

Table of Contents

Preface Overview

Who Should Use this Manual? . . . . . . . . . P-1

Reference Materials . . . . . . . . . . . . . . . . . P-1

Manual Conventions . . . . . . . . . . . . . . . . . P-2

Drive Frame Sizes . . . . . . . . . . . . . . . . . . . P-2

General Precautions . . . . . . . . . . . . . . . . . P-3

Catalog Number Explanation . . . . . . . . . . P-4

Chapter 1 Installation/Wiring

Opening the Cover . . . . . . . . . . . . . . . . . . 1-1

Mounting Considerations . . . . . . . . . . . . . 1-4

AC Supply Source Considerations . . . . . . 1-6

General Grounding Requirements . . . . . . 1-8

Fuses and Circuit Breakers . . . . . . . . . . . . 1-9

Power Wiring . . . . . . . . . . . . . . . . . . . . . 1-11

I/O Wiring Recommendations . . . . . . . . 1-15

Start and Speed Reference Control . . . . . 1-24

RS485 Network Wiring. . . . . . . . . . . . . . 1-26

EMC Instructions . . . . . . . . . . . . . . . . . . 1-27

FCC Instructions . . . . . . . . . . . . . . . . . . . 1-29

Chapter 2 Start Up

Prepare For Drive Start-Up . . . . . . . . . . . . 2-1

Integral Keypad . . . . . . . . . . . . . . . . . . . . . 2-3

Viewing and Editing Parameters. . . . . . . . 2-5

Keypad Hand-Off-Auto Functions . . . . . . 2-6

Chapter 3 Programming and Parameters

About Parameters . . . . . . . . . . . . . . . . . . . 3-1

Parameter Organization. . . . . . . . . . . . . . . 3-2

Basic Display Group . . . . . . . . . . . . . . . . . 3-4

Basic Program Group . . . . . . . . . . . . . . . . 3-7

Terminal Block Group. . . . . . . . . . . . . . . 3-12

Communications Group . . . . . . . . . . . . . 3-27

Advanced Program Group. . . . . . . . . . . . 3-31

Aux Relay Card Group . . . . . . . . . . . . . . 3-47

Advance Display Group . . . . . . . . . . . . . 3-52

Parameter Cross-Reference – by Name . 3-58

Chapter 4 Troubleshooting

Drive Status . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fault Descriptions . . . . . . . . . . . . . . . . . . . 4-3

Common Symptoms and

Corrective Actions . . . . . . . . . . . . . . . . . 4-5

2Table of Contents

Appendix A Supplemental Drive Information

Drive, Fuse & Circuit Breaker Ratings . . . A-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . A-2

Input Power Connections. . . . . . . . . . . . . . A-7

Appendix B Accessories and Dimensions

Product Selection. . . . . . . . . . . . . . . . . . . . B-1

Product Dimensions. . . . . . . . . . . . . . . . . . B-7

Appendix C RJ45 DSI Splitter Cable

Appendix D Application Notes

Damper Control Setup. . . . . . . . . . . . . . . . D-1

PID Setup. . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Auxiliary Motor Control Setup . . . . . . . . D-11

Appendix E Modbus RTU Protocol

Network Wiring . . . . . . . . . . . . . . . . . . . . . E-1

Parameter Configuration . . . . . . . . . . . . . . E-2

Supported Modbus Function Codes . . . . . E-2

Writing (06) Logic Command Data. . . . . . E-3

Writing (06) Reference . . . . . . . . . . . . . . . E-3

Reading (03) Logic Status Data. . . . . . . . . E-4

Reading (03) Feedback . . . . . . . . . . . . . . . E-4

Reading (03) Drive Error Codes . . . . . . . . E-5

Reading (03) and Writing (06) Drive

Parameters . . . . . . . . . . . . . . . . . . . . . . . E-5

Additional Information . . . . . . . . . . . . . . . E-5

Appendix F Metasys N2

Understanding Metasys N2 . . . . . . . . . . . . F-1

Network Points . . . . . . . . . . . . . . . . . . . . . F-3

Using Percent (%) for the Reference . . . . . F-5

Using Metasys Configurable Objects to Access

Parameters . . . . . . . . . . . . . . . . . . . . . . . F-6

Appendix G P1 – Floor Level Network (FLN)

Understanding P1-FLN . . . . . . . . . . . . . . . G-1

Network Points . . . . . . . . . . . . . . . . . . . . . G-2

Using Percent (%) for the Reference. . . . . G-6

Using P1 Configurable Points to Access

Parameters . . . . . . . . . . . . . . . . . . . . . . . G-7

Index

Preface

Overview

The purpose of this manual is to provide you with the basic information

needed to install, start-up and troubleshoot the PowerFlex 400

Adjustable Frequency AC Drive.

This manual is intended for qualified personnel. You must be able to

program and operate Adjustable Frequency AC Drive devices. In

addition, you must have an understanding of the parameter settings and

functions.

The following manuals are recommended for general drive information:

For information on… See page…

Who Should Use this Manual? P-1

Reference Materials P-1

Manual Conventions P-2

Drive Frame Sizes P-2

General Precautions P-3

Catalog Number Explanation P-4

Who Should Use this Manual?

Reference Materials

Title Publication Available Online at …

Wiring and Grounding

Guidelines for Pulse Width

Modulated (PWM) AC Drives

DRIVES-IN001…

www.rockwellautomation.com/

literature

Preventive Maintenance of

Industrial Control and Drive

System Equipment

DRIVES-TD001…

Safety Guidelines for the

Application, Installation and

Maintenance of Solid State

Control

SGI-1.1

A Global Reference Guide for

Reading Schematic Diagrams

100-2.10

P-2 Overview

•In this manual we refer to the PowerFlex 400 Adjustable Frequency

AC Drive as; drive, PowerFlex 400 or PowerFlex 400 Drive.

•Parameter numbers and names are shown in this format:

•The following words are used throughout the manual to describe an

action:

Similar PowerFlex 400 drive sizes are grouped into frame sizes to

simplify spare parts ordering, dimensioning, etc. A cross reference of

drive catalog numbers and their respective frame sizes is provided in

Appendix B.

Manual Conventions

P031 [Motor NP Volts]

Name

Number

Group

b = Basic Display Group

P = Basic Program Group

T = Terminal Block Group

C = Communications Group

A = Advanced Program Group

R = Aux Relay Card Group

d = Advanced Display Group

Word Meaning

Can Possible, able to do something

Cannot Not possible, not able to do something

May Permitted, allowed

Must Unavoidable, you must do this

Shall Required and necessary

Should Recommended

Should Not Not Recommended

Drive Frame Sizes

Overview P-3

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.

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). In addition, installing a properly sized

dynamic brake resistor will provide equal or better performance in most

cases.

P-4 Overview

Catalog Number Explanation

Code Vo l ta g e Ph.

B 240V AC 3

D 480V AC 3

Code Version

3 RS485

Code Interface Module

1 Fixed Keypad

Code Enclosure

N Panel Mount - IP20/UL Open-Type(1)

A Panel Mount - IP30/NEMA 1/UL Type 1(2)

F Flange Mount - IP20/UL Open Type(3)

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

22C - D 038 A 1 0 3

Drive Dash Voltage Rating Rating Enclosure HIM Emission Class Comm Slot

Output Current @ 200-240V 60Hz 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

Code Rating

0 Not Filtered

Output Current @ 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

Code

22C PowerFlex 400

(1) Frame C drives only available with IP20/UL Open-Type enclosure. Field installed conversion kit available

to achieve IP30/NEMA 1/UL Type 1 rating.

(2) Frame D, E and F drives only available with IP30/NEMA 1/UL Type 1 enclosure.

(3) Frame C drives only.

Additional accessories, options and adapters are available. See Appendix B for details.

Table of contents

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