Allen-Bradley PowerFlex400 User Manual Download Page 1

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Adjustable
Frequency AC
Drive for
Fan & Pump
Applications

FRN 4.xx

User Manual

www.abpowerflex.com

Summary of Contents for PowerFlex400

Page 1: ...Adjustable Frequency AC Drive for Fan Pump Applications FRN 4 xx User Manual www abpowerflex com...

Page 2: ...bility 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...

Page 3: ...d 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...

Page 4: ...ent 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...

Page 5: ...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...

Page 6: ...ter 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 Cod...

Page 7: ...formation 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 Sho...

Page 8: ...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 Progra...

Page 9: ...wed 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 incor...

Page 10: ...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...

Page 11: ...See page For information on See page Opening the Cover 1 1 Fuses and Circuit Breakers 1 9 Mounting Considerations 1 4 Power Wiring 1 11 AC Supply Source Considerations 1 6 I O Wiring Recommendations 1...

Page 12: ...iring Frame D Drives 1 Loosen the two captive cover screws 2 Pull the bottom of the cover out and up to release Frame E Drives 1 Loosen the four captive cover screws 2 Pull the bottom of the cover out...

Page 13: ...Installation Wiring 1 3 Frame F Drives 1 Turn the latch counterclockwise 2 Pull on the latch to swing the door open...

Page 14: ...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 Se...

Page 15: ...move the panel for IP 20 Open Type applications Frame D E and F Drives These drives have built in debris protection Installation of a protective panel is not required Storage Store within an ambient t...

Page 16: ...Figure 1 4 Figure 1 3 Phase to Ground MOV Removal Figure 1 4 Jumper Location Note Frame D drives do not contain a MOV to ground connection and are suitable for operation in both grounded and unground...

Page 17: ...closest to the branch and sized to handle the total current of the branch circuit Table 1 A Input Power Conditions Input Power Condition Corrective Action Low Line Impedance less than 1 line reactanc...

Page 18: ...rounding points must comply with national and local industrial safety regulations and or electrical codes Motor Ground The motor ground must be connected to one of the ground terminals on the drive Sh...

Page 19: ...iodically checked The PowerFlex 400 does not provide branch short circuit protection This product should be installed with either input fuses or an input circuit breaker National and local industrial...

Page 20: ...16 100 C23 3 7 5 0 30 140M F8E C25 100 C37 5 5 7 5 35 140M F8E C32 100 C37 7 5 10 45 140M F8E C45 100 C45 11 15 70 140 CMN 6300 100 C60 15 20 90 140 CMN 9000 100 C85 18 5 25 100 140 CMN 9000 100 D95 2...

Page 21: ...d Armored Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical...

Page 22: ...ion of these types may limit the allowable cable length Particularly some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield This construction can greatly inc...

Page 23: ...ive is intended to be commanded by control input signals that will start and stop the motor A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and...

Page 24: ...n 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 Use...

Page 25: ...173 lb in I O Wiring Recommendations ATTENTION A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damag...

Page 26: ...rove noise immunity the I O terminal block Common must be connected to ground terminal protective earth If using the RS485 DSI port I O Terminal 20 should also be connected to ground terminal protecti...

Page 27: ...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...

Page 28: ...V External 0 10V unipolar 0 20mA or 4 20mA input supply or potentiometer wiper Default input is 0 10V For current mA input set AI1 DIP Switch to 20mA Program with T069 Analog In 1 Sel Input Impedance...

Page 29: ...election DIP Switches Analog Input AI1 AI2 Analog Output AO1 AO2 0 10V Sets analog output to either voltage or current Settings must match AI1 T069 Analog In 1 Sel AI2 T073 Analog In 2 Sel AO1 T082 An...

Page 30: ...Hi Check Results d306 Analog In 2 Analog Input Unipolar Speed Reference 0 to 10V Input DIP Switch AI1 10V Parameters P038 Speed Reference 2 Analog In1 T069 Analog In 1 Sel 2 0 10V Scaling T070 Analog...

Page 31: ...for the drive to run When input is opened the drive will stop as specified by P037 Stop Mode User supplied 24V DC power source must be used Each digital input draws 6 mA Drive will not run if I O Term...

Page 32: ...fault if I O Terminal 01 is open Drive will coast to stop if opened while running Requires drive reset once terminal is closed DIP Switch SNK SRC SRC Parameters P036 Start Source 6 2 W Lvl Enbl P037 S...

Page 33: ...on together for all drives If they are to be tied into another common such as earth ground or separate apparatus ground only one point of the daisy chain of I O Terminal 04 should be connected Multipl...

Page 34: ...Start and Speed commands come from Integral Keypad Direction is Forward unless an input is programmed for Cmd Reverse Analog Input 1 Override Enabled Active Digital Inx Sel 14 Analog Input 2 Override...

Page 35: ...P039 Accel Time 1 P040 Decel Time 1 or A147 Accel Time 2 A148 Decel Time 2 can be selected when RS485 DSI port is active Input is programmed as Acc Dec 2 Digital Inx Sel 18 No Yes A147 Accel Time 2 A1...

Page 36: ...y Modbus device manufacturers interpret them differently If you have problems with initially establishing communications try swapping the two network wires at the master controller On Drive Connection...

Page 37: ...electrical power drive systems Part 3 EMC product standard including specific test methods General Notes All Drive Frames The motor cable should be kept as short as possible in order to avoid electrom...

Page 38: ...red 11 15 B049A103 22 RFD070 150 Required Deltron MIF Series 50 Required 15 20 B065A103 22 RFD100 150 Required Deltron MIF Series 50 Required 18 5 25 B075A103 22 RFD100 150 Required Deltron MIF Series...

Page 39: ...otection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in a...

Page 40: ...22 RF034 CS 10 No 3 7 5 0 22C B017N103 22 RF034 CS 10 No 5 5 7 5 22C B024N103 22 RF034 CS 10 No 7 5 10 22C B033N103 22 RF034 CS 10 No 11 15 22C B049A103 22 RFD070 150 Required 15 20 22C B065A103 22 R...

Page 41: ...for 200 240V AC 11 22 kW 15 30 HP PowerFlex 400 drives R L1 S L2 T L3 U T1 V T2 W T3 EMI Fittings and Metal Conduit IP 30 NEMA 1 UL Type 1 Option Kit Frame C Drives Only Shielded Enclosure 1 Building...

Page 42: ...1 32 Installation Wiring Notes...

Page 43: ...trol 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 s...

Page 44: ...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 st...

Page 45: ...ment and Decrement Arrows Used to control speed of drive Default is active Control is activated by parameter P038 Speed Reference or P042 Auto Mode Run Start Hand 1 Used to start the drive Default is...

Page 46: ...is in Auto mode No Description Parameter Name Run Stop Status Stopped Running flashes to indicate that the drive is stopping but is still decelerating flashes when DC Injection is commanded Direction...

Page 47: ...Press the Up Arrow or Down Arrow to scroll through the group menu b P T C A and d 6 Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash 7 Press t...

Page 48: ...al keypad in a bumpless transfer and switches the speed reference to the integral keypad Stop key stops the drive and the drive switches to HAND mode Table 2 A P042 Auto Mode 1 Hnd Off Auto Default T0...

Page 49: ...mmand is defined by P038 Speed Reference Auto key stops the drive and the drive switches to Local mode Table 2 B P042 Auto Mode 2 Local Remote T051 T054 Digital Inx Sel 2 Auto Mode or 3 Local Importan...

Page 50: ...or 3 Local Important Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for details Manual Mode AUTO Mode Key LED Key Function LED Key...

Page 51: ...e 0 No Function T051 T054 Digital Inx Sel 2 Auto Mode or 3 Local Important Certain digital input settings can override drive operation Refer to Start and Speed Reference Control on page 1 24 for detai...

Page 52: ...2 10 Start Up Notes...

Page 53: ...These parameters have a single numerical value i e 0 1 Volts Bit Parameters Bit parameters have four or more individual bits associated with features or conditions If the bit is 0 the feature is off...

Page 54: ...ut2 Sel T085 Analog Out2 High T086 Analog Out2 Setpt T087 Anlg Loss Delay T088 Communications Language C101 Comm Format C102 Comm Data Rate C103 Comm Node Addr C104 Comm Loss Action C105 Comm Loss Tim...

Page 55: ...R249 Aux Start Delay R250 Aux Stop Delay R251 Aux Prog Delay R252 Aux AutoSwap TmeR253 Aux AutoSwap Lvl R254 Advanced Display Control Source d301 Contrl In Status d302 Comm Status d303 PID Setpnt Disp...

Page 56: ...rtant The frequency command can come from a number of sources Refer to Start and Speed Reference Control on page 1 24 for details Values Default Read Only Min Max 0 00 P035 Maximum Freq Display 0 01 H...

Page 57: ...de that represents a drive fault Fault 1 Code is the most recent fault Repetitive faults will only be recorded once Refer to Chapter 4 for fault code descriptions Values Default Read Only Min Max 0 12...

Page 58: ...0 9999 Hrs Display 1 10 Hrs b013 Torque Current Displays the torque portion of the output current Values Default Read Only Min Max 0 0 Drive Rated Amps 2 Display 0 1 Amps b014 Drive Temp Present oper...

Page 59: ...2 T055 T060 T065 A175 A179 A180 A181 A183 Set to the maximum allowable motor current The drive will fault on an F7 Motor Overload if the value of this parameter is exceeded by 150 for 60 seconds Value...

Page 60: ...01 Stop Coast to Stop I O Terminal 02 Run FWD I O Terminal 03 Run REV Drive will restart after a Stop command when Stop is removed and Run FWD is held active 4 2 W Hi Speed I O Terminal Block control...

Page 61: ...d by removing the ENBL enable jumper on the control board See page 1 17 for details In this case the drive will always coast to a stop regardless of the settings of P036 Start Source and P037 Stop Mod...

Page 62: ...function 2 Analog In 1 Default External frequency command from an analog source as determined by T069 Analog In 1 Sel and DIP Switch AI1 on the control board Default Dip Switch setting is 10V 3 Analo...

Page 63: ...pplications ship with custom default settings that differ from Factory Defaults Setting this parameter to option 1 will require reprogramming of select parameters Refer to publication 22C IN002 for pa...

Page 64: ...ypad as start source and digital speed keys on the integral keypad as speed source 4 Comm Port 1 T054 Default When active sets communication device as default start speed command source 5 PID Disable...

Page 65: ...ive A180 Current Limit 2 determines the drive current limit level 20 Force DC If the drive is not running applying this input causes the drive to apply a DC Holding current use A177 DC Brake Level ign...

Page 66: ...Volt Drive exceeds the DC bus voltage value set in T056 Relay Out1 Level Use T056 to set threshold 9 Above Anlg 2 Analog input voltage I O Terminal 17 exceeds the value set in T056 Relay Out1 Level Do...

Page 67: ...12 0 320 Hz 0 180 0 815 Volts 0 100 1 180 degs 0 1 T058 Relay 1 On Time Related Parameter s T055 T056 T059 Sets delay time before Relay energizes after required condition testing Values Default 0 0 S...

Page 68: ...ds the DC bus voltage value set in T061 Relay Out2 Level Use T061 to set threshold 9 Above Anlg 2 Analog input voltage I O Terminal 17 exceeds the value set in T061 Relay Out2 Level Do not use if T073...

Page 69: ...12 0 320 Hz 0 180 0 815 Volts 0 100 1 180 degs 0 1 T063 Relay 2 On Time Related Parameter s T060 T061 T064 Sets delay time before Relay energizes after required condition testing Values Default 0 0 S...

Page 70: ...nt 8 Above DCVolt Drive exceeds the DC bus voltage value set in T066 Opto Out Level Use T066 to set threshold 9 Above Anlg 2 Analog input voltage I O Terminal 17 exceeds the value set in T066 Opto Out...

Page 71: ...ote Setting output to NC may cause output to glitch on power up The off reset state of all outputs is open Values Default 0 Min Max 0 1 Display 1 T068 Option Opto Out Logic 0 1 NO Normally Open NC Nor...

Page 72: ...ency in the event the analog input is lost It is strongly recommended to activate T072 Analog In 1 Loss to protect from this potential occurrence Values Default 0 0 Min Max 0 0 100 0 Display 0 1 0 P03...

Page 73: ...s at A143 Preset Freq 0 T073 Analog In 2 Sel Related Parameter s P038 T055 T065 T074 T075 T076 A152 Sets the analog input signal mode 0 20mA 4 20mA 0 10V 10 to 10V This parameter must match DIP Switch...

Page 74: ...52 A153 Stop drive before changing this parameter Sets the analog input level that corresponds to P035 Maximum Freq Analog inversion can be accomplished by setting this value smaller than T074 Analog...

Page 75: ...function can cause unexpected machine operation during the Wake mode Equipment damage and or personal injury can result if this parameter is used in an inappropriate application In addition all applic...

Page 76: ...t 0 20 0 20 mA 0 mA 0 Volts 120 Drive Rated Output V None 20 mA b004 11 OutPowr 0 20 0 20 mA 0 mA 0 kW 200 Drive Rated Power Filter A 20 mA b010 12 Setpnt 0 20 0 20 mA 0 mA 0 0 100 0 Setting None 20 m...

Page 77: ...0 10 0 10V 0V 0000 65535 Hex FFFF None 10V A196 7 OutFreq 0 20 0 20 mA 0 mA 0 Hz Maximum Frequency None 20 mA b001 8 OutCurr 0 20 0 20 mA 0 mA 0 Amps 200 Drive Rated FLA Filter A 20 mA b003 9 OutTorq...

Page 78: ...18mA for 200 Drive Rated Power T087 Anlg Out2 Setpt Related Parameter s T085 T086 Sets direct parameter control over the analog output If enabled this sets the percent value of analog output Values D...

Page 79: ...port on the drive Refer to Appendix D and Appendix E for details on using the drive communication features Important Power to drive must be cycled before any changes will affect drive operation Option...

Page 80: ...ommanded speed saved in RAM 4 Run Preset 0 Drive will run at preset speed 5 Kypd Inc Dec Drive will run at keypad digital pot speed C106 Comm Loss Time Related Parameter s d303 C105 Sets the time that...

Page 81: ...Default I O Terminal Block controls drive operation I O Terminal 01 Stop Coast to Stop I O Terminal 02 Run FWD I O Terminal 03 Run REV Drive will restart after a Stop command when Stop is removed and...

Page 82: ...m A142 Internal Freq Must be set when using MOP function 2 Analog In 1 Default External frequency command from an analog source as determined by T069 Analog In 1 Sel and DIP Switch AI1 on the control...

Page 83: ...eter acts as the MOP frequency reference if P038 Speed Reference is set to 1 InternalFreq Values Default 60 00 Hz Min Max 0 00 320 00 Hz Display 0 01 Hz A143 Preset Freq 0 1 A144 Preset Freq 1 A145 Pr...

Page 84: ...00 600 00 Secs Display 0 01 Secs Maximum Freq Accel Time Accel Rate Speed 0 Time P035 Maximum Freq P039 or A147 Accel Time x P040 or A148 Decel Time x 0 A c c e le r a t io n D e c e le r a t io n A14...

Page 85: ...Total Time 10 5 15 Seconds 1 2 S Curve Time 2 5 Seconds Total Time to Accelerate Accel Time S Curve Time 50 S Curve Target Target 2 Accel Time 10 Seconds 1 2 S Curve Time 2 5 Seconds Total Time to Acc...

Page 86: ...ugh programming these two parameters If A152 PID Ref Sel is not set to zero PID can be disabled by programming a digital input A153 PID Feedback Sel Related Parameter s T070 T071 T074 T075 Select the...

Page 87: ...de is enabled by A152 PID Ref Sel Values Default 0 0 Min Max 0 0 100 0 Display 0 1 A158 PID Deadband Sets the lower limit of the PID output Values Default 0 0 Min Max 0 0 10 0 Display 0 1 A159 PID Pre...

Page 88: ...odes standards regulations or industry guidelines A164 Auto Rstrt Delay Related Parameter s A163 Sets the time between restart attempts when A163 Auto Rstrt Tries is set to a value other than zero Not...

Page 89: ...r NP FLA is set to the motor s actual full load amp value Options 0 Disabled Default 1 Enabled A168 PWM Frequency Related Parameter s A169 Sets the carrier frequency for the PWM output waveform The ch...

Page 90: ...0 50 1 2 Motor NP Volts 1 2 Motor NP Hertz 4 3 2 1 0 50 100 Settings 5 14 A174 Maximum Voltage can be set anywhere Settings greater than P031 Motor NP Volts define a point on the V Hz curve Settings l...

Page 91: ...tz P035 Maximum Freq A171 Start Boost P031 Motor NP Volts A174 Maximum Voltage A172 Break Voltage A034 Minimum Freq A172 Break Voltage Related Parameter s P031 P032 P034 P035 A170 A171 A173 A174 Sets...

Page 92: ...et to either 4 Ramp or 6 DC Brake Refer to parameter A177 DC Brake Level Values Default 0 0 Secs Min Max 0 0 99 9 Secs A setting of 99 9 Continuous Display 0 1 Secs A177 DC Brake Level Related Paramet...

Page 93: ...d before current limiting occurs Values Default Drive Rated Amps 1 1 Min Max 0 0 Drive Rated Amps 1 5 Display 0 1 Amps A180 Current Limit 2 Related Parameter s P033 Maximum output current allowed befo...

Page 94: ...0 1 Amps A184 Load Loss Level Related Parameter s P033 Provides a software trip Load Loss fault when the current drops below this level for the time specified in Load Loss Time Values Default 0 0 Dis...

Page 95: ...0 disables this parameter Values Default 0 Hz Min Max 0 320 Hz Display 1 Hz A189 Skip Freq Band 1 Related Parameter s A188 Determines the bandwidth around A188 Skip Frequency 1 A189 Skip Freq Band 1 i...

Page 96: ...Output Frequency Skip Frequency Band A192 Skip Frequency 3 Related Parameter s A193 Sets the frequency at which the drive will not operate A setting of 0 disables this parameter Values Default 0 Hz Mi...

Page 97: ...3 Both 1 1 Use Dead Time Compensation algorithm to minimize flat spots in motor current waveforms Use this solution also to achieve motor stability A195 Reset Meters Related Parameter s d310 d317 Res...

Page 98: ...ed Default 1 Locked Locks all parameters 2 Locked Parameter edits allowed over communications network 3 Locked Locks P035 Maximum Freq and A170 Boost Select A199 Motor NP Poles Related Parameter s d32...

Page 99: ...evel must be entered in percent of drive rated output current 8 Above DCVolt Drive exceeds the DC bus voltage value set in Relay OutX Level Use T056 to set threshold 9 Above Anlg 2 Analog input voltag...

Page 100: ...R234 Relay Out7 Level R237 Relay Out8 Level Sets the trip point for the digital output relay if the value of Relay OutX Sel is 6 7 8 9 10 or 12 Values Default 0 0 Min Max 0 0 9999 Display 0 1 Relay Ou...

Page 101: ...contactor outputs R240 Option Drive Relays Auxiliary Relay Card Relays 1 Relay 2 Relay 3 Relay 4 Relay 5 Relay 6 Relay 7 Relay 8 Relay 1 Motor 2 AC Line 2 Motor 2 AC Line Motor 3 AC Line 3 Motor 2 AC...

Page 102: ...ng auxiliary motor once the output frequency has dropped below the value set in Aux X Stop Freq Values Default 3 0 Secs Min Max 0 0 999 9 Secs Display 0 1 Secs R252 Aux Prog Delay Sets the time delay...

Page 103: ...tinued R254 Aux AutoSwap Lvl Sets the maximum level allowable for an AutoSwap to occur If the PID output is above this level AutoSwap will be delayed until the PID output drops below this parameter se...

Page 104: ...0 Local Keypad Potentiometer 1 A142 Internal Freq 2 Analog Input 1 3 Analog Input 2 4 A143 A146 Preset Freq x T051 T053 Digital Inx Sel must be set to 4 5 Communications Reserved Digit 2 Reserved Digi...

Page 105: ...value Values Default 0 0 Min Max 0 0 100 0 Display 0 1 d305 Analog In 1 Related Parameter s C102 C103 Displays the status of Analog Input 1 Values Default 0 0 Min Max 0 0 120 0 Display 0 1 d306 Analo...

Page 106: ...these parameters in the order they occur b007 Fault 1 Code the most recent fault Repetitive faults will only be recorded once As faults occur this parameter will be overwritten by Fault 2 Code Refer...

Page 107: ...ault occurred Values Default Read Only Min Max 0 0 60 0 Min Display 0 1 Min d316 Elapsed Time hr Related Parameter s A195 d310 d312 d314 Displays the total elapsed powered up time in hours since timer...

Page 108: ...equency in percent The scale is 0 at 0 00 Hz to 100 0 at P034 Maximum Freq Values Default Read Only Min Max 0 0 100 0 Display 0 1 d323 Output RPM Related Parameter s A199 Displays current output frequ...

Page 109: ...eter s b005 Displays the value of b005 DC Bus Voltage when the last fault occurred Values Default Read Only Min Max 0 820 VDC Display 1 VDC d327 Status Fault Related Parameter s b006 Displays the valu...

Page 110: ...anced Display 3 53 Comm Write Mode C107 Communications 3 28 Commanded Freq b002 Basic Display 3 4 Compensation A194 Advanced Program 3 45 Contrl In Status d302 Advanced Display 3 52 Control Source d30...

Page 111: ...Relay Out1 Sel T055 Terminal Block 3 14 Relay Out2 Level T061 Terminal Block 3 17 Relay Out2 Sel T060 Terminal Block 3 16 Relay Out3 Level R222 Relay Card 3 48 Relay Out3 Sel R221 Relay Card 3 47 Rel...

Page 112: ...3 60 Programming and Parameters Notes...

Page 113: ...e For information on See page Drive Status 4 1 Fault Descriptions 4 3 Faults 4 1 Common Symptoms and Corrective Actions 4 5 Drive Status Faults Type Fault Description Auto Reset Run When this type of...

Page 114: ...s the Escape key to regain control of the integral keypad Step Key s 1 Press Esc to acknowledge the fault The fault information will be removed so that you can use the integral keypad Access b007 Faul...

Page 115: ...sive motor load exists Reduce load so drive output current does not exceed the current set by parameter P033 Motor OL Current 2 Verify A170 Boost Select setting F8 Heatsink OvrTmp Heatsink temperature...

Page 116: ...rCurrent Programmed A183 SW Current Trip has been exceeded Check load requirements and A183 SW Current Trip setting F64 Drive Overload Drive rating of 110 for 1 minute or 150 for 3 seconds has been ex...

Page 117: ...heck all fuses and disconnects Check the motor Verify that the motor is connected properly Check the control input signals Verify that a Start signal is present If 2 Wire control is used verify that e...

Page 118: ...Local and the input is active None Check parameter settings Incorrect input wiring See 1 20 for wiring examples 2 wire control requires Run Forward Run Reverse or Jog input 3 wire control requires St...

Page 119: ...ettings for T051 T054 Digital Inx Sel Check P038 Speed Reference for the source of the speed reference Reprogram as necessary Review the Speed Reference Control chart on page 1 24 Cause s Indication C...

Page 120: ...control None Check T051 T054 Digital Inx Sel and P036 Start Source Choose correct input and program for reversing mode Digital input is incorrectly wired None Check input wiring See page 1 18 Motor w...

Page 121: ...t match the tables provided the closest fuse rating that exceeds the drive rating should be chosen IEC BS88 British Standard Parts 1 2 1 EN60269 1 Parts 1 2 type gG or equivalent should be used UL UL...

Page 122: ...0 460V 3 Phase Output 22C D6P0N103 2 2 3 0 6 6 340 528 6 3 7 5 10 140M D8E C10 100 C09 22C D010N103 4 0 5 0 10 5 10 5 340 528 10 9 13 20 140M D8E C16 100 C16 22C D012N103 5 5 7 5 12 12 340 528 11 9 14...

Page 123: ...trol Ride Thru 0 5 seconds minimum 2 seconds typical Electronic Motor Overload Protection I2 t protection 110 for 60 seconds Provides Class 10 protection Overcurrent 180 hardware limit 220 instantaneo...

Page 124: ...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...

Page 125: ...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 min...

Page 126: ...19 28 146 3 7 5 0 207 174 33 207 5 5 7 5 266 228 39 266 7 5 10 359 315 44 359 11 15 488 15 20 650 18 5 25 734 22 30 778 30 40 1055 37 50 1200 380 480V AC 2 2 3 0 105 77 28 105 4 0 5 0 171 143 28 171 5...

Page 127: ...Figure A 2 Frame F Connections Note UL Approval pending for Single Phase operation Input Power Connections Input Protection Three Phase Input T S R Input Protection Single Phase Input T S R Input Pro...

Page 128: ...A 8 Supplemental Drive Information Notes...

Page 129: ...33N103 C 11 15 49 49 22C B049A103 D 15 20 65 65 22C B065A103 D 18 5 25 75 75 22C B075A103 D 22 30 90 81 22C B090A103 D 30 40 120 120 22C B120A103 E 37 50 145 130 22C B145A103 E 480V 50 60 Hz 3 Phase 2...

Page 130: ...Type 1 3 Impedance 2 2 3 0 12 18 1 25 26 1321 3R12 A 1321 3RA12 A 3 7 5 0 18 27 0 8 36 1321 3R18 A 1321 3RA18 A 5 5 7 5 25 37 5 0 5 48 1321 3R25 A 1321 3RA25 A 7 5 10 35 52 5 0 4 49 1321 3R35 A 1321 3...

Page 131: ...75 100 130 195 0 2 180 1321 3R130 B 1321 3RA130 B 90 125 160 240 0 15 149 1321 3R160 B 1321 3RA160 B 110 150 200 300 0 11 168 1321 3R200 B 1321 3RA200 B 5 Impedance 2 2 3 0 8 12 7 5 28 1321 3R8 D 1321...

Page 132: ...nge Mount drive ratings 15 20 40 2 0 29 1321 DC40 4 1 Drive Ratings Catalog Number Input Voltage kW HP 240V 50 60 Hz 3 Phase 2 2 3 0 22 RF034 CS 4 0 5 0 22 RF034 CS 5 5 7 5 22 RF034 CS 7 5 10 22 RF034...

Page 133: ...e 22 SCM 232 DSI Cable 2 0 meter RJ45 to RJ45 cable male to male connectors 22 RJ45CBL C20 Serial Cable 2 0 meter serial cable with a locking low profile connector to connect to the serial converter a...

Page 134: ...HIM A3 Bezel Kit Panel mount for LCD Display Remote Handheld unit IP30 NEMA Type 1 22 HIM B1 DSI HIM Cable DSI HIM to RJ45 cable 1 0 Meter 3 3 Feet 2 9 Meter 9 51 Feet 22 HIM H10 22 HIM H30 Item Desc...

Page 135: ...6 7 3 55 7 8 C 5 5 7 5 3 65 8 0 4 2 9 3 C 7 5 10 3 75 8 3 4 3 9 5 C 11 15 6 41 14 1 7 41 16 3 C 15 20 6 47 14 3 7 49 16 5 D 18 5 25 12 7 28 0 14 30 9 D 22 30 12 7 28 0 14 30 9 D 30 40 14 3 31 5 15 6 3...

Page 136: ...Dimensions Figure B 1 PowerFlex 400 Frame C Drive Dimensions are in millimeters and inches 260 10 2 320 12 6 246 9 7 130 0 5 1 116 0 4 57 111 2 4 38 152 2 5 99 22 2 0 87 28 5 1 12 107 0 4 21 66 0 2 60...

Page 137: ...e B 2 PowerFlex 400 Frame D Drive Dimensions are in millimeters and inches 226 0 8 90 250 0 9 84 206 1 8 11 383 4 15 09 436 2 17 17 71 6 2 82 132 0 5 20 175 5 6 91 192 0 7 56 156 3 6 15 132 7 5 22 167...

Page 138: ...B 3 PowerFlex 400 Frame E Drive Dimensions are in millimeters and inches 130 2 5 13 240 2 9 46 315 2 12 41 55 2 2 17 174 9 6 89 234 9 9 25 204 9 8 07 22 2 0 87 62 7 2 47 567 4 22 34 605 5 23 84 335 0...

Page 139: ...F Drive Dimensions are in millimeters and inches 137 5 5 41 287 5 11 32 370 0 14 57 55 0 2 17 169 0 6 65 228 5 9 00 199 0 7 83 74 8 2 94 22 0 0 87 381 0 15 00 381 0 15 00 425 0 16 73 13 0 0 51 850 0 3...

Page 140: ...00 Frame C Flange Mount Drive Dimensions are in millimeters and inches 138 2 5 44 105 8 4 17 325 12 8 300 11 81 130 3 5 13 22B CCC Cutout Dimensions 291 5 11 48 164 6 46 180 7 09 90 3 54 307 5 12 11 2...

Page 141: ...3 00 12 7 28 1321 3R45 C 229 9 00 184 7 25 135 5 30 93 3 66 76 3 00 17 7 39 1321 3R55 A 229 9 00 187 7 35 118 4 66 80 3 16 76 3 00 10 9 24 1321 3R55 B 229 9 00 187 7 35 118 4 66 80 3 16 76 3 00 12 3 2...

Page 142: ...3 81 114 4 50 72 2 82 51 2 00 80 3 13 5x8 20x 33 5 9 13 0 1321 DC18 1 A 95 3 75 83 3 25 51 2 00 80 3 13 4 7 0 19 1321 DC18 4 B 118 4 63 133 5 25 102 4 00 64 2 50 95 3 75 5x8 20x 33 3 6 8 0 1321 DC25...

Page 143: ...B 8 EMC Line Filters Dimensions are in millimeters and inches Catalog Numbers 22 RF018 CS 22 RF018 CL 22 RF026 CS 22 RF026 CL 22 RF026 CL 22 RF034 CS 5 5 0 22 17 0 67 30 1 18 90 3 54 130 5 12 60 2 36...

Page 144: ...298 11 73 13 5 0 53 7 0 28 22 RFD070 93 3 66 312 12 28 190 7 48 79 3 11 298 11 73 13 5 0 53 7 0 28 22 RFD100 93 3 66 312 12 28 190 7 48 79 3 11 298 11 73 13 5 0 53 7 0 28 22 RFD150 126 4 96 312 12 28...

Page 145: ...d Dimensions B 17 Figure B 9 Remote Panel Mount Small HIM Dimensions are in millimeters and inches Catalog Number 22 HIM C2S 93 3 66 25 0 98 2m 180 7 09 154 6 06 77 3 03 23 5 0 93 67 2 64 60 2 36 19 1...

Page 146: ...s and Dimensions Figure B 10 NEMA Type 1 Bezel Dimensions are in millimeters and inches Catalog Number 22 HIM B1 93 3 66 25 2 0 99 2m 180 7 09 11 1 0 44 19 1 0 75 4 8 0 19 154 6 06 77 3 03 23 5 0 93 6...

Page 147: ...plitter Cable with a drive that has an internal network communication adapter installed Since only one additional peripheral can be added the second peripheral can be connected directly to the RJ45 po...

Page 148: ...le Catalog Number AK U0 RJ45 SC1 RJ45 Two Position Terminal Block Adapter Catalog Number AK U0 RJ45 TB2P RJ45 Adapter with Integrated Termination Resistor Catalog Number AK U0 RJ45 TR1 Slave Port Mast...

Page 149: ...plitter Cable DSI DSI Hand Held or Parameter 9 Device Type set to Auto default or Master and connected to Master port M on RJ45 Splitter Cable DSI Drive Serial Converter NEMA 4 Panel Mount Unit or NEM...

Page 150: ...er Cable Parameter 9 Device Type set to Slave and connected to Slave port S on RJ45 Splitter Cable M S DSI Drive or AK U0 RJ45 TR1 Terminating Resistor end of network AK U0 RJ45 TB2P Two position Term...

Page 151: ...rive to run at commanded speed Example The System Run Command can come from a terminal block integral keypad or communication port Configure parameter P036 Start Source per application requirements Se...

Page 152: ...oint 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...

Page 153: ...ovides PID Feedback to the drive Fluctuations in actual system pressure due to changes in flow result in a PID Error value The drive output frequency increases or decreases to vary motor shaft speed t...

Page 154: ...Pot signal provides PID Feedback to the drive Fluctuations in tension result in a PID Error value The Master Speed Reference sets the wind unwind speed As tension increases or decreases during windin...

Page 155: ...ple with Maximum Freq 60 Hz a value of 600 sent over the network would represent 100 reference 5 Setpnt Trim Selects Trim Control A157 PID Setpoint will be used to set the value of the PID Reference 6...

Page 156: ...70 Analog In 1 Lo or T074 Analog In 2 Lo 0 0 T071 Analog In 1 Hi or T075 Analog In 2 Hi 50 0 A152 PID Ref Sel 0 0 10V Input Invert Function For a 4 20mA signal the following parameter settings are use...

Page 157: ...y start or enable This will cause the drive s frequency command to initially jump to that preload frequency and the PID loop starts regulating from there PID Limits A150 PID Trim Hi and A151 PID Trim...

Page 158: ...the output of the integral gain component would integrate up to 100 of max frequency when the PID error is 100 for 2 seconds A larger value for PID Integ Time makes the integral component less respons...

Page 159: ...PID begins to go unstable 2 Adjust the integral gain leave the proportional gain set as in Step 1 After a step change in the PID Feedback If the response is too slow see Figure D 2 or the PID Feedbac...

Page 160: ...ints during adjustment of the PID Gains Figure D 1 Unstable Figure D 2 Slow Response Over Damped Figure D 3 Oscillation Under Damped Figure D 4 Good Response Critically Damped PID Feedback PID Referen...

Page 161: ...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...

Page 162: ...Parameter R242 Aux 1 Stop Freq The time that Motor 1 is below the value set by R242 Aux 1 Stop Freq before turning off Motor 2 is set via Parameter R251 Aux Stop Delay PID setup is done via Parameters...

Page 163: ...via Parameter R242 Aux 1 Stop Freq The time that Motor 1 is below the value set by R242 Aux 1 Stop Freq before turning off Motor 2 is set via Parameter R251 Aux Stop Delay The running time between th...

Page 164: ...D 14 Application Notes Notes...

Page 165: ...werFlex 400 RJ45 socket contain power etc for other Rockwell Automation peripheral devices and must not be connected Wiring terminations on the master controller will vary depending on the master cont...

Page 166: ...ource Set to 5 RS485 DSI Port if Start is controlled from the network Page 3 8 P038 Speed Reference Set to 5 RS485 DSI Port if the Speed Reference is controlled from the network Page 3 10 C102 Comm Fo...

Page 167: ...s 5 4 00 No Command 01 Forward Command 10 Reverse Command 11 No Command 6 1 Local Control 1 0 Comm Control 1 Local Control causes the drive to use C108 Start Source 2 and C109 Speed Ref 2 for start an...

Page 168: ...ve 2 1 Cmd Forward 0 Cmd Reverse 3 1 Rotating Forward 0 Rotating Reverse 4 1 Accelerating 0 Not Accelerating 5 1 Decelerating 0 Not Decelerating 6 1 Alarm 0 No Alarm 7 1 Faulted 0 Not Faulted 8 1 At R...

Page 169: ...mation Refer to http www ab com drives for additional information Logic Status Address Decimal Value Decimal Description 8449 0 No Fault 2 Auxiliary Input 3 Power Loss 4 Undervoltage 5 Overvoltage 6 M...

Page 170: ...E 6 Modbus RTU Protocol Notes...

Page 171: ...ted virtual object data in the virtual objects is refreshed from or transferred to the drive The Metasys N2 master performs read and write commands to the virtual objects one at a time The data types...

Page 172: ...Float Analog Input Value 8 Float Low Alarm Limit 9 Float Low Warning Limit 10 Float High Warning Limit 11 Float High Alarm Limit 12 Float Differential Table F 3 Internal Structure of Metasys N2 Binary...

Page 173: ...Status bit 13 Drive Terminal 3 On Off BI 15 Digital In 3 Logic Status bit 14 Drive Terminal 4 On Off BI 16 Digital In 4 Logic Status bit 15 Drive Terminal 5 On Off BI 17 Digital In 5 Drive Terminal 6...

Page 174: ...req 3 BO 15 MOP Dec Logic Command bit 15 Decrement Not Decrement BO 16 Pnl Lock Lock out Drive Front Panel Lock Unlock BO 17 Digital Out 1 Relay 1 on Drive Drive Terminal R1 R2 R3 On Off BO 18 Digital...

Page 175: ...Source Param 0 Max Drive Params b014 Drive Temperature ADI 5 Param OUT1 User OUT 1 AO 11 Data Source Param 0 Max Drive Params A154 PID Gain ADI 6 Param OUT2 User OUT 2 AO 12 Data Source Param 0 Max Dr...

Page 176: ...User INx See Figure F 1 and Table F 13 Figure F 1 Configurable Input Point Operation Objects Inputs Using Metasys Configurable Objects to Access Parameters Table F 13 Configurable Objects Inputs Netw...

Page 177: ...not create a program that frequently uses configurable outputs to write parameter data to NVS Table F 14 Configurable Objects Outputs Network Point Description Range Default Type NPT Address NPA AO 6...

Page 178: ...F 8 Metasys N2 Notes...

Page 179: ...ite commands to certain points and the internal P1 FLN protocol firmware transfers translates the data between these points and the drive When a read or write command occurs to a certain point data in...

Page 180: ...LDO RUN ENABLE STOP 1 0 ENABLE STOP 29 LDO DAY NGT DAY 1 0 NIGHT DAY 30 LAO CURRENT LIMT 1 AMPS 0 1 0 31 LAO ACCEL TIME 20 SEC 0 02 0 32 LAO DECEL TIME 20 SEC 0 02 0 33 LDO KEYPAD LOCK UNLOCK 1 0 LOCK...

Page 181: ...CELERATING OFF 1 0 ON OFF 73 LDI ALARM NORMAL 1 0 ALARM NORMAL 74 LDI AT SPEED OFF 1 0 ON OFF 75 LDI MAIN FREQ OFF 1 0 ON OFF 76 LDI OPER CMD OFF 1 0 ON OFF 77 LDI PARAM LOCK UNLOCK 1 0 LOCK UNLOCK 78...

Page 182: ...AM 37 READ VALUE 38 WRITE PARAM 39 WRITE VALUE 40 DIGITAL OUT 1 T055 T056 41 DIGITAL OUT 2 T060 T061 42 DIGITAL OUT 3 T065 T066 43 OPT RELAY 1 R221 R222 1 44 OPT RELAY 2 R224 R225 1 45 OPT RELAY 3 R22...

Page 183: ...it 4 Decelerating 73 ALARM 74 AT SPEED 75 MAIN FREQ d301 Digit 0 76 OPER CMD d301 Digit 1 77 PARAM LOCK 78 JOG 79 LOCAL CNTRL 80 MOP INC 81 ACCEL RATE 1 82 ACCEL RATE 2 83 DECEL RATE 1 84 DECEL RATE 2...

Page 184: ...0 to 100 Using Percent for the Reference Table G 3 Example Speed Reference and Feedback for a PowerFlex 400 P035 60 Hz Reference Point 92 PCT Output Point 4 Percent Speed Speed Percent 100 60 Hz 60 Hz...

Page 185: ...ram in the Read Param point The drive reads the value of the parameter configured in the Param for the Read Param point and shows the result in the Read Value point The Param for the Read Param point...

Page 186: ...changed if desired A value of 0 in the Param for Write Param point field disables the writing of data Figure G 2 Configurable Output Point Operation Table G 5 Configurable Points Outputs Point Name D...

Page 187: ...s P 3 Display 2 3 2 4 2 6 2 7 2 8 2 9 Display Group Parameters 3 4 Distribution Systems Ungrounded 1 6 Drive Frame Size P 2 B 7 Drive Grounding 1 8 Drive Overload Fault 4 4 Drive Ratings P 4 A 1 Drive...

Page 188: ...meters Display Group 3 4 Program Group 3 7 PE Ground 1 8 Phase Short Fault 4 4 Phase to Ground Fault 4 4 point map Metasys N2 F 3 G 2 Power Cables Wiring 1 11 Power Conditioning Input 1 7 Power Connec...

Page 189: ...T Terminal Block I O 1 16 Power 1 15 Three Wire Control 1 20 1 23 Two Wire Control 1 20 1 23 U UnderVoltage Fault 4 3 Ungrounded Supply 1 6 Unshielded Power Cables 1 11 W Wiring 1 1 Block Diagram 1 17...

Page 190: ...Index 4...

Page 191: ......

Page 192: ...ion 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium T...

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