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Quick Start

PowerFlex 40 Adjustable
Frequency AC Drive

FRN 5.xx - 6.xx

This Quick Start guide summarizes the basic steps needed to install, 
start-up and program the PowerFlex 40 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 40 information including EMC instructions, 
application considerations and related precautions, refer to the 
PowerFlex 40 User Manual, Publication 22B-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.

Aotewell Ltd 

www.aotewell.com  Industry Automation

HongKong|UK|China [email protected]

+86-755-8660-6182

Summary of Contents for PowerFlex 40

Page 1: ...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 Failur...

Page 2: ...n Ambient Temperature Enclosure Rating Minimum Mounting Clearances Minimum Maximum 10 C 14 F 40 C 104 F IP20 NEMA UL Type Open Use Mounting Option A IP66 NEMA UL Type 4X Use Mounting Option A IP30 NEMA UL Type 1 1 1 Rating requires installation of the PowerFlex 40 IP 30 NEMA UL Type 1 option kit Use Mounting Option B 50 C 122 F IP20 NEMA UL Type Open Use Mounting Option B 25 mm 1 0 in 120 mm 4 7 i...

Page 3: ...igures 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 Important Tighten screw after jumper removal Phase to Ground MOV Removal Typical Grounding U T1 V T2 W T3 R L1 S L2 T L3 SHLD Disconnecting MOVs IP66 NEMA UL Type 4X IP20 NEMA UL Type Open R L1 S L2 T L3 1 2 3 4 Three Phase AC Input ...

Page 4: ...4 7 5 10 0 33 0 180 264 16 3 34 6 60 140M G8E C45 100 C60 2069 305 380 480V AC 10 3 Phase Input 0 460V 3 Phase Output 22B D1P4x104 0 4 0 5 1 4 342 528 1 4 1 8 3 140M C2E B25 100 C07 1655 35 22B D2P3x104 0 75 1 0 2 3 342 528 2 3 3 2 6 140M C2E B40 100 C07 1655 50 22B D4P0x104 1 5 2 0 4 0 342 528 4 0 5 7 10 140M C2E B63 100 C09 1655 70 22B D6P0x104 2 2 3 0 6 0 342 528 5 9 7 5 15 140M C2E C10 100 C09...

Page 5: ...reakers HMCP circuit breakers or equivalent Protective Features Motor Protection I 2 t overload protection 150 for 60 Secs 200 for 3 Secs Provides Class 10 protection Overcurrent 200 hardware limit 300 instantaneous fault Over Voltage 100 120V AC Input Trip occurs at 405V DC bus voltage equivalent to 150V AC incoming line 200 240V AC Input Trip occurs at 405V DC bus voltage equivalent to 290V AC i...

Page 6: ...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 ...

Page 7: ...utral 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 40 User Manual for specific line reactor ...

Page 8: ...ast to stop without software interpretation Refer to the PowerFlex 40 User Manual for more information Control Terminal Block 04 05 06 07 01 02 03 08 09 11 12 13 14 15 16 17 18 19 Digital Common Digital Input 1 Digital Input 2 Digital Input 3 Stop 1 4 Start Run FWD 2 Direction Run REV Digital Input 4 Opto Common R1 R2 R3 Relay N O Relay Common Relay N C 24V DC 10V DC 0 10V or 10V Input Analog Comm...

Page 9: ... Referenced to Digital Common Drive supplied power for digital inputs Maximum output current is 100mA 12 10V DC Referenced to Analog Common Drive supplied power for 0 10V external potentiometer Maximum output current is 15mA P038 13 10V In 2 Not Active For external 0 10V unipolar or 10V bipolar input supply input impedance 100k ohm or potentiometer wiper P038 A051 A054 A123 A132 14 Analog Common F...

Page 10: ...r to the Drive 6 Apply AC power and control voltages to the drive 7 Familiarize yourself with the integral keypad features see next page before setting any Program Group parameters If a fault appears on power up refer to page 20 for an explanation of the fault code For complete troubleshooting information refer to the PowerFlex 40 User Manual Prepare For Drive Start Up ATTENTION Power must be appl...

Page 11: ...l frequency is being adjusted its value is displayed and the Hertz LED flashes Any changes are saved immediately The display then returns to the Display Group parameter previously shown TIP By default the speed reference of an IP66 NEMA UL Type 4X rated drive is set to the internal frequency A069 Internal Freq TIP You can also change the speed reference by editing the parameter A069 Internal Freq ...

Page 12: ...gh groups and parameters Increase decrease the value of a flashing digit Used to adjust internal frequency of IP66 NEMA UL Type 4X rated drives only when a Display Group parameter is shown and P038 Speed Reference is set to internal frequency A069 Internal Freq Enter Advance one step in programming menu Save a change to a parameter value Potentiometer 1 Used to control speed of drive Default is ac...

Page 13: ... group 7 Press Enter or Sel to view the value of a parameter If you do not want to edit the value press Esc to return to the parameter number 8 Press Enter or Sel to enter program mode to edit the parameter value The right digit will flash and the Program LED will illuminate if the parameter can be edited 9 Press the Up Arrow or Down Arrow to change the parameter value If desired press Sel to move...

Page 14: ...Analog In 0 10V 0 0 100 0 0 1 d021 Analog In 4 20mA 0 0 100 0 0 1 d022 Output Power 0 00 Drive Power 2 0 01 kW d023 Output Powr Fctr 0 0 180 0 deg 0 1 deg d024 Drive Temp 0 120 degC 1 degC d025 Counter Status 0 9999 1 d026 Timer Status 0 0 9999 Secs 0 1 Secs d028 Stp Logic Status 0 7 1 d029 Torque Current 0 00 Drive Amps 2 0 01 Amps Smart Start Up with Basic Program Group Parameters Stop drive bef...

Page 15: ...s set to option 2 4 5 6 13 or 14 and the digital input is active A051 A052 A053 or A054 will override the speed reference commanded by this parameter Refer to Chapter 1 of the PowerFlex 40 User Manual for details P039 Accel Time 1 0 0 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of accel for all speed increases P040 Decel Time 1 0 1 600 0 Secs 0 1 Secs 10 0 Secs Sets the rate of decel for all speed...

Page 16: ...g 6 Above Freq 7 Above Cur 8 Above DCVolt 9 Retries Exst 10 Above Anlg V 11 Logic In 1 12 Logic In 2 13 Logic 1 2 14 Logic 1 or 2 15 StpLogic Out 16 Timer Out 17 Counter Out 18 Above PF Ang 19 Anlg In Loss 20 ParamControl 21 NonRec Fault 22 EM Brk Cntrl 23 Above Fcmd 24 MsgControl for FRN 6 01 and later 0 A056 Relay Out Level 0 0 9999 0 1 0 0 A058 A061 Opto Out1 Sel Opto Out2 Sel 0 24 See A055 for...

Page 17: ...A 0 kW 200 Drive Rated Power 0 20 mA 9 TstData 0 20 0 20 mA 0 mA 0000 65535 Hex FFFF 0 20 mA 10 OutFreq 4 20 4 20 mA 4 mA 0 Hz P035 Maximum Freq 0 20 mA 11 OutCurr 4 20 4 20 mA 4 mA 0 Amps 200 Drive Rated FLA 0 20 mA 12 OutVolt 4 20 4 20 mA 4 mA 0 Volts 120 Drive Rated Output Volts 0 20 mA 13 OutPowr 4 20 4 20 mA 4 mA 0 kW 200 Drive Rated Power 0 20 mA 14 TstData 4 20 4 20 mA 4 mA 0000 65535 Hex F...

Page 18: ...p 0 0 Drive Amps 2 0 1 Amps 0 0 Disabled A099 Process Factor 0 1 999 9 0 1 30 0 A100 Fault Clear 0 2 0 Ready Idle 1 Reset Fault 2 Clear Buffer 0 A101 Program Lock 0 9999 0 Unlocked 1 Locked 0 A102 Testpoint Sel 400 FFFF 1 Hex 400 A103 Comm Data Rate 0 5 0 1200 1 2400 2 4800 3 9600 4 19 2K 5 38 4K 3 Power to drive must be cycled before any changes will affect drive operation A104 Comm Node Addr 1 2...

Page 19: ...A Input 4 Comm Port 5 Setpnt Trim 6 0 10V Trim 7 4 20mA Trim 8 Comm Trim 0 A133 PID Feedback Sel 0 2 0 0 10V Input 1 4 20mA Input 2 Comm Port 0 A134 PID Prop Gain 0 00 99 99 0 01 0 01 A135 PID Integ Time 0 0 999 9 Secs 0 1 Secs 0 1 Secs A136 PID Diff Rate 0 00 99 99 1 Secs 0 01 1 Secs 0 01 1 Secs A137 PID Setpoint 0 0 100 0 0 1 0 0 A138 PID Deadband 0 0 10 0 0 1 0 0 A139 PID Preload 0 0 400 0 Hz 0...

Page 20: ...nput Loss 1 An analog input is configured to fault on signal loss A signal loss has occurred F33 Auto Rstrt Tries Correct the cause of the fault and manually clear F38 Phase U to Gnd Check the wiring between the drive and motor Check motor for grounded phase Replace drive if fault cannot be cleared F39 Phase V to Gnd F40 Phase W to Gnd F41 Phase UV Short Check the motor and drive output terminal w...

Page 21: ...09 136 5 35 87 3 43 168 6 61 87 4 3 44 2 2 4 9 C 130 5 1 260 10 2 180 7 1 116 4 57 246 9 7 4 3 9 5 A E B D C F 5 5 0 22 111 2 4 38 152 2 5 99 107 0 4 21 66 0 2 60 22 2 0 87 28 5 1 12 24 0 0 94 74 3 2 93 109 9 4 33 64 1 2 52 79 1 3 11 22 2 0 87 22 2 0 87 25 6 1 01 40 6 1 60 76 3 3 00 105 3 4 15 134 3 5 29 50 0 1 97 77 5 3 05 22 5 0 89 45 7 1 80 109 8 4 32 144 8 5 70 179 8 7 08 69 2 2 72 92 2 3 63 1...

Page 22: ...rport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Power Control and Information Solutions Headquarters Publication 22B QS001G EN P June 2013 Supersedes December 2008 Copyright 2013 Rockwell Automation Inc All rights reserved IP66 NEMA Type UL Type 4X Dimensions are in millimeters and inches Weights are in kilograms and pounds Weight 5 2 11 5 165 6 50 146 5 75 6 5 0 26 270 10 63 253 9 96 82 ...

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